Note: Descriptions are shown in the official language in which they were submitted.
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DESCRIPTION
SHELF STABLE, BAKEABLE SAVORY CHEESE PRODUCT
AND PROCESS FOR PREPARING Tf
Background of the Invention
The invention relates to a shelf stable, bake-stable, smooth-textured cheese
product, other bakeable savory spreads and filler compositions and to
processes for
preparing them. The savory, especially cheese, products provide a number of
product
variations and combinations.
Cheese is a favorite that extends across generations and cultures. Tn America
and
Europe, in particular, people enjoy cheese at any meal~and at many times in
between. One
very desirable combination with cheese is to serve it with some form of baked
goads.
Bread and crackers are popular choices and there are, in fact, cheese-flavored
breads and
crackers available on the market. Other combinations of this type employ a
shelf stable
cheese filler in corribination with crackers, puffed snacks and the like.
Products of these
types are satisfactory to some extent, but the filler lacks a desired
creaminess and smooth
melt that would be desired. Also, the crackers must be baked first and then
filled. There is
no known technology to add a cheese filler to an unbaked dough and achieve a
baked
product having suitable texture, flavor and shelf stability.
In U. S. Patent No. 3,741,774, Burkwall, used the term "shelf stability" in
his
context, to define a single property, i.e., microbiological stability.
Burkwall provided a
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simulated cheese product containing S to 35% of sugar or sugar equivalents to
lower the
osmotic pressure of the cheese to "render it substantially free from
bacteriological
problems". The provision of large amounts of sugars (13 parts sucrose versus 5
parts
cheese in the Example) is largely incompatible with savory flavors such as
cheese. The
S high percentage of protein binding agents and starch are also incompatible
with the
provision of a smooth and creamy texture necessary for a good cheese filler.
As a practical matter, the property of "shelf stability" requires more than
microbiological stability. Indeed, there are a number of organoleptic and
rheological
criteria that must be met before a product can be considered "shelf stable".
There is a
technical challenge in modifying a savory food such as cheese such that it
becomes stable
to baking, i.e., bakeable, without sacrificing its flavor or creamy texture.
To be fully shelf stable a product must maintain its texture. The savory food
;rust
also retain its flavor, and it must not adversely affect that of a copackaged
baked dough
such as is found in pretzels, crackers or puffed snacks, such as cheese filled
puffed
snacks, e.g., cheese balls, in terms of taste, texture or color. This means
that the baked
dough portion of the composite product must maintain a crisp texture. It must
not become
soggy due either to the migration of moisture from the cheese or oil-soaked
due to the
release, i.e., so-called "oil out" of oil from the cheese.
The 'problem of oil release from the cheese is a particular problem, Oil
release
affects the texture of baked dough as well as its flavor and color, Moreover,
when oil is
released from the cheese, the flavor and texture of the cheese are also
altered. In U. S.
Patent No. 5,935,634, Gamay, et at., describe a low-water activity cheese
product
containing 40 to ~0% cheese and utilizing 1 to 10% lactose and 2 to 15% of a
humectant
to provide shelf stability. The examples reporting satisfactory results and
utilizing the
claimed amounts of cheese also included over 5% of sugars and alkali metal
lactates. It
would be desirable to achieve shelf stability without utilizing either sugars
or lactates.
And, it would be desirable to achieve this in a product that was stable to the
heat of
baking and showed minimal if any oil release initially and over time.
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In. the case of cheese products, it is important to provide significant
quantities of
cheese. In U. S. Patent No. 4,752,494, for example, Tang, et al., describe a
"thermostable
cream" containing any one of a variety of flavors, including savory flavors,
in a
formulation designed to achieve their objectives. Essential to meet their
objectives is the
presence of Cad ions, caseinate ions and corn syrup. While they refer to their
product as
savory, the sole example on cheese-flavored fillers employs about 10% cheese
(in the
form of cheese powder) and more than 50% corn syrup. The product is sand to
withstand
baking and be shelf stable, but the presence of the binder and the large
amounts of sugars
in the corn syrup will seriously detract from a desirable cheese flavor and
texture_
In U. S. Patent No. 5,529,01, Morano points out that products of the type
produced by Tang, et al., suffer from a common problem in the art when dealing
with
water-soluble gelling agents, whether protein or carbohydrate based.
Typically, these
products require significant water contents to hydrate the gelling agent.
Morano would
like to provide an essentially water free product and proposes the use of an
ultra high
surface area cellulose which is able to hydrate in a,hydrophilic liquid phase
comprised of
an edible polyol humectant. Thus, this composition requires the presence of a
particular
form of cellulose to avoid the need for water, and fats are preferably avoided
because the
product is desired to be fat free. Zt would be desirable, however, to meet the
challenge of
providing a bakeable cheese filler without resorking to adding cellulose or
decreasing fat.
