Note: Descriptions are shown in the official language in which they were submitted.
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LAYERED CEREAL BAR WITH THIXOTROPIC FILLING
AND METHODS OF MAKING SAME
[0001] This is a divisional application of Canadian Patent application
No. 2,464,203
filed April 13, 2004. It should be understood that the expression "the present
invention"
or the like used in the specification encompasses not only the subject matter
of this
divisional application but that of the parent application also.
Field
[0002] This invention relates to cereal bars, and in particular
this invention
relates to layered cereal bars, and the method and apparatus for their
manufacture.
Background
100031 There have been many efforts in the food industry to develop
meal
substitutes, particularly breakfast substitutes, for consumers who do not have
the
time or desire to consume a conventional meal. To serve as a convenient meal
substitute, a product should be a portable ready-to-eat food product that
requires no
cooking, no application of additional ingredients, and so forth. Ideally a
meal
substitute does not require the use of utensils such that it can be eaten in
nearly any
location at any time, including while driving, riding on a train, walking, and
so
forth.
[0004] Some of the most popular meal substitutes are substantially
nonperishable hand-to-mouth food products that are packaged in disposable
packaging materials. Many such products come in the form of a hand held food
bar.
However, food bars are not necessarily nutritionally complete. Specifically,
many
food bars lack adequate protein, vitamins, minerals, fiber and so forth, to
accurately
be considered a "meal substitute."
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[0005] Further, many of these products are difficult to handle, either
because
they are too dry or too moist. Bars that are too dry fall apart easily,
producing
unwanted crumbs. Bars that are too moist become excessively sticky and messy.
Additionally, the organoleptic properties of many of these bars are quite
poor. In
some instances, this is due to a high level of soy proteins, which can cause
an
undesirable off-flavor, if not otherwise masked.
[00061 It is also important that food, particularly meal substitutes, have
an
appealing appearance so that the entire eating experience is a pleasant one.
Many of
the meal substitutes on the market today, however, have been processed to such
an
extent that they bear little or no resemblance to their original state.
[0007] Thus, what is needed is a portable food product that has improved
nutritional and organoleptic characteristics, yet maintains an appealing
appearance.
Summary
[0008] A layered cereal bar with at least two cereal layers having
identifiable ready-to-eat (RTE) cereal pieces and at least one visible filling
layer in
between the at least two cereal layers is described. In one embodiment, the
cereal
bar is a non-cooked (e.g., not baked) cereal bar having a total nutrient level
equal to
or greater than the nutrient level of a single serving of boxed cereal with
milk. In
another embodiment, the cereal bar has about six (6) grams (g) of protein.
[00091 In one
embodiment, the filling layer is a confectionery center
that is high in milk content, but possesses a relatively low water activity.
In another
embodiment, the filling layer is a compound coating. In another embodiment,
the
filling layer is a visible milk filling layer comprised of milk powder,
sweeteners and
fat in a ratio of about 1:2:1.4. In yet another embodiment, the filling layer
comprises about 20%, by weight, of the cereal bar. In another embodiment, the
filling layer is a low water activity fruit filling. In another embodiment the
filling
comprises both a confectionery filling layer and a low water activity fruit
filling.
[0010] In one embodiment, the cereal layer is comprised of a cereal
composition containing RTE cereal, high-protein rice pieces and texturized
vegetable protein (TVP) in a ratio of about 2:1:1. The cereal layer further
comprises
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a binder to hold the cereal composition together. In one embodiment, the
binder is a
complex carbohydrate binder made from soy protein, fat, sweeteners, water and
gelatin. In another embodiment, flavorings, colorings and macronutrients in
the
form of a vitamin/mineral blend are added to the binder. In a particular
embodiment, tricalcium phosphate is added to provide calcium fortification. In
another embodiment, the RTE cereal is fortified with added protein and the TVP
and/or rice pieces are not used in the cereal composition. In one embodiment,
the
density of the cereal composition increases by about 1.5 to two (2) times
after being
compressed into layers.
100111 In one embodiment, components of the layered cereal bar are
comprised of about 20% cereal, 40% binder, 10% TVP, 10% rice and 20% milk
filling, by weight, although the invention is not so limited. Within
acceptable
ranges, the ratios of the various components can be altered, depending on a
particular application.
[0012] In another embodiment, a method for manufacturing a layered cereal
bar having a visible filling layer is described. The steps include mixing a
binder
with a cereal composition having identifiable cereal pieces to form an
amorphous
mass, compressing the amorphous mass into a first layer and a second layer,
applying a filling layer on the first layer, combining the first layer and
filling layer
with the second layer, and pressing the first layer, filling layer and second
layer
together to form pressed layers, wherein the pressed layers are cut into
individual
cereal bars having identifiable cereal pieces, each cereal bar having a total
nutrient
level equal to or greater than the nutrient level of a single serving of ready-
to-eat
cereal and milk.
[0013] In another embodiment, various devices for manufacturing a layered
cereal bar are described. Such devices include beltless compressing rollers
that
operate in series to combine a mixture comprising the cereal composition and
binder. The rollers rotate in the same direction as a conveyor below, although
at a
faster speed. By operating the rollers in this manner, the surface of the
product is
more polished, giving it a better, less rough appearance. Compression is also
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improved with reduced breakage of cereal pieces. The
rollers have the further advantage of staying cleaner during
operation.
[0014] In one embodiment, the protein in the layered
cereal bar of the present invention is derived from grain
protein in the cereal components, soy protein in the form of
soy protein isolates and texturized vegetable protein, and
milk protein in the form of whole and non-fat milk powder.
In addition to providing approximately the same quantity of
protein as a bowl of cereal and milk, these three diverse
sources provide a high quality protein due to the inherent
advantage of complementary amino acids, particularly from
the soy and grain sources.
