Note: Descriptions are shown in the official language in which they were submitted.
CA 02673414 2009-07-21
,
,
MICRO WAVABLE REFRIGERATED SCRAMBLED EGGS AND PROCESS
FIELD OF THE INVENTION
[0001] The present invention relates to a means of
manufacturing and
formulating a scrambled egg composition that is stored in a refrigerator and
preferably
heated by a microwave oven.
BACKGROUND OF THE INVENTION
[0002] Scrambled egg products are highly valued as a food
source, due to their
nutrition value and particularly in view of their flavor, mouth feel and other
organoleptic qualities. There are different styles of preparation of scrambled
eggs. It
is possible, for example to simply bake or fry the eggs to form a solid mass
that is in
fact edible. A more tender and generally organoleptically desirable style of
scrambled
eggs is the so called "French-style scrambled egg," wherein the eggs are
cooked
slowly and gently, to form a fluffy, moist texture that is not overcooked.
When not
properly prepared, however, scrambled eggs can be a disappointment.
[0003] Another degree of complexity is introduced when the
eggs are
provided in a ready-to-heat environment. For example, eggs have been pre-
scrambled, packaged and frozen for later reheating. However, when the cooked
eggs
are frozen, ice crystals can form, and water will separate from the eggs with
adverse
effects. A proposed solution for the problems associated with provided
precooked,
frozen scrambled eggs is described in US Patent Application No. 2005/0202150
and
US Patent Application No. 2005/0202151, wherein a water-absorbent thickener is
distributed throughout the egg based material. Eggs have long been provided in
a
storage-stable liquid form, for example as Sunny Fresh ESL Products
(commercially available from Cargill, Incorporated) or Egg BeatersTM liquid
egg
substitutes, and similar products. While these have the convenience of being
storage
stable under refrigeration as a liquid, they require that the person
responsible to
prepare the food have both time and skill in preparation of eggs to form the
desired
egg product.
[0004] While the consumer demands excellence in organoleptic
qualities of
the food they consume, there is an equally strong demand for convenience in
both
storage and preparation. Microwave cooking presents significant advantages in
convenience of preparation, but it is exceptionally difficult to meet food
quality
CA 02673414 2009-07-21
=
standards when using this form of heating. The disadvantages of microwave
heating
have been widely experienced, mostly in that the final microwaved food product
tends
to have a dry, tough and chewy texture, particularly on the perimeter of the
food
product.
SUMMARY OF THE INVENTION
[0005] The present invention provides a microwavable, refrigerated
scrambled
egg composition. The composition comprises a first component that is frozen
precooked egg portions. At least about 50% by weight of the frozen egg
portions are
pieces that are at least about 1/2 inch in one dimension.
[0006] The second component is a slurry comprising pasteurized liquid egg
and pregelatinized modified food starch. The precooked egg portions are from
about
50% to about 85% by weight of the total scrambled egg composition and the
slurry is
from about 15% to about 50% by weight of the total scrambled egg composition.
[0007] The scrambled egg composition can be provided in convenient
microwaveable packages.
[0008] The present invention also provides a process for preparing the
scrambled egg composition described above, comprising:
a) providing frozen precooked egg portions at least about 50% by weight of
the frozen egg portions being pieces that are at least about 1/2 inch in one
dimension;
b) preparing a slurry comprising pasteurized liquid egg and pregelatinized
modified food starch,
c) mixing the precooked egg portions and the slurry together to provide a
scrambled egg composition.
[0009] The scrambled egg product as described herein provides excellent
manufacturing efficiencies and ease of preparation for the ultimate customer,
while at
the same time providing a very satisfying eating experience. More
specifically, the
composition may be assembled using ingredients that are very adaptable to
large scale
production operations, while at the same time having the appearance of being a
hand-
made product. The product is easy to store, and provides refrigerator
convenience to
the supplier and consumer alike. The consumer appreciates both the convenience
of
the product in terms of serving size and portability, and in particular the
ease of
preparation of the food product. The scrambled egg product can be heated by
any
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technique suitable for providing a cooked egg product. Because the product is
provided in an convenient, pre-prepared and packaged format, the product is
easy for
the consumer to prepare using any desired technique. The resulting cooked
scrambled
egg product is very moist and exhibits a soft texture that is unexpected,
particularly
when heated in a microwave oven.