There is a need for a process that would enable modifying a normally unstable,
savory food such as cheese to render it stable to the heat of baking without
sacrificing its
flavor or creamy texture. As used herein, the terms "bakeable", "bake-stable"
and "stable
to baling" are used interchangeably and refer to a minimal heat stability of a
cheese
filling within a composite baked dough and savor filling product, such as a
filled pretzel,
cracker or puffed snack, to maintain suitable homogeneity and rheology and to
remain
acceptable as a filling without significantly degrading the baked dough. Among
the
puffed snack products are starch-based snack products, possibly extruded, such
as cheese
bates and the like. Products such as cheese-filled cheese balls can be
coextruded as an
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enrobed "rope" of the savory filling within a "rope" of dough that is fully
cooked, e.g.,
baked, during forming by extrusion or thereafter. Products of this type can be
made by a
number of techniques, such~as, for example, as described in U. S. Patent No.
6,21U,723.
For example, , a cheese filler is extruded within a casing which consists of
an unbaked
dough which typically would comprise a corn or wheat flour and/or starch. In
this
context, the terms "bakeable" and "bake stable" refer to rheological and
homogeneity
stability at savory filler composition temperatures in the range of
115°C +5%. Such
terr~peratures would be encountered for example, in a filled extruded product,
such as a
cheese filled puffed snack, prepared using an extrusion process wherein the
temperature
1 U of the extruder at the tip of the extruder die would reach 155°C-
160°C. Such
temperatures are sufficient to cook the unbaked dough surrounding the cheese
filler. That
is, their temperatures are sufficient to gelatinize the corn or wheat starch
which typically
would be in the casing surrounding the cheese filler, and such temperatures
would ensure .
that raw flavor notes in the starch would be eliminated or minimized.
In the case of other products, such as oven baked products, "bake stable" may
refer to stability at actual filler temperatures in the range of 125°C
+S%. Such
temperatures would be encountered for example, in an oven baked product, such
as a
2U filled cracker dough product, prepared using an oven bake process wherein
the
temperature of the oven might reach ZUU°C-21U°C for a period of
~ or more minutes.
There is a need to accomplish this in a manner that would enable adding a
cheese filler to
an unbaked dough which could be baked to provide a product having suitable
texture,
flavor and shelf stability. In the case of filled cheese and cracker type
products it would
be desirable fox the crackers to maintain their crisp textures -- not becoming
soggy due
either to the migration of moisture from the cheese or oil-soaked and off
flavored due to
the release of oil, i.e., so-called "oil out" from the cheese.
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Disclosure of Invention
Accordingly, it is an object of the invention to provide a shelf stable,
bakeable,
smooth-textured cheese product.
5
It is another object of the invention to provide other bakeable savory spreads
and
fillers.
It is another object of the invention to provide processes for preparing shelf
stable,
bakeable, smooth-textured cheese products and other bakeable savory spreads
and fillers.
It is another and specific object of the invention to provide a process that
enables
processing a normally unbakeable, savory food such as cheese and modifying it
such that
it becomes bakeable without sacrificing its .flavor or a creamy texture
expected of
processed cheese.
It is yet another and more specific object ofthe invention to provide a
process that
enables processing cheese, a normally savory and unbakeable food, and
modifying it to
make it bakeable without sacrificing its flavor or a creamy texture expected
of processed
cheese.
It is yet another and specific object of the invention to provide a process
that
enables adding a cheese filler to an unbaked dough and baking the resulting
composite to
provide a product having suitable cheese and cracker textures and flavors,
with shelf
stability, wherein. the cheese filler remains smooth and creamy with good
cheese flavor
and the cracker maintains its crisp texture -- not becoming soggy due either
to the
migration of moisture from the cheese or oiI-soaked due to the release of oil
from the
cheese.
It is yet another object of the invention to provide a range of products of
the
savory type which can be provided in a variety of product fornis, both baked
and unbaked,
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and adaptable fox other uses by the consumer, e.g., cheese spread that can be
used as is or
baked.
It is another object of the invention to provide unique baked products of a
type not
heretofore possible.
It is a more specific object of the invention to provide a shelf stable cheese
product that can be added to dough prior to forming or baking and to provide
processes
for preparing the cheese product and the combined dough and cheese products.
'These and other objects are realized by the present invention, which provides
both
a process for preparing a shelf stable savary, e.g., cheese, product and the
products, baked
and unbaked, having improved properties.
In one aspect of the invention, a savory, smooth-textured, bakeable and shelf
stable cheese product is provided. The cheese product comprises: a) a
dispersed fat phase
comprised of fat in an amount of at Ieast 5%, typically at least 7% and
preferably at least
10%, by weight of the total weight of the cheese product; b) an aqueous liquid
phase
comprising a polyol m an amount of at least SO% by weight of the aqueous phase
and
dissolved soluble solids, the combined amount of the polyol and the dissolved
soluble
solids being sufficient to provide the total cheese product with an Aw in all
cases of less
than 0.8, and for cracker=like products, preferably less than 0.5, more
preferably less than
U.4, and most preferably less than 0.3, and less than 0.7 fox products that
will be 'baked or
toasted before serving, and c? a solids phase, containing cheese flavor in an
amount
sufficient to comprise at least 3% by weight of the total weight of the cheese
product.