In one embodiment, there is provided a cereal bar,
comprising: at least two cereal layers, each of the at least
two cereal layers comprising a cereal composition made from
identifiable ready-to-eat (RTE) cereal pieces, extruded rice
pieces and a protein source combined with a carbohydrate
binder containing greater than 0%, up to less than 30%, by
weight, of fat, wherein at least one of the identifiable
RTE cereal pieces is a whole cereal piece; and at least one
visible thixotropic semi-solid fruit filling layer
containing a gelling agent, the thixotropic semi-solid fruit
filling layer having a water activity between about
0.4 and 0.5 and located in between each of the at least two
cereal layers to form an intermediate layer, wherein the
cereal bar has a water activity between about 0.35 and 0.55
and is disposed within an individual package.
In one embodiment, there is provided a cereal bar
comprising: at least two cereal layers; and a layer of
thixotropic semi-solid fruit filling containing a gelling
agent and having one (1) to 10% fruit solids,
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50 to 80% sugars (dry weight basis), 0 to 15% humectant,
0 to 10% thickeners, 8 to 20% moisture, and
one (1) to 5% minor ingredients.
In one embodiment, there is provided a method for
making cereal bars, comprising: mixing a carbohydrate binder
with a cereal composition having identifiable cereal pieces,
extruded rice pieces and a protein source to form an
amorphous mass, wherein the carbohydrate binder contains
less than 30%, by weight, of fat; compressing the amorphous
mass into a first layer and a second layer, each layer
having identifiable cereal pieces and a bulk density about
1.5 to 2 times higher than the amorphous mass; at ambient
temperatures, dispensing a thixotropic semi-solid fruit
filling having a gelling agent onto the first layer, the
thixotropic semi-solid fruit filling having a water activity
between about 0.4 and 0.5; combining the first layer and
thixotropic semi-solid fruit filling layer with the second
layer; and pressing the first layer, filling layer and
second layer together to form pressed layers, wherein the
pressed layers are cut into individual cereal bars having
identifiable cereal pieces, wherein the thixotropic
semi-solid fruit filling maintains the water activity of
between about 0.4 and 0.5 over time.
In one embodiment, there is provided a cereal bar,
comprising: at least two cereal layers, each of the at least
two cereal layers comprising a cereal composition made from
RTE cereal, rice pieces, and a protein source, the cereal
composition combined in a ratio of about 1:1 with a
carbohydrate binder containing less than about 30%, by
weight, of fat; and a visible semi-solid fruit filling layer
located in between each of the at least two cereal layers to
form an intermediate layer, wherein fruit filling in the
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fruit filling layer has a water activity between about 0.4 and 0.5.
In one embodiment, there is provided a cereal bar, comprising: at least two
cereal layers, each of the at least two cereal layers comprising a cereal
composition made
from identifiable puffed ready-to-eat (RTE) cereal pieces, high-protein
extruded rice
pieces having a crispy texture and a protein source, the cereal composition
combined in a
ratio of about 1:1 with a carbohydrate binder comprising ingredients selected
from vitamin
and mineral macronutrients, flavorings and colorings, the binder further
comprising
syrups, glycerins, sugars, water and less than 30%, by weight, of fat, wherein
the syrups
include a maltose syrup and the mineral macronutrients include tri-calcium
phosphate,
further wherein at least one of the identifiable RTE cereal pieces is a whole
cereal piece
selected from flakes, shreds, biscuits, rings, spheres, squares, rounds,
triangles,
hexagonals, tubes and oblongs; and at least one visible semi-solid fruit
filling layer having
a water activity between about 0.4 and 0.5 and located in between each of the
at least two
cereal layers to form an intermediate layer.
In one embodiment, there is provided a cereal bar, comprising: identifiable
ready-to-eat (RTE) cereal pieces; a layer of thixotropic semi-solid fruit
filling in between the
at least two cereal layers and containing a gelling agent and having one (1)
to 10% fruit
solids, 50 to 80% sugars, 0 to 15% humectant, 0 to 10% thickeners, 8 to 20%
moisture, and
one (1) to 5% minor ingredients, wherein all percentages are by weight; and a
carbohydrate
binder combined with the RTE cereal pieces, wherein the carbohydrate binder
contains inulin.
[0015] The layered cereal bar of the present invention further has
excellent storage
stability properties. With a water activity (Aw) in the range of about 0.35 to
0.55, the
finished product has a crisp texture that does not crystallize and dry out,
yet does not
become soft and stale. Use of butylated hydroxy toluene (BHT) also limits
lipid oxidation
that is known to cause flavor degradation. In some embodiments, cereal
formulas that are
more stable due to relatively low levels of highly unsaturated fats are used.
In other
embodiments, modifications are made to a RTE cereal base to reduce certain
components,
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such as oats, known to have shorter shelf lives. Use of a carbohydrate binder
further slows
moisture uptake, which can cause textural defects.
100161 The layered cereal bar is completely portable, yet provides
the calcium,
vitamins, minerals and protein of a bowl of cereal and milk. The cereal bar
can essentially
be eaten at anytime, in any place. The bar has consumer appeal due to the
presence of a
defined milk layer. The milk layer has a white, creamy appearance, a smooth,
lubricious
texture, as well as a clean, dairy flavor. The layered cereal bar is
substantially larger than
conventional food bars, weighing about 40 to 50 g. The layered cereal bar
contains
virtually no cholesterol and is low in sodium. The additional benefits of
relatively high
levels of protein, fiber, and complex carbohydrates results in a product that
is more than
just a light treat or snack, as it is relatively satiating, providing energy
lasting up to several
hours. Such nutritional characteristics differentiate this product from other
types of known
portable grain-based snacks.
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Brief Description of the Drawings
[0017] Fig. 1 is a schematic drawing of a layered cereal bar having two
outer
cereal layers and a visible inner filling layer in one embodiment of the
present
invention.
[0018] Fig. 2A is a simplified flow diagram of a process for making a milk
filling in one embodiment of the present invention.
[0019] Fig. 2B is a simplified flow diagram of a process for making a
binder
in one embodiment of the present invention.
[0020] Fig. 3A is a simplified flow diagram of a first part of a process
for
making a layered cereal bar through the step of forming a bottom layer and a
top
layer in one embodiment of the present invention.
