Note: Descriptions are shown in the official language in which they were submitted.
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PROCESS UTILIZING AGAR-AGAR IN A HIGH
TEMPERATURE, SHORT TIME PROCESSING OF
HIGH SOLIDS CONFECTIONERY PRODUCTS
FIELD OF THE INVENTION
The present invention relates to a continuous
process for making high-solids confectionery products
containing agar-agar utilizing high temperature short
time processing.
BACKGROUND OF THE INVENTION
Agar-Agar is a complex mixture of
polysaccharides which are extracted from red seaweed.
All components of the mixture contain the same backbone
structure composed of alternating monosaccharide units of
D-galactose and 3,6 anhydro-L-galactose. Some of the
polysaccharide chains are substituted to a variable
degree with charged groups, namely sulfate, pyruvic acid
and uronic acid.
Agar-Agar is the least soluble of all of the
polysaccharide gelling agents. It is virtually insoluble
in cold water, slightly soluble in hot water and readily
soluble in boiling water. It forms a strong brittle,
turgid gel when hot aqueous dispersions of same are
prepared and cooled.
The melting and setting properties of agar-agar
display hysteresis, i.e., agar-agar jelli.es.melt at 80°-
90°C (176°-194°F), yet they set at 30-40°C
(86°-104°F).
Such properties are obviously useful when depositing hot
products into molds, for there is little or no risk of
premature setting or pre-gelling.
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Agar-agar is used in various foods, such as
baking icings, no oil salad dressings and low fat yogurt.
It can also be used in many confectionery
products, especially in gums and jelly products,
marshmallows and the like, as a gelling agent. It is
usually present in small amounts, typically ranging from
0.2~ to 1.8~ by weight.
One of the drawbacks of using agar-agar is that
it requires a large quantity of water to make a good
solution and an aqueous dispersion. Typically, it
requires 30-50 times its weight in water to make an
aqueous solution of same. For example, standard methods
for using agar-agar in confectionery products recommend
hydrating the agar-agar for several hours, usually at
least 12 hours, in at least a 30:1 ratio by weight of
water to agar-agar, or a short-time boiling, usually 3-5
minute boil, of the agar-agar in water at the
aforementioned ratio, to fully hydrate the gum for
incorporation into the high solids confectionery product.
This extensive hydration time~that is required makes it
unattractive for use in a continuous process or in
automated plants. As a result, although found in
confectionery products, its use is limited to batch type
operations.
Moreover, it is widely held in the
confectionery industry that agar-agar cannot be used in a
continuous process in which it is subjected to high
temperatures. It is commonly believed in the food arts
that one of the drawbacks of agar-agar is that it cannot
be subjected to the high temperatures required for
solubility of various components by normal pasteurization
or pasteurization-like processes. Subjecting the food
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containing agar-agar to high temperatures has been shown
to be detrimental in many food applications, e.g., the
food loses its flavor or develops off-flavor.
Furthermore, since agar-agar is used in a batch
process, rather than a continuous process, there are
further drawbacks to its use.
A batch process is generally more expensive,
more inefficient and more labor intensive than a
continuous process, especially in making high solids
confections. In an example of the batch process for
making high solids confectionery products, an aqueous
solution of sucrose is mixed with corn syrup and other
ingredients in a large kettle at a concentration of about
60 to 75~ solids. The solution is cooked in this kettle.
The solution is normally cooked at atmospheric pressure
to concentrate the product to about 85 percent solids.
The solution is then cooled to about 70°C-45°C
(158°F-
113°F).
The above described batch method often requires
multiple mixing steps and transferal of the various
intermediate products prepared after each step of the
process from various production apparatus and work areas
until the final product is produced. These operations
are not performed continuously, but batchwise. Batch
processes usually require more equipment than continuous
processes, and they are usually less efficient.
Moreover, since the batch process is non-continuous, the
various mixing steps require the continuous input of
operators in order to adjust the processing parameters,
resulting in the batch process requiring more manual
labor relative to continuous processes.
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Thus, batch processes are generally slower than
continuous processes, require substantial amount of
manual labor and are consequently more expensive. It
also introduces a number of opportunities for error,
resulting, for example, in poor or wasted batches, as the
result of mis-measurement, overmixing and the like.
On the other hand, a continuous process for
making high solids confectionery products has several
advantages relative to a batch process. As the name
suggests, a continuous process involves a continuous mode
of operation. In a continuous process, automated
equipment is used so that the entire process is run
continuously. As soon as a vessel is emptied, it is
immediately filled with, in the case of high solids
confectionery, a mixture of the ingredients to be
processed. By "continuous", as used herein, it is meant
the mixture is introduced over an extended period of time
either as a flowing stream or as a series of spaced apart
portions. However, as used herein,.a continuous process
also includes the situation wherein the additions of the
ingredients to form the uncooked mixture is performed
manually or by other batch-wise means. In other words
after the majority of the ingredients, i.e., gelling
agent, water and sweeteners are added to the appropriate
tank or apparatus, and mixed, the process is continuous
thereafter. In a continuous process, the various
apparatus and equipment used in the process are in fluid
communication with one another. Thus an embodiment of a
continuous process for making high solid confectionery
contemplates adding the sugar solution and corn syrup in
predetermined amounts and in measured volumes to a mixer
tolform a homogenous solution, introducing the solution
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as a flowing material into the various apparatus used in
the process, such as other mixers or heaters, through
inlet valves automatically and continuously or at
predetermined spaced intervals, continuous removal of
S intermediate products from mixers and heaters through
exit valves, automatically and continuously introducing
the heated solution into coolers, etc. Thus, the entire
process is performed continuously, with little, if any,
stoppage. Thus, there are several advantages of the
continuous process relative to the batch process, such as
shorter processing time, reduced labor, reduced amount of
material used and less cost. In consequence, modern food
plants primarily utilize continuous manufacturing methods
and installed equipment to effectuate such processing,
incorporating high temperature short time processing
steps.
Because of the problems referred to
hereinabove, it has been disadvantageous heretofore to
use agar-agar in high solids confectionery products. In
general, high solids confectionery products prepared by a
continuous process, especially those products which
utilize gelling agents or have chewy characteristics,
utilize other hydrocolloids. One of the most common
hydrocolloids used is gelatin. High solids confections
containing gelatin are produced by the continuous
process, and the products produced are quite satisfactory
to the public; they are stringy and chewy and, if
necessary, they can be aerated to produce a marshmallow
or marshmallow-like texture.
However, there are a number of disadvantages
utilizing gelatin. One disadvantage is that since it
contains protein, gelatin must be added after the cooking
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step; if added before cooking, it will denature.
Moreover, there is an increased risk of microbial
problems, especially if the solution containing gelatin
is stored for an extended period of time. Furthermore,
S gelatin is prepared from collagen which is present in
skins, bones, hides and connective tissues from animals.
It is, therefore, generally non-kosher since, in most
cases, the animal is not properly killed. Although
Kosher gelatin is available, it is not only extremely
expensive, but in addition, it is difficult to obtain a
constant supply since availability is limited.
Thus, although gelatin is attractive since it
has been used in preparing high solids confectioneries,
it is also unattractive for the reasons given
IS hereinabove, but especially because of the commercial
reality that certain portions of the population may not
purchase products containing non-kosher gelatin and the
enhanced risk of microbial problems.