Tn another a.speet of the invention, a savory, smooth-textured, bakeable and
shelf
stable savory product is provided. The savory product comprises: a) a
dispersed fat phase
comprised of fat in an amount of at least S%, typically at least ?% and
preferably at least
IO%, by weight of the total weight of the savory product; b) an aqueous liquid
phase
comprising a polyol in an amount of at least 50% by weight of the aqueous
phase and
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dissolved soluble solids, the combined amount of the polyol and the dissolved
soluble
solids being sufficient to provide the total savory product with an Aw in all
cases of less
than 0.8, and for cracker-like products preferably less than 0.5, more
preferably less than
0.4, and most preferably less than 0.3, and less than 0.7 for products that
will be baked or
toasted before serving; and c) a solids phase, containing a solid savory
flavor in an
amount sufficient to comprise at least 3% by weight of the total weight of the
savory
product.
In another of ifis several aspects, the invention provides a process for
preparing a
savory, smooth-textured, bakeable and shelf stable cheese product. The proc$ss
comprises: providing ingredients for forming a) a dispersed fat phase
comprised of fat in
an amount of at least S%, typically at least 7% and preferably at least 10%,
by weight of
the total weight of the cheese product; b) an aqueous liquid phase comprising
a polyol in
an amount of at least 50% by weight of the aqueous phase and dissolved soluble
solids,
the combined amount of the polyol and the dissolved soluble solids being
sufficient to
provide the total cheese product with an AW in all cases' of less than 0.8,
and for cracker-
like products preferably less than 0.5, rnoxe preferably less than 0.4, and
most preferably
less than 0.3, and less than 0.7 for products that will be baked or toasted
before serving;
and c) a solids phase, containing cheese flavor in an amount sufficient to
comprise at least
3% by weight of the total weight of the cheese product; and mixing the
ingredients
sufficiently to provide a uniform blend.
Tn another aspect the invention provides a process for preparing a savory,
smooth-
textured, bakeable and shelf stable product. The process comprises: providing
ingredients
2S for for~xiing a) a dispersed fat phase comprised of fat in an amount of at
least 5%, typically
at least 7% and preferably at least 10%, by weight of the total weight of the
savory
product; b) an aqueous liquid phase comprising a polyol in an amount of at
least 50% by
weight of the aqueous phase and dissolved soluble solids, the combined amount
of the
polyol and the dissolved soluble solids being sufficient to provide the total
savory product
with an Aw in all cases of less than 0.8 and, fox cracker-like products
preferably less than
0.5, more preferably less than 0.4, and most preferably less than 0.3, and
less than 0.7 fox
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products that will be baked or toasted before serving; and c) a solids phase,
containing a
savory flavor in an amount sufficient to comprise at least 3% by weight of the
total weight
of the savory product; and mixing the ingredients sufficiently to provide a
uniform blend.
In another aspect of the invention, a process is provided for preparing a
cheese and
dough composite product comprising at least one discrete region of a cheese
product as
described above and at least one discrete region of a dough, preferably baked
to a crisp
texture.
In yet another aspect, the invention provides savory products as described
above,
packaged in sealed containers, e.g., of either rigid or , flexible
construction. In one
embodiment, a flexible plastic tube is provided for squeezing the cheese or
other savory
product onto or into a cooked or raw food product for eating as is or after
cooking.
Other preferred aspects of the invention will be detailed below.
Detailed Description of the Invention
The invention will be described below with specific reference to preferred
savory
filler formulations, and composite baked dough and filler products and
preferred
processing techniques; however, it will be clear to the experienced food
scientist that the
principles that enable improvements in these will apply to other products as
well.
The savory filler products of the invention provide unique combinations of
often
competing properties of being savory, smooth-textured, bakeable and shelf
stable. They
achieve these properties by providing a unique three-phase combination,
including an
aqueous liquid phase, a dispersed fat phase and a solids phase, preferably
containing a
cheese flavoring component. Before describing the composite baked dough and
filler
products of the invention, we will describe the composition and preparation of
the savory
filler composition that makes the composites possible.
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Savory Filler Composition
The savory filler composition of the invention in its cheese product
embodiment
comprises:
a) a dispersed fat phase comprised of triglyceride fat in an amount of at
least 5%
by weight of the total weight of the cheese product;
b) an aqueous liquid phase comprising water in an amount which does not exceed
6% by weight based on the total weight of the cheese product and a polyol in
an amount
of at least 50% by weight of the aqueous phase and dissolved soluble solids,
the combined
amount of the polyol and the dissolved soluble solids being sufficient to
provide the total
cheese product with an AW of less than 0.5, and
c) a solids phase, containing cheese filavor in a amount sufficient to
comprise at
least 3% by weight of the total weight of the cheese product;
d) lactose in an amount of less than 5% by weight based on the total weight of
the
filler composition.