10009a1 In accordance with an aspect of the present invention there is
provided
a microwavable, refrigerated scrambled egg composition, comprising:
a) frozen precooked egg portions, at least about 50% by weight of
the frozen egg portions being pieces that are at least about 1/2 inch in
one dimension; and
b) a slurry comprising pasteurized liquid egg and pregelatinized
modified food starch;
wherein the precooked egg portions are from about 50% to about 85% by weight
of
the total scrambled egg composition and the slurry is from about 15% to about
50% by
weight of the total scrambled egg composition.
BRIEF DESCRIPTION OF THE DRAWINGS
10010] The patent or application file contains at least one drawing
executed in
color. Copies of this patent or patent application publication with color
drawing(s) will
be provided by the Office upon request and payment of the necessary fee.
[0011] The accompanying drawings, which are incorporated in and constitute
a part of this application, illustrate several aspects of the invention and
together with a
description of the embodiments serve to explain the principles of the
invention. A
brief description of the drawings is as follows:
FIG. I is photograph of an egg product provided in a microwavable tray
package.
FIG. 2 is photograph of an egg product provided in a microvvavable package.
FIG. 3 is photograph of an egg product after being cooked in a microwave.
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DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS
[0012] The embodiments of the present invention described below are not
=
intended to be exhaustive or to limit the invention to the precise forms
disclosed in the
following detailed description. Rather a purpose of the embodiments chosen and
described is so that the appreciation and understanding by others skilled in
the art of
the principles and practices of the present invention can be facilitated.
(001.31 The first component of the microwavable, refrigerated scrambled egg
composition is frozen precooked egg portions. These portions, in combination
with the
slurry as described below, provide varied texture and visual appeal to the
food product
after cooking. While not being bound by theory, it is believed that the
provision of
these cooked portions initially in the frozen state during mixing of the
composition
provides a particular textural benefit at the interface of the materials. It
has been
observed that products prepared using frozen precooked egg portions exhibit
superior
organoleptic properties as compared to like products prepared using unfrozen
precooked egg portions. The frozen precooked portions are advantageously
provided
3a
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in sizes large enough to provide a perceptible texture and visual distinction.
At least
about 50% by weight of the frozen egg portions are pieces that are at least
about 1/2
inch in one dimension. In an embodiment of the present invention the frozen
egg
portions have a smallest dimension, and at least about 50% by weight of the
frozen
egg portions are pieces that are at least about 1/2 inch in the smallest
dimension. In
another embodiment, the frozen egg portions have a smallest dimension, and at
least
about 50%, or alternatively 75%, by weight of the frozen egg portions are
pieces that
are from about 1/2 inch to about 1 inch in the smallest dimension.
[0014] Preferably, all of the frozen precooked egg portions are provided
in a
size large enough to be readily perceptible to the consumer, so that the
desired texture
and visual benefits are apparent. In a preferred embodiment, less than about
5% by
weight of the frozen precooked egg portions are provided by pieces small
enough to
pass through a U.S. standard No. 7 sieve screen with a nominal sieve opening
of 2.8
mm. The frozen precooked egg portions may be provided in any desired
configuration. In an embodiment, the frozen egg portions are uniform in size
and
shape. In another embodiment, the frozen egg portions are non-uniform in size
and
shape.
[0015] The frozen precooked egg portions may be prepared by first cooking
the egg, bulk freezing the egg and then cutting, chopping, slicing or
otherwise
dividing the egg into the desired piece size. In an embodiment, the frozen
precooked
egg portions are prepared by pouring an uncooked egg composition into cooking
trays
divided into separate portions having random or uniform sizes and shapes, and
cooking the composition to provide portions in the desired final size and
shape.