Thus, the problem was to find another gelling
agent to replace gelatin which can be used in preparing
high solid confectionery products by a continuous
process, and which would impart the necessary chewy
characteristics, stringiness and gelling properties to
the confection.
2S The task was not simple. When the present
inventors used other gelling agents instead of gelatin to
prepare,high solid confectionery products by a continuous
process, the products containing them were inferior to
the gelatin containing products. The confection products
containing a gelling agent other than the gelatin did not
exhibit the stringiness or chewy characteristics that are
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found in jellies, gum or other high solids confectionery
products containing gelatin.
The present inventors also attempted to make
high solid confectionery products utilizing new
speciality products which have been developed in recent
years which are also useful as gelling agents. These are
referred to as "quick soluble agars", and they are
physically modified agar-agar to permit hydration at
temperatures below boiling, i.e. 60-80°C. Therefore they
have several advantages, such as easy preparation, less
preparation time and application to continuous cooking.
However, the quick soluble agars require further
processing of the agar-agar by the supplier and are very
expensive. For these reasons, these quick soluble agars
seemed unattractive. Furthermore, when used in attempts
to make high solid confectionery products, it hydrates
before cooking resulting in the pre-cooked product being
more viscous. Consequently, it is more difficult to work
with, for example, it exhibits less efficient heat
transfer during cooking and it is more difficult to pump
than if the mixture contained other hydrocolloids or, as
shown hereinbelow, agar-agar.
The present inventors then focused on agar-
agar. Since it is made from plants, it is kosher.
However, due to its properties described hereinabove, it
was never used heretofore in preparing high solids
confectionery products in a continuous process. In order
to use agar-agar in a continuous process, the present
inventors needed to find a solution to circumvent the
extensive pre-hydration procedures referred to
hereinabove.
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Thus, the present inventors searched for a
method of using natural agar-agar in a continuous process
for making high solids confectionery using high
temperature and short time processing.
They finally found a solution. More
specifically, they found that by mixing an agar-agar
dispersing agent with agar-agar in the appropriate
amounts, they could prepare high solids confectionery in
a high temperature, short time continuous process without
the need for the extensive pre-hydration procedures
described hereinabove.
SUl~l:RY OF THE INVENTION
Accordingly, the present process is directed to
an improved method for making a high solids confectionery
product in a high temperature short time~continuous
process in which a homogenous mixture comprising a
sweetener, agar-agar, and water is heated under cooking
conditions; concentrating the cooked mixture by removing
water therefrom; and then cooling the concentrated
mixture, the improvement comprising (a) prior to cooking,
mixing said homogenous mixture with an agar-agar
dispersing agent under conditions sufficient to form a
homogenous mixture, said agar-agar dispersing agent being
present in an amount sufficient to control the hydration
of the agar-agar; and (b) conducting the process as a
continuous process and cooking the mixture under high
temperature short time conditions.
The present process is also directed to a
method of making a high solids confectionery product in a
continuous process which comprises:
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(a) preparing a homogenous mixture comprising
agar-agar, an agar-agar dispersing agent in an amount
sufficient to control hydration of agar-agar when water
is added thereto, a sweetening effective amount of a
sweetener, and water, said homogenous mixture containing
a solids content ranging from about 60~ to about 80o by
weight solids;
(b) feeding the homogenous mixture of step (a)
to a heating apparatus having an inlet and an outlet with
heating means interposed therebetween and subjecting said
mixture to a high temperature short time continuous
process under conditions sufficient to cook and
concentrate the mixture; and
(c) removing the formed water vapor therefrom
and cooling said cooked mixture; thereby forming said
high solids confectionery product, all aforesaid steps
being conducted substantially continuously in said
continuous process.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic representation of a
preferred process used in practicing the present
invention.
Figure 2 is a variation of the schematic
representation of the process of Figure 1.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
The present process has wide applicability. It
is useful for preparing high solids confectionery
products, especially those which usually contain agar-
agar and which were heretofore prepared by the batch
process. Moreover, the present process permits the
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preparation of high solids confectionery products by a
continuous process which heretofore contained other
gelling agents. For example, using the process described
hereinabove, confectionery products prepared by a
continuous process which heretofore contained gelatin now
can be prepared in a continuous process containing agar-
agar.
' As used herein, a "high solid confectionery
product" is a confection having at least about 75~ by
weight solids and more preferably having a total solid
content of about 80~ to about 90~ total solid and most
preferably having a total solid content of about 84~ to
about 89~ total solids. The high solid confectionery
products produced by the present invention are
crystalline or non-crystalline. Examples of high solids
confectionery products that can be prepared by the
present process include marshmallow, caramel, nougat,
jellies and gums, such as orange slices, gum drops, gummy
bears, jelly beans, fruit snacks and jujubes, chewy
candy, and the like. The high solids confectionary
product includes those confections in which gelling
agents are typically present such as those indicated
hereinabove. The term also includes confections having
the solid content indicated hereinabove in which gelling
agents are not normally present, but can be added to
change the texture and flavor thereof, such as cremes,
fondants, fudges and the like.
The confectionery product prepared by the
present process contains a sweetener content of at least
70~ of the total solids, and more preferably at least
about 75~ of the total amount of solids. It is preferred
that the sweetener comprises from about 70~ to about 90~
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by weight of the total solids in the confection and more
preferably from about 75~ to about 85~ by weight of the
total solids.
The moisture content of the high solid
confectionery product of the present process is that
typically found in high solids confectionery products.
The moisture content varies depending upon the type of
product. For example, jellies and gums typically contain
10-25~ by weight moisture, caramel typically contains 8-
15~ by weight moisture, marshmallows typically contain
about 8-25~ by weight moisture, nougats contain about 9
to 11~ by weight moisture, fondants typically contain 8-
12~ by weight moisture, cremes typically contain 8-12~
moisture and fudges typically contain 8-12~ moisture.
Since all of these products are contemplated. to be
produced by the present invention, the moisture content
of the high solids confectionery products produced by the
present process range, depending upon the product, from
about 5~ to about 25o by weight moisture. In the more
preferred products of the present invention, the moisture
content of the product produced by the present process
ranges from about 8~ to about 15~ by weight of the total
weight of the product.
The water activity of the confectionery
products formed in accordance with the present invention
is less than or equal to 0.65.
Water activity is a measurement of the amount
of water available for chemical reactions in foods, e.g.,
browning, enzyme activity, microbiological spoilage,
hydration. of colloids, and the like. It is a measurement
of the free water available for chemical reactions. A
higher water activity signifies that more free water is
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available, while a lower water activity indicates less
free water is available. Obviously, the water activity
is related to the amount of water present in the food,
but the relationship is quite complex and non-linear. In
addition, water activity is dependent upon other factors,
such as the amount and type of solids present in the food
and the interaction of the solids with water. Thus, even
if two foods contain the same moisture content, the water
activity would be different if the solid composition of
the foods are different.
It is important to maintain the water activity
below a certain level. In general, molds grow on foods
with water activity greater than 0.70, yeast grow on
foods having water activity greater than 0.8, and
bacteria grow on foods having water activity greater than
0.9. It is preferred, therefore, that the water activity
of the confectionery products produced by the present
process is below 0.65.
The water activity of the confectionery product
formed in accordance with the~present invention
preferably ranges from about 0.30 to about 0.65 and more
preferably from about 0.30 to about 0.45.
The ingredients used in preparing the
confectionery products are those typically found in
confections .
One of the ingredients utilized is a sweetener.