[0021] Fig. 3B is a simplified flow diagram of a second part of a process
starting with the step of adding milk filling to the bottom layer in one
embodiment
of the present invention.
[0022] Fig. 4 is a simplified drawing of a series of compression rollers
used
in the embodiment described in Figs. 3A and 3B.
[0023] Fig. 5A is a simplified flow diagram of a first part of a first
alternative process for making a layered cereal bar in one embodiment of the
present
invention.
[0024] Fig. 5B is a simplified flow diagram of a second part of the process
described in Fig. 5A for making the layered cereal bar.
[0025] Fig. 6A is a simplified flow diagram of a first part of a second
alternative process for making a layered cereal bar in one embodiment of the
present
invention.
[0026] Fig. 6B is a simplified flow diagram of a second part of the process
described in Fig. 6A for making the layered cereal bar.
Detailed Description
[0027] In the following detailed description, reference is made to the
accompanying drawings that form a part hereof, and in which is shown by way of
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illustration, specific embodiments in which the invention may be practiced.
These
embodiments are described in sufficient detail to enable those skilled in the
art to
practice the invention, and it is to be understood that other embodiments may
be
utilized. It is also to be understood that structural, procedural and system
changes
may be made without departing from the spirit and scope of the present
invention.
The following detailed description is, therefore, not to be taken in a
limiting sense,
and the scope of the present invention is defined by the appended claims and
their
equivalents.
[0028] Various terms used throughout the description are defined first,
followed by a discussion of various layered cereal bar embodiments, including
information on their compositions. The process and apparatus for making the
layered cereal bars is described next, followed by a brief conclusion
highlighting
some of the advantages of the various embodiments of the invention.
Introductory Definitions
[0029] As used herein, the term "additive" is intended to encompass any
type of food ingredient added to the food product at any time during
manufacturing.
A "topping" is one type of additive which typically stays on "top" of the end
product, although a "topping" can also be applied as a "coating" such that it
adheres
to some or all of the end product, with or without the assistance of a carrier
substance. Liquids in any form are also considered to be additives.
Embodiments
that discuss the use of "toppings" can also include the use of any type of
"additive." Additives also include non-nutritive (non-carbohydrate) sweeteners
(such as aspartame, acesulfame K, and saccharin) as well as carbohydrate-based
sweeteners, and any other "carbohydrate" as defined below. Additives further
include acids, bases, salts, buffering systems, chelating agents,
antioxidants,
antimicrobial agents, gases/propellants, and so forth. Additives further
include
nutrient and health additives such as vitamins, minerals, encapsulated
biologically
active components, nutraceuticals (defined below), dietary supplements, anti-
oxidants, fibers, inulin, calcium carbonate, probiotic bacteria sprinldes
(e.g.,
lactobacillus or acidophilus), energy additives, protein powders, powdered
milk
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fractions, protein or satiety additives, herbs, aromatic substances, and other
similar
=
health-enhancing additives.
[0030] The term "binder," when used without qualification herein
refers to a
syrup composition that essentially acts as a "glue" for combining relatively
dry
ingredients. The syrup composition can be a gelatin matrix comprised of
gelatin,
water, fat, syrup and sugars. When mixed with other ingredients, such as soy
products, the binder can also be a source of protein. A binder can also
contain
vitamins, minerals and macronutrients, flavorings and colorings.
[0031] The term "carbohydrate" refers to any organic compound
(and its
derivatives and analogs) containing carbon, hydrogen, and oxygen as well as a
saccharose group, as represented by the formula:
___________________________________ C¨
I I I
HO 0
[0032] As such, carbohydrates include mono-, di-, oligo-, and
polysaccharides and their derivatives (such as sugar alcohols and sugar
esters).
Carbohydrates may impart sweetness (as in the case of sugar) or non-sweetness
(as
in the case of starch). Examples of sweet and non-sweet carbohydrates include
fructose, sucrose, lactose, maltose, galactose, xylose, dextrose, maltose,
trehalose,
raffinose, stachyose, corn syrups, honey, molasses, malt syrups, corn syrup
solids,
maltodextrins, starches, pectins, gums, carrageenan, and inulin.
[0033] The term "color" or "coloring agent" as used herein refers
to natural
or uncertified colors from natural sources or certified colors for the effect
of color.
In one embodiment, the colors include dyes, certified aluminum lakes or colors
derived from a natural source. Coloring agents may also be water-based or oil-
based or dry. Coloring agents may be primary colors, blends of colors or
discrete
mixtures of colors, such as confetti.
[0034] The term "compound coating" refers to a coating containing
any fat
other than cocoa butter. This is unlike "chocolate" which must contain cocoa
butter.
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[0035] The term "density" when used without qualification herein refers to
"bulk density" of a component or composition.
[0036] The term "edible particulate" as used herein refers to edible
flakes,
grits and meal of corn, oats, rice, potatoes and other tubers, psyllium,
wheat, sugars,
soy, and combinations of these materials.
[0037] The term "fat" as used herein is synonymous with the term "lipid"
and refers to substantially all fats and fat substitutes, including any animal
or
vegetable fat in solid or liquid form.
[0038] The term "flavor" or "flavoring" as used herein refers to an
organoleptic agent in the form of an emulsion, concentrate, aqueous- or oil-
soluble
liquid or a dry powder, as well as any type of chunky piece or pieces that may
be
added to a mixture at any time in the process. Flavorings can also be
considered
additives and can include nuts, nut pieces, fresh fruits, dried fruits, fruit
products,
candies, marshmallows, "marbits," chocolates and chocolate products, and so
forth.
Flavorings further include any fruit flavors such as berry flavors, apple,
cherry,
plum, raisin, banana, pear, peach, figs, dates and so on. Flavorings may also
include
fats, salts, honeys, cheeses, frosting, powdered food products, sugar, sugar
substitutes, gelatins and spices. Flavorings may also include colorings as
well as
any nut flavors as well as any sweet flavors such as chocolate, vanilla,
caramel,
butterscotch, lemon, malt, cinnamon, graham, coconut flavors, mint and so on.