Iu the context of this application, by "bake stable" we mean that the filler
composition is resistant to degradation at actual filler composition
temperatures of up to
125°C +5°C. Since fillers may to an extent be insulated from
actual baking temperatures
by surrounding dough, a filler which is stable to a given temperature, such as
125°C, is
suitable for use in a composite filled dough product which may be subjected to
substantially higher cooking temperatures than 125°C.
Fillers which lack stability at a given temperature may become hard, dry, may
oil
out, may spread and perhaps brown. Browning is partially the result of thermal
degradation of sugars, such as lactose. Also, sugars such. as lactose may
crystallize upon
cooling from elevated temperatures, leaving the filler with a grainy texture.
An objective
measure of hardening is the change in viscosity which a filler composition may
undergo
upon exposure to heat, While some increase in filler viscosity is acceptable,
dramatic,
e.g., ten-fold or more increases are clear indicia of poor bake stability.
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One simple screening test for bake stability in fillers involves observing the
extent
to which the filler spreads on a sheet when heated to a given temperature. If
the spread
test is conducted with the filler placed on a filter paper, the extent of "oil
out" may also be
5 observed. Oil out results in a ring of oil on the paper which will extend
beyond the extent
of the spread of the filler composition. Minimal spread and oil out are
indicia of good
bake stability.
10 The amount of aqueous liquid phase is important. The product must have a
liquid
phase in sufficient quantity to suspend and disperse the fat and solids phases
and to have
sufficient dissolved solids and humectants to raise the viscosity for this
phase sufficientlx
to result in a creamy texture for the final product. A creamy lubricious,
mouthfeel depends
on the correct balance of liquid and solids phase materials. As used herein
the term
aqueous material embraces polyols, the content of which contributes to the
texture of the
cheese filler in a manner similar to water.
It has also been found to be important that sufficient savory flavor
ingredients are
present as undissolved solids of sufficiently small particle size to provide
the proper
flavor release for the flavor and a texture consistent with the savory flavor.
For example,
the mouthfeel for cheese products should be smooth and creamy. Preferred
cheese
products will have a lubricous, slippery, smooth mouthfeel and a flavor
release that
endures until the palate is essentially clean. It would be unacceptable for
the flavor to be
completely released during the dissolution of only the liquid phase in saliva
in the mouth,
leaving an unflavored portion of undissolved solids.
With these general guidelines, we proceed with the discussion. of preferred
forms
of the invention.
The dispersed fat phase is preferably comprised of triglyceride fat in an
amount of
at least 5%, e.g., from about 7 to 60% and preferably 10% to 55% by weight of
the total
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weight of.the savory filler compositions. T'he fat provides a desirable
mouthfeel that is
expected of cheese products but is often missing in processed cheeses that
have been first
processed and then heat set. The fat phase of the products of the invention is
present
within the composition in a form that permits release in the mouth, but
surprisingly does
not migrate from it into a baked dough material. And, unlike the fat present
in cheese or
added heat-settable matrix materials, it is neither encapsulated -- making it
unavailable to
the palate -- nor expressed from the cheese during heat processing. Thus, the
product of
the invention is imbued with a very acceptable mouthfeel without causing taste
or stability
problems in the overall formulation. Oil and other liquids are important to
provide enough
liquid to the composition to give the product the proper texture without
migrating into an
associated dough portion. Desirable, the degree of spread should be less than
about 1.0 cm
and preferably less than 0.8 cm, e.g., less than 0.5 cm or even 0.2 cm, when
tested by the
procedure set out in Example 1.
1 S The relatively high permissible fat percentage within the savory filler
composition
is facilitated in part by the presence of an emulsifier which serves to hold
together the oil
and polyol which is a ,component of the aqueous phase which is described
below. The
emulsifier should desirably be resistant to melting under baking conditions.
Applicants
have determined that a whey protein concentrate will perform this emulsifier
function
while resisting melting and thereby contributing to bake stability. . A fatted
whey protein
concentrated may also be employed. A "fatted whey protein concentrate" as used
herein,
is a fat stabilized by whey protein which is formed by preparing an emulsion
of a dairy
fat, whey protein, and water and having an average particle size of about 0.5
to about 2
microns (preferably about O.S to about :! microns) and which is then spray
dried to form a
powder. Preferably, the resulting powder has an average particle size of about
50 to 400
microns. Preferably, this emulsified high fat whey protein which we refer to
herein as
fatted whey protein concentrate contains about 40 to about 50 pexcer~t dairy
fat, about 15
to about 20 percent whey protein and about 1 to about 4 percent water. More
preferably,
this fatted whey protein concentrate contains about 44 to 46 percent dairy
fat, about 18 to
about 20 percent whey protein, and about 2 to about 3 percent water. This
fatted whey
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protein concentrate can conveniently be employed in the present invention in
the powder
form.
.The amount of whey protein concentrate employed in the savory filler
S composition will typically be 3% or less based on the total weight of the
cheese product.
If a fatted whey protein concentrate is employed, the amount will generally be
greater and
may range up to 10% or more by weight of the savory filler composition.