The sweetener content of the cooked material used as a
component in the final product is at least about 700 of
the solids, and more preferably from about 75~ to about
90~ of the solids, as described hereinabove. As used
herein, the term "sweetener" is a sweetening agent that
normally is used to sweeten confectionery products. They
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include such foods as sugars, corn syrups, invert sugar,
and the like.
A sugar is a carbohydrate normally used in
confectionery products. Preferably, the sugars are water
soluble. The sugars can be monosaccharides, especially
D-monosaccharides, dissaccharides, polysaccharides or
mixtures thereof. The sugar can be a ketose or an aldose
and may contain 3, 4, 5 or 6 carbon atoms. Examples of
sugars that may be utilized include ribose, arabinose,
I0 lyxose, allose, altrose, gulose, idose, talose, ribulose,
xyulose, tagatose, erythrulose, sorbose, xylose, glucose,
mannose, galactose, fructose, sucrose, maltose, lactose,
invert sugar (a mixture of fructose and glucose derived
from fructose), and the like or mixtures thereof. The
preferred sugars are monosaccharides and dissaccharides.
The more preferred sugars are ribose, xylose, glucose,
mannose, lactose, fructose, sucrose, and maltose. The
even more preferred sugars are sucrose, glucose, and
fructose, and the most preferred sugar is sucrose.
Sugar substitutes and sugar replacements can
also be utilized as the sweetening agent. However, if
present, they are present up to about 40~ by weight of
the sweetening agent content. Examples include bulking
agents, such as polydextrose, dextrins,~and
maltodextrins, inulin and hydrolyzed products thereof,
corn syrup solids, cellulose, cellulose derivatives and
extracts and the like; sugar alcohols, such as sorbitol,
xylitol, mannitol, maltitol and the like; hydrogenated
starch hydrolysate (HSH), isomalt and the like; and
mixtures thereof. Preferred sugar substitutes and sugar
replacement are polyols, e.g., sorbitol, inulin,
polydextrose, maltodextrin, HSH and isomalt.
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Sweeteners also include corn syrup and invert
sugars or foods containing same, such as honey, molasses,
maple sugar and the like.
By corn syrup, it is meant a purified
concentrated solution of nutritive saccharide obtained
from starch and having a DE of 20 or more.
There are various types of corn syrup. There
are regular acid converted corn syrup, acid-enzyme
converted corn syrup, enzyme-enzyme converted corn syrup
and enzyme isomerized corn syrup. All of these various
corn syrups are contemplated to be used in the process of
making the confectionery products of the present
invention.
The acid converted corn syrups are those
derived from the acid hydrolysis of starch. Examples of
this type corn syrup are glucose syrup and starch syrup,
for example, 42 DE acid converted syrup. (DE refers to
dextrose equivalent, which is defined as the percent
reducing sugars, calculated as dextrose on a dry
substance basis).
In the 1950's, high maltose syrups were
introduced. These are produced by first converting the
starch to a DE of about 20 and then treating it with a
maltogenic enzyme such as cx-amylase or (3-amylase, both of
which selectively hydrolyze the starch to maltose.
Typically, the hydrolysate produced by this method
contains about 40 to about 50 wt ~ maltose. Higher
levels of maltose, i.e., 60-80 wt ~, are produced by
saccharification with a combination of a maltogenic
enzyme and a debranching enzyme, e.g., pullulanase.
The high fructose corn syrups are prepared from
the regular acid conversion of starch, which provides the
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dextrose or glucose syrup which is then treated with an
enzyme that converts the dextrose to fructose (an
isomerization reaction).
Examples contemplated within the term corn
syrup include glucose syrup, high maltose syrup, DE acid
converted syrup, such as 42 DE corn syrup, as well as the
high fructose corn syrup. The corn syrups utilized in
the present process can have a DE value ranging from as
low as 20 to a value as high as 68 or higher. The term
"corn syrup", as used herein, contemplates all of these
various types of corn syrup. To distinguish between the
various corn syrups, if necessary, the present
specification will utilize the term "acid converted corn
syrup", "acid enzyme corn syrup", "enzyme-enzyme
converted corn syrup" and "high fructose corn syrup".
The preferred corn syrups are the regular acid
converted corn syrups, and the high fructose corn syrup.
More specifically, it is preferred that the confectionery
product produced by the present process contain at least
the acid converted corn syrup.and optionally contain the
high fructose corn syrup.
The sweetener may be one sweetener or a mixture
of two or more sweeteners. If the sweetener is a sugar,
it is preferred that a second sweetener is present. The
second sweetener is one that controls sugar
crystallization. As would be expected during the process
of making confections in which sugar is an ingredient, it
is necessary to minimize sugar crystallization during
the last steps of the process. Thus, the second
sweetener is present in amounts that controls sugar
crystallization in the final product. Examples of such
sweeteners include invert sugar and corn syrup,
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especially the acid converted corn syrup, acid enzyme
corn syrup, and enzyme-enzyme converted corn syrup, and
foods containing either invert sugar or corn syrup or
both, as described hereinabove.
It is preferred that the confectionary products
produced by the present process contain a mixture of
sweeteners. It is more preferred that the sweetener
comprises sugar, especially sucrose, and a sweetening
agent that controls sugar crystallization.
The second sweetener which controls sugar
crystallization is preferably corn syrup. This second
sweetener which controls sugar crystallization is used in
the present process not only to impart sweetness to the
confection, but it also controls hydroscopicity, water
activity, viscosity, and texture. It is preferred that
the corn syrups utilized are 42 DE, corn syrup, 62 DE
corn syrup, and 55 high fructose corn syrup. When the
first sweetener is sugar, the second sweetener is
utilized in amounts that controls the crystallization of
the sugar.
Another component of the present invention is
the agar-agar. The agar-agar is present in amounts
sufficient to form a gel and/or enhance viscosity of the
cooked material. The agar-agar also imparts the chewy
property and the stringiness of the confectionery product
and is present in the confectionery products in amounts
sufficient to impart those characteristics thereto.
Preferably, the agar-agar is present in amounts ranging
from about 0.1 to about 2~ by weight, more preferably
from about 0.1~ to about 1.5~ and most preferably from
about 0.1~ to about 0.5~ by weight.
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As described hereinabove, it was discovered by
the present inventors that the addition of an agar-agar
dispersing agent to the agar-agar prior to the heating
step in sufficient amounts, as defined herein, permitted
the use of agar-agar in a continuous process. As used
herein, the term "agar-agar dispersing agent" is a
flowable liquid that is capable of suspending, dispersing
and/or separating the agar-agar to permit a controlled
hydration when water is added thereto. Alternatively, a
dry granular material, such as crystalline fructose,
maltodextrin, crystalline sorbitol, polydextrose, and
especially sugar, e.g., sucrose, can be dry blended with
the agar-agar separately, or with the sweetener, water
and other optional ingredients to form a substantially
15' homogenous flowable material. Hereinafter, the terms
"slurry", and "homogenous mixture", as used herein, will
include such material in their definitions.
Thus, in the presence of the agar-agar
dispersing agent each particle of the agar-agar can
hydrate properly when in contact with water. The agar-
agar dispersing agents include polyhydroxy compounds,
especially sugars, sugar alcohols, and alkanes containing
from 1 to 6 carbon atoms, which are substituted by
polyhydroxy groups, in which the number of hydroxy groups
is at least equal to the number of carbon atoms present;
corn syrup and fat. Examples include glycerin, sorbitol,
dry granular sugar, such as sucrose, and corn,syrup and
fat. The agar-agar dispersing agent when mixed with
agar-agar is in liquid form; thus if it is a solid at
room temperature, it is melted and used in its melted
form. The preferred agar-agar dispersing agent has a
viscosity of 50 to 5000 centipoise, preferably 50 to 2000
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centipoise and most preferably 100 to 600 centipoise.