Flavorings additionally include any savory flavors such as all meat, game,
fowl,
fish, dairy, barbecue, smoke, pepper, spicy and vegetable flavors.
[0039] The term "nutraceutical" as used herein refers to edible materials
having, or believed to have, medicinal effects. Nutraceuticals include the
tocopherols, B vitamins, ginseng and other herbs, wheat grass and barley grass
and
extracts of the grasses, soy-based estrogen analogs, minerals and so on.
[0040] The term "soy flour" as used herein refers to defatted soy flour
and
soy flour with fat. Oil content in soy flour ranges from less than one percent
for
defatted soy flour to 18 to 20 percent for full fat soy flour. Soy flour may
contain
many of the phytochemicals of a soybean. Soy flour comprises isoflavones in
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concentrations ranging from about one (1) milligram per gram (mg/g) to about
three
(3) mg/g of soy flour.
[0041] The term "sugar" as used herein refers to substantially all sugars
and
sugar substitutes, including any monosaccharide such as glucose or fructose,
disaccharides such as lactose, sucrose or maltose, polysaccharides such as
starch,
oligosaccharide, sugar alcohols, or other carbohydrate forms such as gums that
are
starch based, vegetable based or seaweed based.
[0042] The term "sweetener" as used herein refers to essentially all
sweeteners that are "carbohydrate"-based, as defined above under
"carbohydrate"
and further includes sweeteners that are "non-nutritive" as defined above
under
"additive" above.
Layered Cereal Bar Embodiments
[0043] The basic physical composition of the cereal bar is that of a
"sandwich" composed of two cereal layers with a visible center or middle
layer, e.g.,
a creamy milk-filling layer. In one embodiment, the cereal bar has a total
nutrient
level equal to or greater than the nutrient level of a single serving of ready-
to-eat
(RTE) cereal with milk. The milk filling can be a confectionery center that is
high in
milk content, but possesses a relatively low water activity. In one
embodiment, the
milk filling is a compound coating comprised of milk powder, sweeteners and
fat.
In one embodiment, the cereal layers are a cereal composition comprised of
conventional RTE cereal, rice pieces and protein that are held together by a
binder.
[0044] The cereal bar can be any suitable shape and size. In the
embodiment shown in Fig. 1, the cereal bar 110 has a substantially rectangular
shape. In an exemplary embodiment, the cereal bar is about nine (9) to 13 cm
(about 3.5 to five (5) in) long, about 3.2 to four (4) cm (about 1.25 to 1.6
in) wide
and about 1.9 to 3.2 cm (about 0.75 to 1.25 in) thick. Fig. 1 is not
necessarily
drawn to scale and does not necessarily represent the actual density or
thickness of
the various layers, nor the actual proportion of the components in the cereal
bar 110.
[0045] In another embodiment, the cereal bar is substantially square-
shaped.
In another embodiment, the cereal bar is substantially round or oval-shaped.
In yet
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another embodiment, the cereal bar is substantially o-shaped with a hole of
any
suitable diameter in the center. In yet another embodiment, the cereal bar is
cut into
bite-size pieces, and can be any suitable shape, such as any type of simple or
complex shape. This includes regular geometric shapes (e.g., squares, rounds,
triangles, hexagonals, tubes, and so forth) and irregular shapes, which can be
patterned (e.g., figurines, animals, trees, holiday shapes, stars, pillows,
twists,
wagon wheels, etc.) or unpatterned, such as a nugget shape. Many of the
geometric
shapes, such as hexagonal, and various combinations of regular and irregular
shapes
(e.g., crab, palm tree and bird), can be interlocked together or "tessellated"
such that
when cut, there is no web or waste left over. In still other variations, one
or more of
the free edges of the bar can be compressed to form a pillow or biscuit shaped
piece.
[0046] The layers can be of any desired thickness and can be arranged in
any suitable way. In the embodiment shown in Fig. 1, the layers are arranged
horizontally. Two outer cereal layers 111 and 112 surround an inner filling
layer
114. In one embodiment, the cereal layers 111 and 112 are about 0.95 cm (about
0.375 in) to about 1.6 cm (about 0.675 in) thick. In one embodiment, the
filling
layer 114 is clearly defined and visible, having a thickness of at least about
0.16 cm
(about 0.062 in). In another embodiment, the filling layer 114 has a variable
thickness with a non-uniform appearance along the outside edge, such that some
of
the components in one or both of the cereal layers 111 and 112 impinge on the
filling layer 114 in various locations. In another embodiment, some or all of
the
layers are arranged vertically in a side-by-side arrangement. In another
embodiment, some or all of the layers are twisted within the cereal bar 110
forming
a swirled pattern.
[0047] In one embodiment, the filling layer 114 is a milk-filling layer.
In
another embodiment, the filling layer 114 is any type of creamy or chunky
layer.
This can include, but is not limited to, any type of peanut butter layer,
chocolate
layer, frosting layer, honey layer, yogurt layer, gelatin layer, fruit filling
layer, and
so forth. The filling layer can also be made with any other suitable foods or
food
combinations, including any type of additive. Examples include cereals and
cereal
pieces, granola pieces, nuggets, nuts, nut pieces, marshmallows, marshmallow
bits
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= (marbits), candies, candy pieces, cookies, cookie pieces, chocolates and
chocolate
products, including white and milk chocolates (e.g., chocolate chips, candy
bars,
etc.), other types of edible particulates (e.g., peanut butter chips,
butterscotch chips,
etc.), dried whole fruits (e.g., coconut, raisins, etc.), fruit parts, dried
fruit products,
fruit products (e.g., fruit syrups, etc.), and so forth.