The fat contained within the fat phase will preferably comprise a triglyceride
fat
and can be in any suitable physical form and from any particular source,
whether animal,
vegetable or synthesized. The terms fat and oils are used interchangeably in
the art, the
term fat often referring to solid materials and oil to those that axe liquid,
but most fats
useful in food exhibit both liquid and solid components over the range of
utility, so no
distinction is meant herein. A fat is chosen to provide the correct amount of
liquid in the
formulation and may contain solid fat as well. Preferred fats have textures
similar to those
employed for soft (tub) margarine and can be similar in formulation to those.
These fats
a are typically of semisolid consistency and can comprise any of .the usual
vegetable oils,
preferably partially hydrogenated, but can also be non-hydrogenated or fully
hydrogenated
oils such as soybean, safflower, sunflower, high oleic sunflower, sesame,
peanut, corn,
olive, rice bran, babassu nut, paten, mustard seed, cottonseed, poppyseed, low
erucic
rapeseed, high erucic rapeseed, shea, marine, meadowfoam and the like oils.
Synthesized
and rearranged fats can also be employed. Preferred oils contain at least
about 70%,
preferably at least about 75%, Cps acid residues (e.g., stearic, oleic,
linoleic) and comprise
oils such as peanut oil, olive oil, soybean oil, canola oil, sesame oi.l, and
corn oil are
especially desirable for some embodiments. Less preferred are anumal fats such
as tallow,
lard, and dairy butter. Of course, incomplete esters and derivatives and waxes
can be
employed in minor amounts.
Semisolid fats are exemplary of suitable oils, e.g., those having an SFI
profile
exhibiting solids contents in the following ranges:
Temperatures Solids (%)
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50° F 9 to 50
70° F 2 to 25
92° F g maximum
Fats of this specification have a semisolid consistency, at room temperature,
buff
essentially fully melt in the mouth. Fat substitutes, such as salatrim and
olestra can also be
employed as full or partial substitutes for the fat. It is noted that unlike
olestra, salatrim is
a triglyceride.
The aqueous liquid phase will typically comprise at least 15% by weight of the
savory cheese product, preferably from about 20 to 40%, more narrowly from 25
to 3S%.
The aqueous liquid phase will comprise a polyol in an amount of at least 25%,
e.g., at
least 50% by weight of the aqueous phase and dissolved soluble solids. The
combined
amount of the polyol and the dissolved soluble solids will be sufficient to
provide the total
cheese product with a water activity, a.e., an Aw, of less than 0.5. For
compatibility with a
cracker-type dough, it is desirable that the savory product have an Aw of Less
than 0.4,
more preferably less than 0.3. An Aw in the range of 0.15-0.45 is generally
appropriate
for use in composite compositions including a cracker dough product. The water
activity
is an important factor in maintenance of 'both microbiological and textural
stability of the
savory product and any composite it is used to make. The water activity of a
product can
be simply measured by equilibrating a product in a sealed container and then
measuring
the relative humidity of the headspace. In essence, it is a measure of the
driving force for
moisture migration. Moisture will migrate from a region of higher water
activity to lower
water activity. Therefore, for the cheese and baked goods combinations of the
invention, it
will be necessary to carefully control the water activities of the savory
product so that it
will be compatible with that of the baked good -- neither giving up or
receiving moisture.
The amount of water present in the aqueous phase should not exceed 6% by
weight based
on the total weight of the cheese product and preferably should not exceed 4%
by weight
based on the total weight of the cheese product. Water content includes water
which may
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14
be added directly during preparation of the cheese product as well as water
which may be
present in other ingredients, such as polydextrose solution.
The aqueous liquid phase will be present in sufficient quantity to suspend and
disperse the fat and solids phases. The dispersed fat must have sufflcieutly
small droplet
size o raise the viscosity for this phase sufficiently to result in a creamy
texture for the
final product. The viscosity of the liquid phase if measured prior to addition
of the
materials that make up the other phases will typically be within the range of
from about 5
to about 30, e.g., from about 10 to about 20, poises as measured by a Stress
Rheometer,
Model SR5000 (Rheometric Scientific) at 25°C and stress fram 0.2 to
7000 dynelcm2_
To aid in obtaining the desired soft, creamy texture and to provide a
controlled
water activity in the product, a plasticizing polyhydric alcohol (humectant)
is employed at
a level of at least 4% up to SO%, but preferably from greater than S%, up to
about 25%.
To the extent possible, the polyol will be minimized within these ranges.
Suitable for use
as the plasticizing agent are any of the normally liquid, edible di-, or tri-
hydric alcohols or
sugar alcohols or other polyhydric alcohols of suitable flavor and effective
fax this
purpose. Prominent among these are glycerol and sorbitol, but others of this
class and
mixtures of these can be employed, far example hydrogenated starch
hydrolysates. It has
been found that due to its highly effective plasticizing effect and its
flavor, glycerol is a
preferred material. In some cases, a flavor modifier such as ariy of those
mentioned in U.