However, solids such as fats and oils including vegetable
oils which are defined hereinbelow can be used in its
melted form (as long as they are not decomposed) as the
agar-agar dispersing agent and mixed with the agar-agar
at temperatures sufficient to form the slurry. It is
preferred that~the fats and oils, in the melted forms
have the aforementioned viscosity at the melting
temperatures. The most preferred agar-agar dispersing
agent is glycerin.
As indicated hereinbelow, the agar-agar
dispersing agent, the agar-agar, sweetener, water and
other optional ingredients are mixed together under
conditions sufficient to form a homogenous mixture. This
is effected using standard techniques in the art, such as
heating the mixture, agitation (including vigorous
agitation), and the like. However, it is preferred that
the agar-agar dispersing agent is mixed separately with
the agar-agar under conditions sufficient to form a
homogenous mixture (slurry), and that this slurry is then
mixed with the sweetening agent, water and optional
ingredients.
In preparing the slurry comprising agar-agar
and agar-agar dispersing agent, the agar-agar dispersing
agent is mixed separately with the agar-agar under
conditions sufficient to form a homogenous mixture
(slurry). Water may be present as long as the viscosity
ranges indicated hereinabove are maintained. If
necessary, the agar-agar dispersing agent may be heated
to effect the formation of the homogenous mixture. If
the agar-agar dispersing agent is a fat, then the agar-
agar dispersing agent is heated to a temperature which is
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equal to or greater than its melting temperature but less
than its decomposition temperature and/or vaporization
temperature, and is mixed with the agar-agar at a
temperature within this range to form the slurry, as
described hereinbelow.
The inventors have found that the agar-agar
dispersing agent is present in an amount sufficient to
disperse and suspend the agar-agar so that it controls
hydration when in contact with water and heat. If the
agar-agar is mixed separately with the agar-agar
dispersing agent, the agar-agar dispersing agent is
present in an amount to form a homogenous mixture
(slurry) with'the agar-agar. At this concentration,
proper hydration occurs when water is added to the agar-
agar, and the agar-agar is cooked, as described herein.
It is preferred that the weight ratio of agar-
agar dispersing agent (e.g., glycerin) to agar-agar is at
least about 2.5:1. Although there is no upper limit, for
practical reasons, it is more preferred that the weight
ratio of agar-agar dispersing.agent to agar-agar ranges
from about 2.5:1 to about 300:1 and even more preferably
from about 2.5:1 to about 60:1 anal especially more
preferably from about 2.5:1 to about 10:1 and most
preferably at about 4:1.
It is to be understood that the amount of agar-
agar dispersing agent referred to hereinabove is the
amount that is added to the agar-agar to disperse and
suspend the agar-agar so that it controls hydration when
in contact with water and heat. Additional agar-agar
dispersing agent, such as glycerin may be added to the
solution containing water and sweetener.
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Additional ingredients (optional ingredients)
may additionally be present in the product of the present
invention. For example, if corn syrup is not utilized as
a sweetener, then it may be utilized in any of its forms
as an additional ingredient. If, on the other hand, it
is utilized as the sweetener then additional corn syrup
may be added to the precooked product. For example, if
the regular acid converted corn syrup is present as the
sweetener, high fructose corn syrup may also additionally
be present in the confertionary products produced by the
° present invention. High fructose corn syrups (HFCS) are
concentrated solutions containing primarily fructose and
dextrose with lesser quantities of higher molecular
weight saccharides. Commercial products contain 42, 55
or 90~ fructose on a dry weight base. By diluting the
HFCS or by mixing various amounts of HFCS 42, HFCS 55 or
HFCS 90, the HFCS utilized may contain various
concentrations of fructose ranging from about 0~ to 900.
The preferred HFCS are HFCS 42 and HFCS 55.
Food grade rations may also be present in the
confectionary products. The food grade rations include
the edible rations of Groups IA, IIA and ITIA of the
periodic table, especially Groups IA and IIA. They are
preferably GRAS and water soluble. Examples include
2S water soluble salts of potassium, sodium, ammonium,
magnesium, calcium, and the like. The preferred edible
rations are salts of calcium or potassium or magnesium,
such as potassium. chloride, calcium lactate, calcium
chloride, calcium carbonate and the like. If present,
the food grade rations are preferably present in amounts
ranging from 0 to about 5~ by weight and preferably less
than 2.5o by weight.
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If the fat is not utilized as an agar-agar
dispersing agent the confectionery product may also
contain fat. Moreover, even if the fat is utilized as an
agar-agar dispersing agent, the confections may contain
additional fat. The additional fat content of the
confectionery may vary from 0 to about 40o by weight for
products that contain chocolate, and from 0~ to about 20o
for fruit flavored and caramel products. It is preferred
that the additional fat content is present in less than
about 15~ by weight.
The fats utilized as either the agar-agar
dispersing agent or the additional ingredient are those
fats normally employed in confectionery products.
Suitable fats and oils include fractionated fat and
hydrogenated, partially hydrogenated and unsaturated
oils, such as coconut, palm, palm kernel, cotton seed,
safflower, soy, corn oil, milk fat, cocoa butter,
hydrogenated vegetable oil, butter and the like and
mixtures thereof. The term "fats" and "oils" are used
interchangeably, although there may be differences as
understood by the skilled artisan. "Fats" is generally a
term that refer to the solid embodiment of the above-
mentioned groups and "oils" refers to the liquid form.
Additional additives may also be present, such
as emulsifiers, like lecithin, mono- and diglycerides or
polysorbate, polyglycerol ester and the like. If
present, the emulsifier is present in an amount ranging
from about 0~ to 5~ by weight.
Salts, such as sodium chloride, may optionally
be present. If present, it is present in an amount
ranging from about 0 to about 2.5~ by weight.
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The confections prepared by the present
invention may also include other additives, such as
preservatives and anti-oxidants, such as BHA, BHT, TBHQ,
citric acid, and the like, which are present in anti-
s oxidizing effective amounts.
Another additive that may be present in the
confections produced by the present invention is
colorants. The colorants may be present in amounts of up
to 1~ by weight. The colorants may include pigments,
such as titanium dioxide or include other dyes suitable
for food. A full recitation of all food colorants and
their corresponding chemical structure may be found in
Kirk-othmer Encyclopedia of Chemical Technology, 3=a
Edition in Volume 5 at Pages 857-884, the contents of
which are incorporated by reference.
Another additive, flavorings, may be included
in the confectionery products produced in accordance with
the present invention. These flavorings include those
known to the skilled artisan, such as natural and
artificial flavorings. Examples include flavor oils,
e.g., peppermint, or cinnamon, and the like; artificial,
natural and synthetic fruit flavors, such as vanilla,
artificial vanilla, powdered honey, citrus oils and the
like; or fruit juices, including lemon, orange, lime,
grapefruit and the like; and fruit essences, including
apple, pear, peach, grape strawberry, raspberry, cherry,
plum, pineapple, apricot, and the like.
The amounts of flavoring employed is normally a
matter of preference subject to such factors as flavor
type, strength desires and individual preferences.