[0048] In one preferred embodiment, the cereal bars include a
fruit filling
layer. The fruit filling layer comprises a fruit based semi-solid having a
water
activity ranging from about 0.4 to 0.5 and preferably about 0.45. In preferred
form,
the fruit filling is a thixotropic semi-solid that upon shear becomes thin
enough to be
pumpable. Good results are obtained when the fruit filling has a viscosity
ranging
from about 800,000 to 1,200,000 cps at 70 F (21 C). For example, suitable
fruit
material has now become available from DeGussa Flavors and Fruit Systems Inc.,
having offices in Langhorne, Pennsylvania. Addition of a pectin, such as a low
methoxy pectin, and the like, as a gelling agent can provide a thixotropic
fruit
material, although other thickeners, such as gums, can also be used to provide
a
thixotropic material. A low methoxy pectin results in a short gel that is
shear-
reversible, so that the filling can first be pumped, deposited and then "set-
up" as
desired.
[0049] In one embodiment, the fruit filling is a low water
activity filling
comprised of fructose, low methoxy pectins with calcium cross linkage,
characterizing fruit, apple powder and sucrose. The fruit filling or fruit
blend can
also include various minor adjuvant ingredients intended to provide additional
color,
flavor, texture and nutritional attributes to the fruit filling.
[0050] For example, in variations, the fruit material includes
acidulants to
provide desirable flavor tartness such as citric acid, malic acid, succinic
acid or
other edible organic acids or mixtures thereof to provide a pH ranging from
about
3.5 to 6, preferably about 4 to 5.
[0051] In a preferred embodiment, the fruit filling has the
following
formulation:
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Ingredient Weight% Wt % Wt%
(preferred) (most preferred)
Fruit solids 1-10 2-5 5
Sugars (dry weight basis) 50-80 60-70 72
Glycerin (or other 0-15 1-8 5
humectant)
Gums and thickeners 0-10 0.5-5 1.5
Moisture 8-20 10-20 15
Minor ingredients (salt, 1-5 2-5 3
emulsifier, flavors, colorings,
acidulants, etc.)
[0052] In preferred form the fruit filling is substantially unaerated,
i.e.,
having less than about 5% overrun. (that is, a given weight of the fruit
filling has a
volume of less than 105% of a degassed equivalent) and will have a density
ranging
from about 1.1 g/cc to about 1.2 g/cc. Normal handling and filling can result
in
some degree of air incorporation into a fruit filling but care should be
exercised to
control the amount of unintended air entrapment during processing and
fabrication
of the present cereal bars. Excessive air entrapment can lead to loss of color
intensity as the amount of air increase in number or air cells causes the
fruit filling
to lighten in color. However, it is not essential that the fruit filling be de-
aerated to
remove residual oxygen.
[0053] Of course, cereal bar embodiments are contemplated that have more
than one intermediate layer. For example, a cereal bar can have both an
intermediate fruit filling layer and a milk layer or milky (i.e., white color
or off-
white colored) layer in the form a laminate array or sandwich to form a milk
and
fruit and cereal bar. In another variation, the cereal bar can include a fruit
layer and
a nut butter, e.g., peanut butter, layer to provide a peanut butter and fruit
sandwich
cereal bar. This can include, for example, a fruit layer and a peanut butter
layer. In
a particular variation, a fruit layer and a peanut butter layer are combined
with a
cocoa flavored cereal bar that can include cocoa flavored puffed cereal
pieces. In
still other variations, the layers can be in abutting relationships such as to
provide a
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cereal bar with a single intermediate layer that is one half center filling of
fruit and
one half of a milk layer. In still other variations, the milk layer can be a
topical or
base or bottom layer and the fruit layer can be an intermediate layer or the
milk and
fruit layers can be reversed.
[0054] It will be appreciated that the fruit filling material employed is
at
substantially its fmal moisture content upon fabrication of the present cereal
bars.
Unlike other cereal bar products that are fabricated with a finish baking or
other
heating or cooking steps, in the present invention no heating or cooking step
is
practiced that significantly alters the moisture content of the fruit filling.
Moreover,
since no finish heating or baking step is practiced in the present methods of
fabrication, preferred for use herein are aseptically processed fruit filling
materials.
[0055] The binder used in this fruit filling embodiment does not typically
contain any soy protein, although protein could be added if desired.
Additionally,
such a binder preferably contains a corn syrup that is not excessively sweet
(e.g.,
fructose syrup). In one embodiment, a corn syrup rich in maltose is used.
Maltose
syrups are known to provide functionality or "binding" while not contributing
excessively to perceived sweetness. The binder is also typically low in fat,
such as
less than about 30%. In a particular embodiment, the binder has 2 grams of fat
per
40 gram serving, i.e., about 5% fat.
[0056] In still another embodiment, all or a part of the binder can be
provided by a heat tolerant low sweetness glaze forming carbohydrate(s).
Useful
glaze forming carbohydrates can be selected from the group consisting of
isomalt,
maltitol and lactitol and mixtures thereof. Preferred for use herein due to
availability, cost and reduced laxative properties is isomalt.
[0057] The isomalt ingredient provides a less sweet attribute to the bar
product than when equivalent amounts of more sweet binder ingredients such as
sugar and fructose syrups. Isomalts are well known and the skilled artisan
will have
no difficulty in selecting useful commercially available isomalt ingredients
from
commercial suppliers. Discovered in the 1960s, isomalt has been used in Europe
since the early 1980s and is currently used in a wide variety of products in
more
than 50 countries worldwide. Isomalt is made from sucrose and can be supplied
in
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the form of bead particulates. It is white, crystalline and odorless. Isomalt
is a
mixture of two disaccharide alcohols¨gluco-mannitol and gluco-sorbitol.
Sucrose,
by comparison, is a disaccharide sugar, namely gluco-fructose. Chemically,
isomalt
belongs to the class of disaccharide polyols such as maltitol and lactitol. It
is
derived exclusively from sucrose. It consists of two components in a 1:1
ratio, 1,6-
glucopyranosyl-D-sorbitol (GPS) and 1,1-glucopyranosyl-D-mannitol (GPM).
Compared to the group of polyols currently used as sweeteners, isomalt like
maltitol
and lactitol, has a high molecular weight of 344.