[0016] Preferably, the frozen egg portions are quick frozen in an
Individually
Quick Frozen ("IQF") process, meaning that they are cooked, provided in pieces
sizes
suitable for rapid freezing, and then are rapidly frozen by exposure to a
supercooled
material, such as a gas or liquid, to freeze the product. Other types of
freezers, such
as mechanical freezers, air impingement freezers or other suitable freezers
are capable
of providing IQF frozen egg portions. This embodiment provides the egg portion
in
the final size without a further comminuting operation, which both provides
the
desired texture and water content of the frozen egg product and provides an
efficient
manufacture of this component without undue generation of undesirable fines.
[0017] Fast freezing, as preferred in the present invention, normally
provides a
very high quality product by reducing moisture loss and forming small
crystals, which
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,
do less damage to texture. Most often the IQF freezing process involves
cryogenic
gases (liquid nitrogen and liquid carbon dioxide). Additionally, the equipment
is
preferably tailored to the gas. Most of the cooling with nitrogen comes from
the
sensible heat, so the liquid is injected countercurrent to the product flow
and warmed
vapor is exhausted near the entrance of the typical tunnel. With carbon
dioxide, the
heat removal is by sublimation of the dry ice snow, so the liquid is injected
concurrently with the food and vapor exhausted near the exit.
[0018] Cryogenic freezing is especially appealing when
products are frozen
before packaging and when weight loss is important, such as in the vegetable
industry.
IQF freezing provides uniformly frozen discrete particles of egg and avoids
the
formation of lumps. Lumps are the result of non-uniform freezing of the
external
product contact surfaces. Additionally the very low temperatures reduce
moisture loss
and so increase yield. The IQF freezing process also forms small ice crystals
(i.e., not
_
visually apparent by unmagnified visual examination), which provides enhanced
quality.
[0019] The frozen precooked egg portions may be made from
whole egg, egg
white, egg yolk, or mixtures thereof. Additional ingredients, such as
extenders,
diluents, stabilizers, preservatives, seasonings, and flavorants may
optionally be
incorporated in the composition used to prepare the frozen precooked egg
portions.
Specifically contemplated additional ingredients include skim milk, soybean
oil,
modified food starch, salt, xanthan gum, flavors and citric acid. Examples of
suitable
compositions for use in making the frozen precooked egg portions are described
in US
Patent Nos. 6,759,076 and 7,069,844.
[0020] The precooked egg portions are from about 50% to about
85% by
weight of the total scrambled egg composition. In an embodiment of the present
invention, the precooked egg portions are from about 55% to about 70% by
weight of
the total scrambled egg composition.
[0021] The microwavable, refrigerated scrambled egg
composition
additionally comprises a pasteurized slurry comprising liquid egg and
pregelatinized
modified food starch.
[0022] The liquid egg component of the slurry may be made
from whole egg,
egg white, egg yolk, or mixtures thereof. Additional ingredients, such as
extenders,
diluents, stabilizers, preservatives, seasonings, and flavorants may
optionally be
incorporated in the composition used to prepare the frozen precooked egg
portions. In
CA 02673414 2009-07-21
a preferred embodiment, the liquid egg component of the slurry may be
commercially
available extended shelf life egg mixture compositions, such as Golden
NatureTM egg
mixture, commercially available from Cargill Incorporated.
[0023] The pasteurized slurry additionally comprises a pregelatinized
modified food starch. A modified starch is a starch that has been treated to
be
partially degraded. Starch degradation treatments include acid, alkaline,
bleaching,
oxidation, and enzyme treatments. Starch sources include starch sources
consisting of
cereal, root, tuber and legume. starch sources consisting of wheat, waxy
wheat, corn,
waxy corn, high amylose corn, oat, rice, tapioca, mung bean, sago, sweet
potato,
potato, barley, triticale, sorghum and banana. See United States Patent
2006/0188631. In a preferred embodiment, the pregelatinized modified food
starch is
a modified tapioca starch. Tapioca starch is particularly advantageous because
it has
a mild flavor that has been found to be very complimentary to the egg flavors
of the
present scrambled egg composition.