Thus, the amount may be varied in order to
obtain the result desired in the final product. Such
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variations are within the capabilities of those skilled
in the art without the need for undue experimentation.
In general, amounts of about 0.1o to about 5.0~ by weight
of flavoring agents are useable.
The confections produced in accordance with the
present invention may also contain effective amounts of
acidulants, such as malic acid, citric acid, tartaric
acid, adipic acid, and mixtures thereof.
Any other conventional ingredients used in
confections, such as other sweeteners, other seasonings,
other materials derived from fruit and/or vegetable, for
example, pulp, puree of fruit and/or vegetable and the
like, may also be present in the confections of the
present invention. '
As indicated hereinabove, additional agar-agar
dispersing agent in amounts greater than used to hydrate
the agar-agar, when contacted with water may additionally
be present in the confectionery product. In addition,
proteins, such as milk proteins and soy proteins, may
also be added to the confectionery product.
In addition, nuts or pieces of nuts, such as
peanuts, pecans, macadamia nuts, and the like may also be
contained in the confection.
The confection may also employ crispy bakery
products and cereals, like rice, puffed cereal, cookies,
crackers and the like.
The type of optional ingredients added will
vary, depending upon the targeted confection. The
optional ingredients added to the uncooked homogenous
mixture are thus typically added to make the desired
confectionery product, e.g., jellies, gummy products,
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nougats, marshmallow, caramels, fudges, cremes, fondants,
and the like.
The confections of the present invention are
prepared as described hereinabove.
The agar-agar, the agar-agar dispersing agent,
the sweetener, water and optional ingredients are mixed
together under conditions sufficient to form a homogenous
mixture. Heating and sufficient mechanical agitation to
form a vortex in combination with a slow addition of
agar-agar may be required to form the homogenous mixture.
If heating is required, it is preferred that the
temperature of the mixture is heated to a temperature
ranging from about room temperature to about 180°F, and
more preferably from about room temperature to about
IS 260°F.
The heated mixture is then pumped to a heating
apparatus for cooking, as described hereinbelow. As an
alternative method, the various ingredient may be mixed
in a mixer which is then pumped to an evaporation holding
tank, from which portions of the mixture is pumped into
the heating apparatus (cooker).
However, it is preferred that the pre-cooked
mixture is prepared in two steps.
The agar-agar and agar-agar dispersing agent
are first mixed together in an amount sufficient to form
a slurry under conditions sufficient to form the slurry.
Heating may be required to effect the formation of the
slurry. If the agar-agar dispersing agent is a fat, then
the fat is melted as described hereinabove and the melted
fat is mixed with the agar-agar at temperatures
sufficient to maintain the fat in its molten form to form
the slurry. Moreover, the temperature may be maintained
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or raised to a higher temperature when the molten fat and
agar-agar are mixed with the sweetener, water and any
other ingredients. It is preferred that the agar-agar is
added to the agar-agar dispersing agent when mixed to
form the homogenous slurry. It is also preferred that no
additional water is added to the agar-agar and agar-agar
dispersing agent either before or during the mixing.
The agar-agar and agar-agar dispersing agent in its
liquid form are mixed sufficiently to form a homogenous
slurry .
In the second step, the slurry is mixed with
the other components, water, sweetener, such as corn
syrup or sugar or mixture thereof and any other additives
under conditions sufficient to produce a homogenous
mixture. Alternatively, the sweetener and water or other
ingredients may be added to the slurry comprising the
agar-agar and the agar-agar dispersing agent either
individually or they may be added as a homogenous
solution or suspension to the slurry. Moreover, the
sweetener and water and other.ingredients may be added
manually or batchwise or they may be added in a
continuous manner. Preferably, the slurry and the water,
sweetener and any other additive are heated to a
temperature sufficient to form the homogenous mixture.
It is preferred that the mixing be conducted at
temperatures ranging from about room temperature to about
180°F, more preferably to about 160°F. The homogenous
mixture may be a solution or slurry (suspension). The
ingredients are mixed in a mixing vessel, e.g., such as
the batch tank.
Regardless of the method for preparing the pre-
cooked mixture, the amount of solids present in the
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mixture at this point prior to cooking preferably ranges
from about 60 to about 80o by weight and more preferably
from about 65o to about 75~ by weight; the pH of the
mixture preferably ranges from about 5.0 to about 8Ø
The heated pre-cooked mixture is pumped to a
heating apparatus and the mixture is heated under
conditions sufficient to cook the mixture. Preferably,
the temperature of the homogenous mixture in the heating
apparatus ranges from about 180°F to about 260°F.
Moreover, the heating is conducted under high temperature
short time conditions in which the heating apparatus is a
plate-like heat exchanger which permits each drop of the
solution or each particle of the suspension to be heated
to the requisite temperature. Under these conditions,
the heating is effected for a sufficient amount of time
to cook the mixture. Preferably the cooking is effected
in less than 2 minutes and more preferably less than 1
minute and most preferably less than 40 seconds, for
example, 5-15 seconds. The cooking may be effected at
atmospheric pressure or under.a vacuum or under reduced
pressure, e.g., less than 1 atmosphere. Cooking the
mixture at these high temperaturesJfor such a short
period of time is referred to as high temperature short
time heating or processing. This technique is known in
the food art. Examples of heaters used in high
temperature short time processing include plate frame
cookers, thin film cookers, and the like.
During the heating step, water in the mixture
is converted to water vapor. Thus, the cooking step also
concentrates the solution. The cooking is conducted
until approximately the desired solids concentrations is
achieved, which, as indicated hereinbelow, occurs, under
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the high temperature short time processing in less than
about two minutes.
After the cooking step, the mixture is pumped
from the heating apparatus to another vessel, wherein
water vapor formed during the cooking step is removed.
The mixture is next cooled. Additional water vapor may
evaporate during or after cooling, and as a result, the
resultant mixture becomes more concentrated.
After the confection is cooled to about 110°F,
and more preferably to about 120°F and even more
preferably to about 140°F, it may be blended with other
components, such as crispy bakery products, cereals,
rice, nuts, or mixtures thereof or it may be aerated to
form marshmallows, or any combination thereof and then
processed. Alternatively, the cooked mixture may be
charged to suitable containers for later use or for
further processing. For example, the hot product may be
put in molds wherein it is cooled and then cut into
pieces. Alternatively, the product may be cooled using
techniques known in the art, such as a cooling tunnel, to
form slabs, which may be cut into smaller pieces. After
the processing step, the product is ready for marketing,
and can either be eaten or packaged.
The process described hereinabove is conducted
continuously, such that the mixture is transferred from
one vessel automatically by means known to one skilled in
the art such as a pump. Thus, in the continuous process,
as soon as one vessel in the process is emptied, it is
immediately filled. This constant and automatic
continuing emptying and filling of each of the vessels is
continued throughout the process described hereinabove.
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However, as defined hereinabove, the various components,
may be added manually or batchwise.
A schematic illustrating a preferred embodiment
of the present invention is illustrated in.Figure 1.
Agar-agar dispersing agent and agar-agar are
mixed together as described hereinabove in a mixing tank
(1) containing a mixing apparatus (2) until the
components are substantially evenly dispersed. A set
amount of agar-agar/agar-agar dispersing agent is drained
from the bottom through a valve (3) to the syrup hatching
tank (4) by a pump (5). To ensure that sufficient amount
of blend is removed for mixing with the other
ingredients, the agar-agar/agar-agar dispersing agent may
be weighed prior to being added to the syrup hatching
tank. The mixture may be heated with heater (29) at
temperatures effective to form a homogenous slurry.