[0058] Isomalt is a bulk sweetener exhibiting a very clean sucrose-like
taste
profile with no significant off-tastes or aftertastes. Isomalt liquid grade
contains a
blend of pure crystalline isomalt and maltitol syrup sometimes fortified with
minor
amounts of hydrogenated oligosaccharides. Isomalt has a sweetness potency 50%
that of sucrose. Consequently, when using pure crystalline isomalt, a
combination
with an intense sweetener may be required.
[0059] Isomalt is made from sugar; is used in a variety of foods and
pharmaceuticals; provides the taste and texture of sugar; is synergistic with
other
sweeteners; is low calorie (provides at most 2 calories per gram); does not
promote
dental caries; and does not increase blood glucose or insulin levels. Isomalt
is a
widely available food ingredient available from, for example, Pa1atinit of
America,
Inc., having offices in Morris Plains, New Jersey. While particulate isomalt
can be
used by heating above its melting point and admixing with other binder
ingredients,
preferred for use herein is liquid isomalt.
[0060] Maltitol is a member of a family of bulk sweeteners known as
polyols or sugar alcohols. It has a pleasant sweet taste--remarkably similar
to
sucrose. Maltitol is about 90% as sweet as sugar, non-carcinogenic, and
significantly reduced in calories. Maltitol is especially useful in the
production of
sweets, including sugarless hard candies, chewing gum, chocolates, baked goods
and ice cream. It is available worldwide from Cerestar, Roquette, SPI Polyols,
Inc.
and Towa Chemical Industry Co., LTD.
[0061] Maltitol is made by the hydrogenation of maltose, which is obtained
from starch. Like other polyols, it does not brown or carmelize as do sugars.
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Maltitol's high sweetness allows it to be used without other sweeteners. It
exhibits
a negligible cooling effect in the mouth compared to most other polyols.
Although
maltitol is often used to replace sugars in the manufacture of sugar-free
foods, it
may also be used to replace fat as it gives a creamy texture to food.
[0062] Lactitol is manufactured by reducing the glucose part of the
disaccharide lactose. Unlike the metabolism of lactose, lactitol is not
hydrolyzed by
lactase. It is neither hydrolyzed nor absorbed in the small intestine.
Lactitol is
metabolized by bacteria in the large intestine, where it is converted into
biomass,
organic acids, carbon dioxide and a small amount of hydrogen. The organic
acids
are further metabolized resulting in a caloric contribution of 2 calories per
gram
(carbohydrates generally have about 4 calories per gram).
[0063] In another embodiment, one or more additional ingredients are added
to the filling layer 114 or to either or both of the cereal layers 111 and
112,
including any of the creamy or chunky foods noted above. In yet another
embodiment, there are four (4) to five (5) or more total layers. These layers
can
include one or more additional cereal and/or creamy filling layers.
[0064] In another embodiment, a topping layer is also present in addition
to
the filling layer 114. The topping layer can be a creamy topping, such as a
frosting
covering the entire surface of the cereal bar or a glaze that is drizzled onto
the top
layer. The topping layer can also be any other type of coating made from any
of the
foods noted above. In yet another alternative embodiment, dry or powdered
ingredients are used as a topping layer either alone or in conjunction with a
creamy
topping layer. This includes, but is not limited to, colorings, sugars in
various forms
(e.g., brown sugar, white sugar, confectionery sugar, etc.), sugar
substitutes, ground
or powdered spices (e.g., cinnamon, nutmeg, cardamom, various salts, etc.),
herbs,
dried whole fruits flavorings and other flavorings as defined herein, which
can be
added as dried or powdered flavorings, other powdered toppings (including
powdered fruits, milks, milk fractions, juices, cheeses, etc.), aromatic
substances,
including any type of taste-enhancing additives, and so forth.
[0065] In yet another embodiment, the layered cereal bar is partially or
completely enrobed in a coating. The coating can be a liquid coating that
solidifies
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at room temperature and is applied by dipping the layered cereal bar into a
heated
bath of the coating, such as a chocolate coating. Alternatively, the layered
cereal
bar can be submersed into a dry or powdered coating and rolled around until
adequate coverage is obtained. This can include, for example, a dusting with
cinnamon and sugar, milk powder and sugar, and so forth.
[0066] In one embodiment, the filling layer 114 is a confectionery filling
with a milk content of about ten (10)% or more and a water activity of about
0.45 or
less. In another embodiment, the filling layer 114 is a compound coating. In
yet
another embodiment, the filling layer 114 is a visible milk filling layer
comprised of
milk powder, sweeteners and fat in a ratio of about 1:2:1.4. Unlike typical
compound fillings being used in conventional European "high milk" confections,
this type of milk filling is lower in fat, having about 25 to 35% total fat
content. In
one embodiment the milk powder, sweeteners and fat are combined in a ratio of
about 1:2:1.4. Additionally, other minor ingredients can be added, including,
but
not limited to, antioxidants, mono- and diglycerides and/or emulsifiers, such
as soy
lecithin, flavorings and colorings. In a specific embodiment, the filling
layer 114 is
a milk filling layer comprising about 17 to 21%, by weight, of the cereal bar
and has
a minimal water activity of about 0.25 to 0.35. The filling layer 114 is
discussed
further in reference to Fig. 2A.
[0067] The cereal layers 111 and 112, comprised of conventional RTE
cereal 116, rice pieces 118 and protein nuggets 120, are held together by a
binder
(not shown). Any known R11, cereal 116 or RTE cereal combinations can be used
in the cereal layers 111 and 112. The cereal 116 in the cereal layers 111 and
112 are
identifiable and recognizable, although not all are necessarily whole.
However, it is
expected that there will be at least one whole cereal piece somewhere on the
cereal
bar surface. In some embodiments, there may be portions of cereal 116 present
on
the cereal bar surface or the cereal piece may be partially crushed or broken.
In the
embodiment shown in Fig. 1, the cereal 116 in the cereal layers 111 and 112 is
an o-
shaped cereal, such as Honey Nut Cheerios . In other embodiments, the RTE
cereal
in the cereal layers 111 and 112 is comprised of other cereal pieces such as
flakes,
shreds, biscuits, rings, spheres, squares, rounds, triangles, hexagonals,
tubes,
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oblongs, and so forth, including any other desired shape discussed above in
relation
to the possible shapes for the cereal bars themselves.