S. Patent No. 5,641,795 can be employed in minor amounts, e.g., up to about
1.0%, say
form 0.3 to 0.~ %, to suppress any undesired sweeh~ess provided by glycerol,
sorbitol, or
the like. One such product comprises a lactisol-syrup solution (1% lactisol)
and is sold
under the trademark Super Envision by Doxnina Sugar.
In. addition to the plasticizing polyol, the aqueous liquid must also contain
sufficient other dissolved water-soluble materials capable of building
viscosity in the
liquid phase and arresting microbial growth in fihe composition. Among the
preferred
viscosity building materials are nonsweet carbohydrates such as polydextrose,
and salts
such as sodium chloride. Such materials act to lower the water activity, Aw.
Among the
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preferred polydextrose materials are those that have been chemically reduced
to eliminate
their potential to reduce cooperating food ingredients. This type of
polydextrose is
described, fox example, in U. S. Patent No. 5,601,863, and can be purchased
under the
Trademark Litesse~ Ultra from Danisco Sweeteners. The reduced polydextrose is
a
5 polyol and as such can be employed as pant or all of the polyol component
described
above. Regular polydextrose can be employed in addition to the polyols at
levels up to
about 35% by weight of the total food product, e.g., from about S to 20%.
Polydextrose is
highly soluble in water, and is preferably not employed in amounts above its
solubility
limit. It will typically be added as an aqueous solution, e.g., about 70 to
80%, but can be
10 added dry and blended into at least a part of the aqueous ingredients and
dissolved.
The remaining of the distinct component phases is a solids phase, containing a
savory flavor, preferably cheese flavor. Preferably the savory flavor will
comprise at least
3 % by weight of the total weight of the savory product, and mare preferably
at least about
15 5% by weight of the savory product, As used herein, "cheese flavor" refers
to
commercially available cheese flavor with a high, 30%-65%, fat content, and
typically
would consist of dehydrated "cheese", as that term is generally understood
especially
flavorful cheese such as cheddar cheese, which xnifht be blended with such
optional
ingredients as cream, salt, sodium phosphate and lactic acid. Such a product
with
approximately a 50% fat content is available, for example, from Kraft Food
Ingredients
under the brand name Cheeztang. Normally, significant cheese concentrations
result in
oil release on heating and migration thereafter. The upper limit for the
amount of cheese
flavor is determined by the need to provide enough fat and liquid phase
components to
achieve the objectives of the invention. Typically, no more than about 70%
undissolved
solids can be accommodated, and preferably less than 50%, more preferably less
than
40% undissolved solids will be present. Preferred savory products have more
than 5% of
the cheese flavor or other solid savory flavor, e.g,, at least S% and
preferably from over
5% up to 10%, 12% or more. In this context, the solids phase is distinguished
from the
fat phase in that the solids phase is not fat-continuous. Thus, while its
preferred principal
component is cheese, which contains fat, the cheese is not fat continuous but
has a protein
and carbohydrate matrix which encapsulates or otherwise includes the fat, For
products
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16
containing lower amounts of solid cheese or other savory flavor within the
above ranges,
it may be desirable in some cases to add a minor amount of a starch
(preferably cold water
swellable modified starch}. For example, a modified starch such as sold under
the
trademark UltraTEX by National Starch, can be effective in amounts efFective
to increase
the insoluble solids content of the savory flavor if such solids content is
required in order
to achieve desired viscosity.
As another important consideration of the invention, it has been found to be
important to have sufficient savory flavor ingredients present as undissolved
solids of
sufficiently small particle size to provide the proper mouthfeel, flavor
release and texture
consistent with the savory flavor. For example, the mouthfeel for cheese
products sh~uld
be smooth and creamy and the texture viscous enough to stay in place both
before and
after any heat treatment such as baking. Preferred cheese products will have a
lubricous,
slippery, smooth mouthfeel and a flavor release that endures until the palate
is essentially
1 S clean. It would be unacceptable for the flavor to be completely released
during the
dissolution in saliva of only the liquid phase, leaving an unflavored portion
of undissolved
solids in the mouth. 'The complex viscosity of the savory product will
typically be within
the range of from about 400 to about 50,000, s.g., from about 4000 to about
20,000,
poises as measuz~ed by an Advanced Rheometric Expansion System (ARES), Model
LS-M
(Rheometric Scientific) at 25°C and stress from 0.1% strain.
Importantly, however, far
products that are to be funned as sandwiches, like cheese between two
crackers, the
savory product should resist flow due to gravity or other moderate applied
forces.
The savory flavor is preferably principally provided by the flavor in solid
form.
Fox example, in the case of cheese, the flavor should come principally from a
suitable
cheese flavor ingredient, such as cheese powder flavor, that is substantially
insoluble in
the aqueous liquid phase. Suitable for use as the cheese ingredient other than
materials
that may be referred to as cheese powders flavors are cheese products having a
suitably
small panicle size and substantially equivalent properties and flavor. A
preferred cheese
powder flavor is, however, a high fat cheese powder flavor of the approximate
composition of the Cheeztang flavor product described above.