A.homogenous solution of the sweetener and
water, and other optional ingredients, such as calcium
salt and bulking agent, is prepared in a mixing tank (6)
using a stirring device (7) under conditions effective to
form the homogenous solution (sweetener solution). Tf
temperatures higher than room temperature are required,
then a heater or steam is utilized under conditions to
solubilize the ingredients to form a solution or to
evenly disperse the components, in a homogenous mixture.
The homogenous solution produced in the mixing tank (6)
is drained from the bottom through a valve (8) and pumped
with pump (9) to the syrup hatching tank (4), mixed with
the slurry comprising agar-agar and agar-agar dispersing
agent in the syrup hatching tank (4) and the contents are
stirred with a stirring device (8) to make homogenous.
Alternatively, the sweetener, water and other optional
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components may be added manually together under
conditions sufficient to form a homogenous solution in
the mixing tank (6). In another embodiment, the water,
sweetener and other optional components may be added
individually to the syrup hatching tank in the absence of
the slurry comprising agar-agar and agar-agar dispersing
agent. In still another embodiment, the sweetener
solution may be formed in the syrup hatching tank (6) to
which is added the slurry described hereinabove.
The syrup hatching tank is preferably connected
to a heating device (11). The contents, i.e., the slurry
and the sweetening solution are stirred with a stirring
device (13) and heated to a first temperature for a time
sufficient to evenly or substantially evenly disperse all
of the components. It is preferred that the heating is
effected at temperature ranging from room temperature to
about 160°F and more preferably from about 135°F to about
160°F. After the components are evenly dispersed, the
new mixture is transferred through valve (15) by a pump
(16) to the evaporator feed tank (9) which i,s connected
to a heating device (12) which maintains the mixture at a
second temperature, which second temperature is greater,
than or equal to the first temperature, but less than the
cooking temperature described hereinbelow. It is
preferred that the temperature of the evaporator feed
tank ranges from about room temperature to about 180°F
and more preferably from about 130°F to about 180°F and
even more preferably from about 140°F to about 170°F.
The contents therein are stirred with a stirring device
(14). The mixture is maintained at the second
temperature to minimize the heat load requirement for the
final cooking process. The solution is then continuously
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fed to the heating apparatus (17) by a pump (19) through
an inlet valve (20).
This evaporator feed tank (9) can also be
viewed as a storage area inasmuch as only a limited
amount of solution can be fed into the heating apparatus
(17). Thus, when a portion of the solution is being
heated in the heating apparatus, the remainder of the
solution is held in the evaporator feed tank. After the
solution is cooked in the heating apparatus and is pumped
by a pump (19) through the outlet valve of the heating
apparatus, the next set portion of the solution in the
evaporator feed tank is pumped into the heating apparatus
(17) .
The heating apparatus (17) is one which
provides sufficient heat transfer from the apparatus
contact surface to the homogenous mixture (solution or
slurry). One particularly useful apparatus is a thin
film evaporator wherein the solution is fed through an
inlet (20) to the apparatus and through a tube (not
shown) to the outlet (21) of the heating apparatus,
whereby the solution is heated in the tube. The
temperature in the tube may be higher at one end than at
the other end or it may be relatively uniform throughout.
An example of such a heating apparatus is a
plate and frame heat exchanger used in high temperature
short time (HTST) processing. In HTST processing, the
solution from the evaporator feed tank is pumped through
a plate type heat exchanger and brought to the requisite
temperature. The key to the process is that virtually
every drop of the solution, or if it is a homogenous
suspension virtually every particle is heated to the
requisite temperature. This is accomplished by pumping
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the heated solution through a tube of such length and
diameter that it takes every drop of solution or particle
of homogenous suspension at least 10 seconds and more
preferably from about 10 seconds to about 2 minutes even
more preferably from about 10 sec. to about one minute
and most preferably from about 10 seconds to about 40
seconds to pass through the tube.
The solution or homogenous suspension supplied
to the heating apparatus is heated to cooking
temperatures, and preferably at a temperature to
concentrate the carbohydrate solution. The cooking is
effected under condition sufficient to vaporize the water
and to concentrate the mixture to about the predetermined
amount of solids. Preferably, the temperature is greater
than about 180°C and less than about 260°C.
Upon exiting the heating apparatus through exit
valve (21), the water vapor is separated from the liquid
phase. The separation of water vapor from the syrup is
effected by any means known to an artisan of ordinary
skill. One such means is by pumping the cooked solution
or suspension into a flash tank (22) or a cyclone
separator, i..e., vapor/liquid separator, which separates
the two phases, disposing of the gaseous phase, i.e.,
water vapor and directing the liquid phase to the next
phase of the process; that is, the concentrated syrup is
pumped via a pump (23) through an exit valve to a cooler
(25), where the cooked product is cooled to a temperature
below 175°F and more preferably below 150°F and more
preferably between 130°F and 150°F. The cooling is
preferably imparted rapidly to the cooked solution or
suspension. In a more preferred embodiment, the cooked
solution or suspension is pumped through a plate cooler
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(25) and then into tank (26). In an embodiment, not
shown, for the preparation of marshmallows and nougats,
the cooled solution may be passed through an aerator
known. to the skilled artisan and the contents beaten
therein. If an aerator is utilized, it is preferably
after tank (26). From there it may be ultimately charged
to a storage container (27) or it may be blended with
other materials.
Colorants or flavoring agents may be added to
the product as indicated hereinabove in the syrup
batching tank (14) or in the mixing tank (6).
Alternatively, optional ingredients, such as colorings
and flavorings, may be added to the product in tank 26
through inlet valve (not shown) in a continuous manner.
However, in the embodiment shown in Figure 1,
there are preferably two mixing tanks (1) and (16) which
are provided with stirrers (2) and (7), respectively.
The vessels may be attached to heating means (29) and
(30) such as steam jackets. In vessel (1), the agar=
agar and the agar-agar dispersing agent are mixed
together to form a homogenous slurry. Preferably, the
tank is filled with that amount of agar-agar dispersing
agent that is to be used and the agar-agar is added
thereto while the mixture is being stirred. The
sweetener and water and other ingredients, such as salts,
cation, bulking ingredients second sweetener and the like
are added to the second vessel (6) with stirring with a
stirring device and heated, if necessary, with the
heating device (30) until the mixture is homogenous.
As schematically drawn each of the tanks 1 and
6 have drain valves 3 and 8. However, the mixture in
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tanks 1 and 6 may be added manually to the syrup hatching
tank (4), as described hereinabove.
Each of the valves are in fluid communication
with pump 5 and 9 which is adapted to pump the slurry
comprising agar-agar and the agar-agar dispersing agent
into the syrup hatching tank 4. Alternatively, in
another embodiment shown in Figure 2, the slurry
comprising the agar-agar and agar-agar dispersing agent
is prepared in tank 1 and the homogenous mixture is added
to the syrup hatching tank (4) with the separate
components of the sweetener solution, such as sweetener,
'water, and other optional ingredients. The components
are mixed under conditions sufficient to form a
homogenous mixture. The syrup hatching tank (4) is
connected to a heater (11) which if necessary may be used
to help make the mixture homogenous. The contents are
then pumped into another tank, the evaporator feed tank,
which is also linked with heating means (12), such as a
steam jacket. The mixture is heated to a temperature
sufficient for the contents to remain homogenous.