[00681 In other embodiments, the cereal layers 111 and 112 can contain any
known RTE cereal such as any type of Cheerios (e.g., regular Cheerios , Apple
Cinnamon Cheerios , Honey Nut Cheerios ), any type of Chex (e.g., Honey Nut
Chex , Wheat Chex , Rice Chex , Corn Chex , Bran Chex ), Cocoa Puffs ,
Cinnamon Toast Crunch , Oatmeal Raisin Crisp , Wheaties , Total , generic
substitutes for these and other RTE cereal products, various combinations of
one or
more cereal types, and so forth.
100691 RTE cereals typically have a moisture content of less than about
three (3)% and an Aw of about 0.2. RTE cereal is an excellent source of many
nutrients, including protein and fiber. In one embodiment, the cereal 116
comprises
about one (1) to two (2) g of declared fiber or about 2.5% to about four (4)%,
by
weight, of the final product. In one embodiment, the RTE cereal is modified to
increase or decrease fiber or other ingredients. For example, additional
raisins can
be added. In another embodiment, a sugar coating, i.e., slurry coating, is
added to
the outside of the RTE cereal. A sugar coating is used as a flavoring, but can
also
serve to improve shelf life and texture. In yet another embodiment, an "oat-
predominant" (greater than 50% oats dwb) cereal base can be replaced with an
"oat-
containing'' (less than 50% oats dwb) cereal base. An "oat-containing"
formulation
has known advantages relating to shelf life, since oats are known to lose
freshness
sooner than other grains due to their lipid content. It is also possible to
substitute or
add any number of other grains into the cereal base, including sorghum, rye,
wheat,
barley, and so forth, in any suitable ratio, depending on the particular
application.
In one embodiment, the RTE cereal comprises about 20 to 25% by weight of the
total layered cereal bar.
[0070] The cereal layers 111 and 112 further contain extruded high-protein
rice pieces 118. Rice is used to provide protein and to add additional crispy
texture
to the cereal bar 110. Further, since rice tastes relatively bland, there is
no off-
flavor to interfere with the flavor of the cereal 116. In one embodiment, the
high-
protein rice pieces 118 are made by incorporating soy protein in extruded rice
pieces
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at very high levels of about 50% or higher. In a particular embodiment, high-
protein
rice pieces 120 are obtained from Ringger Foods, Gridley, Illinois or Du Pont
Protein Technologies International (PTI) in St. Louis, Missouri. The rice
pieces 118
can be any suitable size and shape. It is known that the size and shape of the
rice
pieces can vary depending on manufacturing conditions, machine die plates,
formulation, and so forth. In one embodiment, the rice pieces 118 have an
elongated oval shape. In another embodiment, the rice pieces 118 have a
variety of
diameters ranging from about two (2) mm to about eight (8) mm. The various
sizes
of rice pieces 118 act as fillers within the cereal layers 111 and 112. The
density of
the rice pieces 118 can vary depending on the particular type of rice used,
method of
producing the rice pieces, and so forth. In one embodiment, the density of the
rice
pieces 118 range from about 10.7 to 29 g/100 cc (about 175 to about 475 g/100
cu
in). In a particular embodiment, a soy crisp rice piece having a density of
about
18.3 to 23.3 g/100 cc (about 300 to 382 g/100 cu in) is used. In one
embodiment,
the rice pieces 118 comprise about 7.5 to 12%, by weight, of the final
product.
[0071] In the embodiment shown in Fig. 1, the cereal layers 111 and 112
further contain texturized vegetable protein (TVP) 120 as an additional source
of
protein and fiber. TVP 120 naturally has a light or dark beige color, as it is
essentially soy flour that has been extruded to produce a minced end product.
The
extruded soy flour has no particular shape, as the pieces are essentially
"nuggets,"
which are sometimes referred to as "ragged" in appearance. TVP 120 typically
has
a particle size of two (2)% max on four (4) Mesh U.S. Sieve, five (5) to 15%
max
on five (5) Mesh U.S. Sieve, zero (0) to 60% max on eight (8) Mesh U.S. Sieve,
and
ten (10)% max through 16 Mesh U.S. Sieve. In one embodiment, the average
diameter of the TVP 120 is about two (2) to about five (5) mm. TVP 120
provides
an inexpensive source of protein, yet adds a desirable crispy texture.
Typically TVP
120 has a protein content of at least about 50%, although TVP having a lower
protein content can also be used. In one embodiment, the protein content is
about
52%. Typically, TVP has a cold-water absorption of about 2.5 to three (3) mug
and
a bulk density greater than about 0.26 g/cc, up to about 0.4 to 0.5 g/cc. TVP
further
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contains about 18% fiber. In one embodiment, TVP comprises about 7.5 to 12%,
by
weight, of the final product.
[0072] In a particular embodiment, "Experimental 4030 Minced Textured
Soy Flour (Cargill 4030) from Cargill Protein Products in Cedar Rapids, Iowa,
is
used. Cargill 4030 has a water absorption greater than about 3.2 ml/g, but has
been
measured as high as about 4.5 ml/g. Cargill 4030 further has a lower bulk
density
than conventional TVP, in the range of about 0.227 to 0.267 g/cc. As a result,
Cargill 4030 absorbs water more slowly than conventional texturized vegetable
proteins. In another embodiment Cargill's "Experimental 4025 Minced Textured
Soy Flour," which is darker in color, is used.
[0073] Since TVP is made from soybeans, it can have high levels of
raffinose and stachyose, which are known to cause flatulence. Additionally,
the
presence of lipoxygenase can cause undesirable off-flavors. In one embodiment,
the
protein source in the cereal layer is soy protein concentrate or soy protein
isolate. In
yet another embodiment, off-flavors are masked using artificial masking agents
known in the art. The use of TVP (as well as the soy product in the binder in
one
embodiment, discussed below) provides the consumer with all the health
benefits
soy is known to provide, including the benefits related to the intake of
isoflavones,
phytoestrogens, and so forth.