[0024] Tapioca starch is preferred for use in egg products because of its
superior very bland flavor, excellent paste clarity and good heat stability.
The most
significant attribute is the smooth and creamy texture, which provides the
cling and
adhesion to the IQF pre-cooked scrambled egg.
[0025] One variety of starch, Cargill CreamTexTm starch (commercially
available from Cargill Incorporated), is a stabilized and cross-linked tapioca
starch
that requires heating (hence it is referred to as a "cook-up" starch) to
achieve the
optimum viscosity and cling.
[0026] Another variety of tapioca starch is stabilized, cross-linked and
additionally processed to provide an instant starch commonly referred to as a
cold
water swelling starch. The starch provides instant viscosity without cooking
(extremely quick hydration) and very high water binding capacity. For example,
FIiFormTM 72348 (commercially available from Cargill Incorporated) is a high
performance cold water swelling starch with superior flavor and a high
viscosity
profile. Starches produced with this particular spray-cooking technology are
uniformly cooked with a minimum amount of heat and shear damage. They exhibit
many properties of premium cook-up tapioca starches, yet hydrate and develop
high
viscosity in the absence of heat.
[0027] In an embodiment of the present invention, the pasteurized liquid
egg
of the slurry is from about 40% to about 95% by weight of the slurry. In
another
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,
embodiment of the present invention, the pregelatinized modified food starch
is from
about 3% to about 15% by weight of the slurry. In another embodiment of the
present
invention, the pregelatinized modified food starch is from about 5% to about
10% by
weight of the slurry. The balance of the slurry composition preferably
comprises a
liquid having a flavor that is complementary to the egg composition, which
liquid
preferably is water. In an embodiment of the present invention, the slurry
comprises
added water in an amount of from about 30% to about 45% by weight of the
slurry.
[0028] A representative preferred slurry composition consists
essentially of
about 52-56% whole egg, 36-40% water and 4-8% starch.
[0029] The slurry may have a viscosity of from about 1,000 to
about 4,000
cps, and preferably has a viscosity of from about 2,000 to about 3,500 cps. If
the
,
viscosity exceeds about 4,000 cps the slurry will not adequately and uniformly
cover
the IQF pre-cooked scrambled egg. If the viscosity is less than about 1,000
cps., the
creamy texture will be less noticeable since the slurry will not cling to the
IQF pre-
cooked scrambled egg. In both cases, the appearance, texture and sensory
qualities
will not match that of freshly prepared scrambled eggs. Viscosity measurements
are
determined with a Brookfield Viscometer Model DV-I+ with the #4 spindle at 60
rpm
for 15 seconds. A minimum sample size of 400 ml. is required and the
temperature of
the sample ranges between 38 F and 42 F.
[0030] In a preferred embodiment, the slurry and the frozen
precooked egg
portions both comprise one or more preservatives provided in an amount to
achieve an
estimated 10 week refrigerated shelf life.
[0031] The present microwavable, refrigerated scrambled egg
composition
may be manufactured using techniques that are readily adaptable to large scale
production.
[0032] In an embodiment of the present invention, a process
for preparing a
scrambled egg composition is provided, comprising:
a) providing frozen precooked egg portions at least about 50% by weight of
the frozen egg portions being pieces that are at least about 1/2 inch in one
dimension;
b) preparing a slurry comprising pasteurized liquid egg and pregelatinized
modified food starch,
c) mixing the precooked egg portions and the slurry together to provide a
scrambled egg composition.
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[0033] In an embodiment of the present invention, all slurry
components are
combined prior to pasteurization. In another embodiment, liquid egg is
pasteurized
prior to mixing with the pregelatinized modified food starch.