Preferably, the temperature of the evaporator feed tank
ranges from about 130°F to about 180°F, anal more
preferably from about 140°F to about 170°F. The
evaporator feed tank can hold more than one batch of
mixture; preferably it holds at least two batches.
A batch of the material is pumped into the
heating apparatus (17) described hereinabove and is
cooked for the short time at high temperature. A monitor
(31) may optionally be attached through line (32)
connecting the heating apparatus (17) and the evaporator
feed tank (9). The homogenous mixture in line 32 may be
monitored for water activity, moisture or solids amounts
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(brix) or any combination thereof to ensure that the
homogenous mixture pumped into the heating apparatus has
the proper characteristics. For example, in one
embodiment, the water activity preferably ranges from
about 0.3 to about 0.5 and more preferably from about
0.440 to about 0.480 at 25-30°C. If through the
monitoring, the characteristics of the precooked
homogenous mixture pumped through line 32 is not within
the desired ranges, other characteristic will also be
determined to confirm the previous findings. As would be
expected, if the characteristics of this precooked
solution is not within predetermined specification, then
the entire product batch prepared from this precooked
mixture will be discarded and the process started anew.
On the other hand, if the precooked solution is within he
predetermined specification, then the products produced.
by the process will be maintained.
The heating apparatus, through which the
homogenous mixture passes, is in fluid communication with
a vapor liquid separator 22, which removes water vapor
through an overhead line 33 in fluid flow communication
with the separator 22, while allowing a more concentrated
mixture to pass in a downward direction into line 34
through valve 24 which is in fluid communication with
pump 23 which moves the mixture through line 34 into
cooling unit 25. The cooling unit 25 is comprised of a
jacket 35 which is adapted to receive and discharge
cooling water. The jacket is positioned above the
cooling chamber (not shown). The line from the cooling
unit is directed to valve (36) to tank (26) containing a
stirrer (37) to maintain homogeneity of the cooked
mixture. The mixture is still hot and,is maintained at
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temperatures ranging up to about 140°F, and more
preferably from about 110°F to about 140°F. The tank
(26) is connected to a valve (38) which is a three
position valve allowing for the collection of material
per se into storage (27) or for routing the material to a
blender (28) for subsequent mixing with other
ingredients, or for further processing (41).
Alternatively, the valve (38) may be in a closed
position.
It is to be noted that throughout the process,
flow of the material from start to finish is in the
direction of arrow A.
Because the process is continuous, when an
outlet valve is open, the inlet valve to a vessel is
closed and vice versa. Thus, when one of the mixing
tanks is drained of its contents to a subsequent vessel
in the process, the valve at the top of the tank is
closed, the valve at the bottom of the tank is opened,
the valve at the top of the vessel (if present) is
opened, and the valve at the bottom of the vessel is
closed. Subsequently, the reverse occurs when the
emptied tank is recharged. The valve at the bottom of
the tank is closed, while the valve at the top of the
tank is opened. When the homogenous mixture is pumped to
2S the evaporation feed tank from the syrup hatching vessel,
the bottom valve of the evaporation feed. is closed, while
the valve at the bottom of the syrup hatching vessel is
opened and the valve, if present, at the top of the
evaporation. feed tank is open. However, when the
contents of the evaporator feed tank are pumped into the
heater, the valve into the evaporator feed tank is
closed, while the valve leading from the evaporator feed
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tank is open. After the material has passed through the
heater, there is a two phase system, a liquid phase and a
gaseous phase comprised primarily of water vapor. The
mixture is charged into the vapor liquid separator (22)
which discharges the gaseous phase or water vapor through
overhead line (33) and into vessel (39) where the vapor
is cooled and condensed to water and the water is then
discharged through discharge (40) to a collecting vessel.
The concentrated mass is pumped from the
separator through pump (23), moving the material into the
cooling unit (25) where it is cooled. From the cooling
unit the material is fed through vessel (26) then to the
valve (28) wherein the mass is mixed with other
components (28), processed (41), or is directly passed
through to the storage bin (27).
As indicated hereinabove, if a marshmallow or a
nougat or a food containing same is to be prepared,
before being pumped to tank (26), the cooled slurry is
pumped to the aerator, wherein. the contents are aerated
and beaten and then the aerated cooled mixture is pumped
to tank (26)~.
Using the procedure described herein various
confectionery products can be prepared. For example,
jellies and gums which have the common general
characteristics of being chewy can be prepared. Orange
slices, gum drops, gummy bears, jelly beans, fruit snacks
and jujubes represent some of the product types. These
can be prepared by mixing the agar-agar with the agar- ,
agar dispersing agent such as glycerine as described
hereinabove and mixing it with homogenous solution of
sucrose, corn syrup and/or invert sugar and additives,
such as flavors, colors and acidulents. The mixture is
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then°pumped through the heating apparatus, and then the
water vapor separated out and the mixture is partially
cooled. The partially cooled material may then be cast
into starch, plastic or metal molds or formed into slabs
and dried to 80-92~ solids and then cooled to room
temperature.
As another example, marshmallows may be
prepared, The agar-agar and agar-agar dispersing agent
such as glycerin are slurried together until homogenous,
and mixed with sugar, water, corn syrup, and other
additives e.g., invert sugar, dextrose, sodium
hexametaphosphate, powdered sugar, color, and flavor.
After the heating step and removal of the water vapor,
and cooling, the homogenous mixture is passed through an
aerator (not shown).. The aerator is located between
cooler (25) and tank (26). Any aerator normally used in.
the confectionary art may be utilized. Examples include
Mondomix, Rotomix, GEI, Oakes or Votator. The mixture is
aerated and the mixture beaten using techniques known in
the art, such as by a pressure beater or continuous
pressure beater, and the like.
The products herein may be enrobed with
chocolate or mixed with other ingredients. For example,
the cooked and partially cooled product in tank (26) may
be mixed with other material separately made containing,
for example, nuts or chocolate or cereal or crispy bakery
products or combination thereof. For instance, the
o product may be metered in and mixed with a homogenous
slurry containing peanut butter and ground peanuts, salt,
anti-oxidant, and other additives. The product resulting
therefrom is extruded onto a belt. The product then
proceeds through a cooling tunnel to set the slab and
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then it proceeds to a guillotine which sets the length.
The product then may be partially or. fully enrobed with
chocolate.
Thus, the present process enables the
preparation of high solids confectionery using agar-agar
in a continuous process.
It is to be noted that, unlike most continuous
processes wherein the gelling agent after prehydration is
added to the cooked mixture, in the present process, the
agar-agar is added to the mixture prior to cooking.
Thus, the need to add pre-hydrated agar-agar after the
cools stage in the present process is eliminated.
Thus, by utilizing the present process, high
solid confectionery products can be prepared in a
continuous process. Moreover, agar-agar taken through
the process is fully hydrated and functional without the
need for the prior and extensive prehydration times.
Thus, the present process has several
advantages. It is efficient. This is the first process
that permits the use of natural unmodified agar-agar in.
preparing high solids confectionery in a continuous
process. Other advantages of utilizing agar-agar in this
way include (1) long pre-hydration times of agar-agar are
eliminated; (2) processing viscosity of the batch slurry
remains low, allowing more efficient pumping and heat
transfer since agar-agar does not hydrate until reaching
the heating apparatus; (3) the need to add pre-hydrated
agar-agar after the cook stage is eliminated; (4)
continuous processing can be accomplished; and (5) it
allows addition of divalent cations (such as Ca++, Mg++)
to the batch slurry without cross-linking or chemical
interference with the agar-agar.