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1'7
In addition to solid cheese flavors, other like solid savory flavors can be
employed.
For example, egg powders, meat powders, vegetable powders and the like can be
employed. Regardless'of the flavor of the powder, it should be substantially
insoluble in
the other ingredients employed, namely those forming the aqueous liquid phase
and the
fat phase. Preserving the solid integrity of the savory flavor will assure a
texture that is
pleasing in the mouth and reminiscent of the natural product represented by
the solid
flavor.
The particle size of the solid phase ingredients is important to the final
texture.
The particle size is best determined organoleptically and is below the
threshold at which
graininess is perceived. Many materials form loose aggregates that break down
in the
mouth to sizes within these ranges and are acceptable according to the
invention.
As stated above, sugar content, which in the case of the instant invention
particularly involves lactose content, is a factor which can impair the
ability of the cheese
product to resist thermal degradation. Lactose may be present either as an
added
ingredient in the cheese filler or as a component of other ingredients. For
example, whey
rnay typically contain 30% by weight lactose. The total amount by weight of
lactose
based on the total weight of the cheese product of the instant invention
should not exceed
5% and preferably should not exceed 3%.
The process of the invention entails mixing the ingredients in a manner that
provides a uniform blend having the noted desirable textural properties.
Although low
shear mixing may be employed, the process preferably involves a high shear
mixing step
which effecti.wely homogenizes the product. While not being bound by any
particular
theory, applicants presently believe that such high shear mixing may act on
the protein
and thereby contribute to overall desired properties of the savory filler
product. In
addition, the high shear mixing reduces the size of the oil droplets which are
dispersed
throughout the savory filler composition. The droplet size following
satisfactory high
shear mixing may be in the range of less than l Olc and perhaps less than 3 p.
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18
The process is exemplified below.
Baked Dough Product
The preferred aspects of the invention are directed to a dough and savory
filler
composite product comprising at least one discrete region of a cheese product
as
described above and at least one discrete region of a dough, preferably baked
to crisp
texture. This enables the preparation of filled or topped baked goods like
crackers,
1 U pastries, pretzels, crisps of various sizes and shapes, and the like.
The doughs can be formed on any of the equipment conventional, including
laminators, extruders, depositors, rotary formers, wire cutters, and the like.
Once the
dough preform is formed, the savory product of the invention can be applied
onto or into a
dough preform in any manner suitable and the resulting composite baked or
other wise
cooked, e.g., fried, extruder heated, drum heated, or the like. T'he invention
enables the
baking of the dough to a crisp texture without degrading the savory filling to
an extent
that oil migeates to the baked dough to cause textural or color problems. The
product will
also not adversely affect the crisp texture of fhe baked good. The savory
product can also
be added to a baked good after the dough has been partially or fully baked.
The invention
has the above advantages and the further advantage that the baking process
will be
essentially the same as for the original product, adjusting only for
differences in mass and
geometry of the composite of dough and savory product. conventional baking
apparatus
can be employed.
The term "dough" as used in this context includes all formulations that the
person
skilled in the art would consider dough. At a minimum, these formulations
contain a
starch component and at least sufficient water to hydrate the starch, both
being employed
in reasonable proportions. The starch component can be provided as whole grain
or grain
ground or refined to any desired degree. It can be supplied in the form of
flour, e.g., from
wheat, barley, coin, oats, rice, rye, treacle, and the like. Or the starch
component can be
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19
supplied as a purified or mechanically refined or less than whole grain dour.
The water
can comprise water itself or an aqueous liquid such as milk (whole, skim,
homogenized,
buttermilk, soy), fruit or vegetable juice, and the like. Yeast or chemical
leavenings are
also typically present. Also typically, the dough will contain shortening in
an amount
suitable for achieving the textural characteristics desired for a given type
of product. Also
typical, is the use of at least some sweetener, though in limited amounts
compatible with
savory flavors. Sucrose and corn syrup are among the most typical. All
conventional
ingredients, typical for desired recipes, can be employed. For the sake of
economy of
description, the entire text of Manley, J. R.; Technology of Biscuzts,
Cracleers and
Cookies, Vols. 1 and 2, is incorporated herein by reference for its
descriptions of
conventional ingredients and processing.
In. another aspect, the invention provides savory products as described above,
packaged in sealed containers, e.g., of either rigid or flexible construction.
In one
embodirrxent, a flexible plastic tube is provided for sdueezing the cheese or
other savory
product onto or into a cooked or raw food product for eating as is or after
cooking. The
process of packaging is not changed from what is typically known for products
of like
viscosity; however, the need for very sophisticated packages, such as aerosol
containers,
to maintain the freshness of the product is eliminated without reducing the
convenience of
the product.
The following examples are provided to further illustrate and explain a
preferred
form of the invention and axe not to be taken as limiting in any regard.
Unless otherwise
indicated, all parts and percentages are by weight.