[0034] In an embodiment of the present invention, the
scrambled egg
composition is deposited in individual portions after mixing the precooked egg
portions and the slurry together. In another embodiment, the precooked egg
portions
and the slurry are deposited as two separate streams and packaged together to
form
the scrambled egg composition. In an embodiment of the present invention, the
scrambled egg composition is provided in individual portions ranging from
about 1.5
to about 3.5 ounces. In another embodiment, the scrambled egg composition is
provided in "family size" portions ranging from about 3.5 to about 16 ounces
or more.
' [0035] The scrambled egg composition is preferably packaged in
containers
. suitable for cooking the product directly in the container by
microwave cooking. In
an embodiment, the containers are suitable for cooking the product directly in
the
container by microwave, oven or steam heating. The container optionally may be
a
bag or in a sealed tray. Optionally the container is a sealed tray suitable
for use both
in cooking and in presenting the cooked product to the ultimate consumer for
eating.
Preferably, the container is a self-venting microwave oven package. In a
preferred
embodiment, the container is self-venting and provides sufficient headspace
that when
the scrambled egg composition is cooked in the microwave, a substantial
component
of the cooking process is carried out by self-generated steam heat. It has
been
discovered that when the scrambled egg composition is heated in the microwave
oven
in such a container, the self-venting package provides an especially evenly
heated,
moist scrambled egg portion.
[0036] Typically, heating a small portion of a conventional
scrambled egg in
the microwave oven creates drying and a tough texture, particularly on the
perimeter
of the package. Reheating the present scrambled egg composition, particularly
in a
self venting package, in the microwave oven allows the product to heat with
steam
that is circulated within the individual portion. The optimum headspace in a
3.5 oz.
individual portion is about 1/2 inch on average. Since the egg portions are
primarily
heated with steam instead of microwave energy, the portions retain the desired
appearance, tender texture and mouthfeel, and fresh sensory profile.
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[0037] Examples of self-venting microwave oven packages are known, such
as disclosed in U.S. Pat. No. 4,013,798; U.S. Pat. No. 4,141,487; 4,404,241;
U.S. Pat.
No. 4,390,554; U.S. Pat. No. 4,640,838; and U.S. Pat. No. 7,034,268.
[0038] As noted above, the scrambled egg composition of the present
invention is advantageously a refrigerated product, and therefore in the
ordinary
course of use the scrambled egg composition is held under refrigeration
conditions for
all times between manufacture and use by the consumer who heats the product
for
consumption. In an embodiment of the present invention, the scrambled egg
composition is stored under refrigeration conditions for a period of at least
96 hours
prior to cooking.
[0039] In a preferred embodiment the microwavable, refrigerated scrambled
egg composition is heated after refrigeration storage by microwave.
Optionally, the
egg composition is heated after refrigeration storage by other cooking
techniques,
such as steam heat (including heating in a pressure cooker, steam cabinet or
on a
steam table), water heat (e.g. placing a bag in hot or boiling water),
conventional or
convection oven heat, and the like.
EXAMPLES
[0040] Representative embodiments of the present invention will now be
described with reference to the following examples that illustrate the
principles and
practice of the present invention.
Example 1.
[0041] 600 Grams of a fully cooked egg formulation was sliced into
randomly
sized pieces and quick frozen in an environment of liquid CO2 by rapid
agitation in a
partially closed container. The irregularly shaped and randomly sized pieces
were
collected such that approximately 75% of the pieces were at least 1/2 inch in
the three
dimensions of length, width and height. Not more than 5% of randomly sized egg
pieces would pass through a U.S. standard No. 7 sieve screen with a nominal
sieve
opening of 2.8 mm.