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Unless indicated to the contrary, all
percentages are by weight on a dry weight basis.
As used herein, the singular includes the
plural and vise versa.
S The present invention is illustrated by the
following non-limiting examples.
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EXAMPLE 1
Using the apparatus schematically described in
Figure 1, the following confection was prepared.
. 21.5 g of glycerin was added to a tank with
stirring. 5.34 g of agar-agar was added to the tank with
stirring in small batches. When all of the agar-agar was
added, the blend was mixed for an additional 10-15
minutes to ensure homogenicity.
In a second tank heated to 140°F were added 819
g of corn syrup 42 DE, about 274 g of sucrose, about 132
g water, about 280 g of additional glycerine and about
468 g HFCS 55, and the ingredients were mixed until a
homogenous solution (sugar solution) is obtained. The
sugar solution was pumped to a third tank.
The agar-agar/glycerin homogenous mixture was
also pumped into a third tank where it was mixed with the
sugar solution. Then tank was heated to 155°F while
mixing for a minimum of ten minutes to insure all
ingredients were dispersed fully. Once the resulting
homogenous mixture, i.e., syrup, reached 155°F and the
requisite time had elapsed, the syrup was transferred to
the evaporator feed tank, which maintained the premix at
4
a temperature of about 155°F. The solution was supplied
to the heating apparatus, a plate heat exchanger,
continuously where it was heated at 208°F for 39 seconds.
The heating was conducted under vacuum, at about 371
mm Hg. It was pumped through the plate heat exchanger
and into the flash tank, wherein water vapor was
separated from the solution. The concentrated cooked
syrup is pumped from the flash tank through a plate
cooler and into tank (26). The solution became more
concentrated as more water was vaporized. The vapor
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condenses using cooling water that is below 80°F to
maintain constant removal of condensate. The product was
allowed to cool. This product exhibited good
stringiness. In addition, it didn't hydrate in the
batch; the resulting product had low viscosity and no
visible clumping. The texture of the product of Example
1 was similar to the target, i.e., a product containing
1~ gelatin.
The product formed had the requisite
stringiness and adhesiveness that was sought in the
targeted product. However, when the agar-agar was
substituted with other gelling agents and/or
hydrocolloids, the products formed were substantially
inferior, with the exception of the product containing
quick soluble agar. However, when the quick soluble agar
was utilized, processing was substantially more difficult
than with agar-agar, as described below.
COMPARATIVE EXAMPLE 1 (CONTROL)
The above experiment was repeated except that
there was no hydrocolloid added. The product had short
texture, no stringing.
COMPARATTVE EXAMPLES 2 AND 3
The procedure of Example 1 was repeated, except
GP 911, carageenan (gelcarin) and GP 328, carageenan
(viscarin) were used in Comparative Examples 2 and 3,
respectively, instead of agar-agar. Both hydrated in the
batch. The batch was viscous and nonhomogenous and could
not be pumped. Also very little stringing was seen.
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COMPARATIVE EXAMPLE 4
The procedure of Example 1 was repeated, except
Avicel CL 611, cellulose gel (microcrystalline cellulose
and sodium carboxymethyl cellulose) was used in lieu of
the agar-agar.
The product became white. Moreover, very
little stringiness was observed in the product.
COMPARATIVE EXAMPLE 5
The procedure of Example 1 was repeated, except
that Rhodigel EZ (Xanthan gum). was used in lieu of agar-
agar.
There was no visible stringing. The product
was slimy.
COMPARATIVE EXAMPLE 6
The procedure of Example 1 was repeated except
that Colloid 600 (furcelleran) was used in lieu of agar-
agar.
The product exhibited little stringiness. In
fact this product exhibited characteristics similar to
the control.
COMPAR.ATTVE EXAMPLE 7
The procedure of Example 1 was repeated except
that Flogel 60 (starch, food starch modified) was
utilized in lieu of agar-agar.
, The product was slightly stringier than the
control, but still exhibited very short texture.
COMPARATIVE EXAMPLE 8
The procedure of Example 1 was repeated, except
that Flogel 65 (starch, food starch modified) was
utilized in lieu of agar-agar. ,
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The product had short texture, much shorter
than,the control. Tt also exhibited no stringiness.
COMPARATIVE EXAMPLE 9
The procedure of Example 1 was repeated, except
that a quick soluble agar-agar was utilised in lieu of
agar-agar.
The agar-agar hydrated immediately in the
batch. The viscosity of the pre-cooked product was
greater than that of Example 1. Moreover, the product.
containing the quick soluble agar-agar was significantly
more difficult to process and harder to pump. But, the
pumped product was similar to Example 1.
COMPARATIVE EXAMPLE 10
The procedure of Example 1 was repeated except
that Avicel LM 310 (microcrystalline cellulose) was used
in the lieu of agar-agar.
The resulting texture of the product was short
and there was no stringiness.
EXAMPLE 2
A gummy bear product is prepared as follows:
The procedure of Example 1 is followed, except
the following components are mixed together under
conditions to form a homogenous mixture.
Amount
Agar-Agar 1~
Glycerine 3.5a
Water 14~
Sucrose 31~
Citric Acid 15~
42 DE Corn Syrup 49~
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The mixture is passed through the heater at 210°F for 30
seconds and the water vapor removed until the product has
a moisture content of about 15~. It is cooled to about
30-40°C, and while liquid, a set amount is placed into
starch molds, wherein it is allowed to cool.
EXAMPLE 3 - MARSHMALLOW
Using the apparatus diagramed in Figure 1, a
marshmallow product was prepared as follows: 20 grams of
agar-agar is added slowly to 80 grams of 42 DE corn syrup
in mixing tank 1 and mixed at.room temperature until a
homogenous slurry is formed. The slurry is pumped to the
syrup batching tank (4) which is maintained at 180°F.
600 grams of sucrose, 700 grams of water, 320
grams of 42 DE corn syrup and 7 grams of sodium citrate
are mixed together in a mixing tank (6) at about 140°F
until a homogenous solution is formed. The homogenous
mixture is pumped from the mixing tank (6) to the syrup
hatching tank (4) and the slurry is mixed with the
homogenous solution until a homogenous mixture is formed.
The homogenous mixture is pumped to a plate and frame
cooker (17) and is heated at 208°F under 371 mmHg and the
homogenous mixture passes therethrough in about 37
seconds. The mixture is concentrated to about 76~
solids. The water vapor thus formed and the homogenous
mixture is pumped to the flash tank (22) wherein the
water vapor is separated and removed. The concentrated
syrup is pumped from the flash tank through a plate
cooler (25) and the cooked mixture is cooled to about
120°F. The cooled mixture is pumped to a Votator aerator
where it is aerated by means of an air compressor. The
aeration is maintained until the mixture forms a firm
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elastic foam. The foam is pumped to tank (26), wherein
it is removed and placed in starch moulds at room
temperature for 12-24 hours and allowed to set until the
marshmallow is formed.
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The above preferred embodiments and examples
were given to illustrate the scope and spirit of the
present invention. These embodiments and examples will
make apparent to those skilled in the art other
embodiments and examples. the other embodiments and
examples are within the contemplation of the present
invention. Therefore, the present invention should be
limited only by the amended claims.
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