Examples
Five (5) samples of bake stable cheese fillers, denominated RS27, RS 27A, RS
32,
WY 136 and WY' 124, were prepared according to the following formulations:
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In~sredients RS RS 27A RS32 WY 136 WY124
27
Cheeztang cheese10 10 10 6 10
solid
5 Fatted whey protein
Concentrate 3 0 3 10 4
Whey protein 0 1.65 0 0 0
concentrate
70% PDX (polydextzose)
Solution ~ IO 10 10 l0 4
10 Glycerin 20 20 20 20 30
Canola Oil 48.8 50.15 24.8 43.3 25
Filler Fat 0 0 24 0 0
Maltodextrin 0 0 0 0 10.3
15 (Staley Star-Dri
10)
Kerryla~eem 0 0 0 0 7
SSL(emulsifier) 0 0 0 0.25 1
Tricalcium citrate2.5 2.5 2.S 5.75 2.S
Salt 4 4 4 2 3
20 Super Euvision 1 1 1 2 2.S
Color 0.2 0.2 0.2 0.2 0.2
Flavor 0.5 0.5 0.5 0.5 0.5
The first sample, RS 27, was prepared according to the following procedure:
STAGE 1: The given amounts of glycerin, 70% PDX solution, fatted whey
protein concentrate, and Cheeztang cheese solid (Group 1- aqueous phase] were
measured out and placed in a bowl . This mixture was then pre-mixed using a
Hobart
mixer at speed 1 for 1 min. and a speed 2 for 3 min.
STAGE 2: The above mixture was then transferred into a Do-Corder bowl used in
conjunction with a Do-Corder "E" recording torque rheometer, which was then
started
and run such that it read 90 rpm. The Do-Corder, which is manufactured by
C.W.Brabender Instruments, permits high shear mixing while providing
continuous
viscosity data. Note that suitable high shear mixing znay also be achieved
using a Hobart
or other suitable mixer, and that if low shear mixing is employed, other mixer
well laiown
in the art may be employed.
STAGE 3: S0% of the total amount of canoia oil to be used was added to the
STAGE 2 mixture and the oil was observed being complexed with the proteins in
the'
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2I
cheese solid and fatted whey protein concentrate. An increase in viscosity was
also
observed in the chart recorder.
STAGE 4: Once the viscosity in STAGE 3 stabilized, the remaining solids
(tricalcium citrate, salt, Super Envision, color and flavor).were added to the
mixture in the
Do-Corder. A two to three fold increase in viscosity was observed from the
charter
recorder.
STAGE 5: Once the viscosity in STAGE 4 again stabilized, 1/3rd of the
remaining
50% of canola oil was added: An initial drop in viscosity was noticed.
However, the
viscosity soon returned to the same level as seen in STAGE 4. Note that if
filler fat is used
in place of canola, it is desirably to pre-melt the filler fat and conduct
this and subsequent
mixing steps at an elevated temperature, sufficient to melt the fat, of
perhaps 45°C.
I5 STAGE 6: STAGE S vas repeated for the second I/3~' portion of canola oil
and
again the viscosity returned to neatly the same level as seen in STAGE S.
STAGE 7: STAGE 6 was repeated for the last 1 /3'~ portion of canola oil and
mixing was continued until the viscosity came back to nearly the same level as
seen in
STAGE 6.
The high shear blending as described above is an important facet of the
preparation of the bakeable cheese fillers of the invention, for the procedure
effectively
homogenizes the fillers into a substantially continuous product with the
desired texture
2S and spread properties.
For larger scale preparation, in lieu of a Do-Corder, a high shear mixer such
as a
Bredds Likwifier may be employed to achieve rapid homogeneity.
The product denominated RS 27 was seen to have an Aw of .26. After being baked
within a cracker casing, during which the casing was exposed to temperatures
of 400°F,
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22
the A~, of the filler increased to .30, indicating slight migration of
moisture from the
cracker dough into the filler. Such migration ensured that the cracker dough
became crisp
after baking, and was not adversely effected by oil or water released from the
savory filler.
The viscosity of the RS 27 filler composition was measured both before and
after
baking at 400°F within the cracker casing. Before baking, the viscosity
of the filler was
about 5200 poise . Following baking the viscosity had increased to about 11000
poise .
Such a two-fold viscosity increase is well within an acceptable range for good
bake
stability.
Samples of both the RS 27 and WY 124 fillers were subjected to temperatures of
400° fox periods of 10 minutes, during which their temperature reached
260°F. Such
temperatures did not degrade the fillers.
The above description is intended to enable the person skilled in the art to
practice
the invention. It is not intended to detail all of the possible modifications
and variations,
which will become apparent to the skilled worker upon reading the description.
It is
intended however, that alI such modifications and variations be included
within the scope
of the invention which is defined by the following claims. The claims are
meant to cover
the indicated elements and steps in any arrangement ox sequence which is
effective to
meet the objectives intended for the invention, unless the context
specifically indicates the
contrary.