[0042] 400 Grams of the liquid portion of the scrambled egg composition
was
prepared and mixed for a period of 3 minutes with the low setting of the
KitchenAid
mixer (Model number K5SSWW). The liquid portion was comprised of the
following: whole eggs (231.84 grams), water (151.84 grams), Cargill CremTexTm
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,
modified tapioca starch (16 gram), citric acid (0.32 grams). All components of
the
liquid portion were mixed in a high speed Waring blender (Model number 33BL79
(700)) for a period of three minutes. The homogeneous mixture was pasteurized
according to the requirements of the U.S.D.A. Immediately after
pasteurization, the
mixture was cooled to a temperature of 38 degrees F. The viscosity of the
mixture
was 2,500 cps when measured with a Brookfield viscometer. This viscosity
provides
the cling and adhesion to the IQF egg pieces required to appear freshly made.
[0043] The collected fully cooked egg formulation and the
pasteurized "liquid
portion" were combined in a KitchenAid mixer using the paddle mixing
attachment.
The resulting mixture was deposited into a flexible, formable co-extruded web
packaging. The high oxygen barrier properties of the packaging provide a long
shelf
life. A similar high barrier flexible non-formable web is sealed onto the
formable web
using a Multi-Vac packaging system. An irregularly shaped die is used to
provide an
attractive, appealing portion. Additionally, air is evacuated from the package
and a
mixture of 40% carbon dioxide and 60% nitrogen is back flushed into the
portions.
The flexible non-forming web has a score, which allows the steam to escape
when the
package is re-thermalized in the microwave oven. The self-venting package
provides
an evenly heated, moist scrambled egg portion.
[0044] Numerous flexible non-formable web and formable web
materials are
commercially available. Typically, they are comprised of multi-layer film
construction utilizing multiple proprietary polymers. Oxygen Transmission
Rates
(OTR) and Moisture Vapor Transmission Rate (MVTR) are critical measures that
define barrier properties. OTR is typically measured in cubic centimeters per
100
square inches per 24 hours. Typically values range from about 11.0 to about
0.2.
MVTR is typically measured as grams of water per 100 square inches per 24
hours.
Typically values range about 0.7 to about 0.13. In the preferred embodiment,
the
protective packaging film has oxygen barrier properties (OTR) of <0.3 cubic
centimeter per 100 square inches per 24 hours at 73 F and 0% relative
humidity.
Additionally, in the preferred embodiment, the MVTR is <0.4 grams water per
100
square inches per 24 hours at 100 F and 90% relative humidity.
[0045] The depth of the package is adjusted so that the
headspace in the 3.5-
ounce individual portion averaged 1/2". The '/2" headspace allows the steam
generated
during re-thermalization to uniformly heat the product without drying the
surface or
CA 02673414 2016-03-04
the edges of the package contents. Since the egg portions are heated with
steam
instead of microwave energy, the portions retain the desired appearance,
tender
texture arid mouthfeel and fresh sensory profile.
[0046] The product provided in a microwavable tray package of this Example
1 is shown in the photograph of FIG. I,
Example 2.
[0047] The procedure described in Example 1 above was used to prepare an
alternative embodiment, except that the fully cooked egg portion and the
pasteurized
liquid portion are deposited in a dual film package using a weight control
filler
system, rather than the KitchenAid mixer. Specifically, 2.1 ounces of fully
cooked
scrambled egg and 1.4 ounces of pasteurized liquid portion are separately
deposited
into the dual film package, resulting in a total weight of 3.5-ounce portion
of a
microwavable, refrigerated scrambled egg composition.
[0048] The product provided in a microwavable package of this Example 2 is
shown in the photograph of FIG. 2.
[0049] This package is heated in a microwave oven for a time sufficient to
heat the egg product, and the contents of the package are placed on a plate,
ready for
consumption, as shown in Fig. 3.
[0050] Unless otherwise indicated, all parts and percentages are by weight
and
all molecular weights are weight average molecular weights. The foregoing
detailed
description has been given for clarity of understanding only. No unnecessary
limitations
are to be understood therefrom. The invention is not limited to the exact
details shown
and described, for variations obvious to one skilled in the art will be
included within the
invention.
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