[0074] The cereal 116, rice pieces 118 and TVP 120 can be combined in any
suitable ratio. In one embodiment, they are combined in a ratio of about
2:1:1,
respectively. In another embodiment, high protein rice is not used in the
cereal
layer, and TVP is used as the sole source of additional protein. Although the
organoleptic properties of the final product may be less desirable due to the
presence of additional TVP, such an embodiment may be desirable in certain low
income markets, including, but not limited to, third world countries,
suppliers of
bulk food programs such as programs providing emergency relief, and so forth.
In
yet another embodiment, TVP is not used in the cereal layer, and high protein
rice is
used as the sole source of additional protein. Although the cost of the final
product
may be higher due to the presence of additional high protein rice, such an
embodiment may be desirable in particular select markets, including, but not
limited
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to, upscale restaurants, food stores, and so forth. In yet another embodiment,
the
cereal pieces themselves are fortified with additional protein, and neither
high
protein rice nor TVP is used in the cereal layer. Although this embodiment
would
not have the varied texture provided by the TVP and rice pieces, the
appearance and
texture of a cereal bar containing only whole cereal pieces (and a binder) in
the
cereal layers may be appealing in certain markets.
[0075] The binder or "glue" used to hold the other ingredients in the
cereal
layers 111 and 112 together can be any type of suitable binder depending on
the
type of RTE cereal used as well as the type of filling layer used. In one
embodiment, a carbohydrate-gelatin binder comprised of a sugar solution, a soy
protein/fat mixture, and hydrated gelatin is used. In other embodiments, the
binder
does not contain protein, such as in the embodiment described above in which a
fruit filling layer is used.
[0076] Use of a carbohydrate-gelatin binder with certain RTE cereals
improves storage stability, as compared with a carbohydrate non-gelatin
binder, by
slowing moisture uptake, which can cause various textural defects in the
cereal, rice
and TVP. In another embodiment, use of a carbohydrate/aqueous binder versus a
conventional maltodextrin/fat-based binder has the further advantage of
providing
no added fat. In one embodiment, the sugar solution is comprised of wet
ingredients, including corn syrups and glycerin, and dry ingredients such as
various
sugars, (i.e., fructose, sucrose, etc.), as well as minor ingredients such as
calcium,
sorbitol, maltodextrin and salt. In one embodiment, the ratio of wet to dry
ingredients is about 2.2:1. In another embodiment, about 0.5% water is added
to the
sugar solution, producing a water activity of about 0.45 to 0.60 in the
finished
binder.
[0077] The soy protein/fat mixture can be comprised of soy protein
isolates
suspended in a suitable amount of fat. In one embodiment, soy protein and fat
are
combined in a ratio of about 3:2. In one embodiment, the hydrated gelatin is
comprised of water and gelatin in a ratio of about 4:1. In another embodiment,
minor ingredients such as antioxidants, flavorings, colors, vitamins, minerals
and
emulsifiers are added to the soy protein/fat mixture. In an alternative
embodiment,
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the vitamins and minerals are present in the RTE cereal itself, the filling
and/or in
any other layer or topical coating. The process of making the binder is
discussed
further in reference to Fig. 2B. The cereal layers 111 and 112 and binder can
be
bonded together in any suitable ratio. In one embodiment, they are bonded in a
ratio
of about 1:1:1.
[0078] The layered cereal bar 110 can have any suitable moisture content
and water activity. Water activity is known to play an important role in
relation to
product stability. Experiments have demonstrated that for each cereal and
binder
combination, there is a relatively narrow ideal Aw target range. This target
range is
related primarily to cereal texture and binder texture/plasticity.
Specifically, as the
Aw increases, the cereal texture is negatively impacted, becoming soggy and
stale at
some specific value, depending on the cereal selected. However, as the Aw
decreases, the binder becomes more crystalline and brittle due to the absence
of the
plasticizing effect of water. As a result of these competing requirements, a
relatively narrow Aw range between about 0.35 to 0.55 has been identified as
an
ideal target range in most cases. In another embodiment, the Aw range is
between
about 0.4 to 0.5. The latter Aw range is typically achieved when the Aw of the
binder is between about 0.50 to 0.60, and the Aw of the filling, such as a
milk
filling, is between about 0.25 to 0.35. In one embodiment, most of the
moisture in
the product is incorporated in the binder. In this embodiment, the filling has
very
little, if any, water, i.e., less than about one (1)%, which comes from the
inherent
moisture in its raw ingredients. Such an approach decreases moisture
equilibration
time and results in a more stable product.
[0079] In one embodiment, the cereal bar has a moisture content of about
six
(6) to eight (8)% and an Aw of about 0.4 to 0.45. For a cereal bar to be
crispy, the
Aw needs to be less than about 0.45. With certain types of cereal bars,
however,
such as those containing oatmeal and raisins, a higher Aw is acceptable
because of
the presence of relatively soft and chewy components, such as raisins. If the
Aw is
too low, the product can be dry and crumbly. In one embodiment, the cereal bar
110 has a "crispy-chewy" texture such that the initial taste sensation is
crispy and
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crunchy. However, as eating continues, there is ultimately a noticeable
chewiness
to the texture.
[0080] Conventional food bars typically weigh about 20 g, with some
weighing up to about 27 g. The novel cereal bar of the present invention can
weigh
any suitable amount, depending on the particular size and shape. In one
embodiment, each cereal bar is intended to essentially substitute for a
conventional
bowl of cereal with milk, such that it provides at least the same nutrition.
In one
embodiment, each cereal bar weighs more than about 50 g. In a particular
embodiment, the cereal bar weighs about 35 to 50 g and the ratio of cereal
composition, binder and filling is about 2:2:1.
[0081] The layered cereal bar can be packaged in any suitable manner. In
one embodiment, each cereal bar is individually wrapped. In a particular
embodiment, each cereal bar is individually "pouched" in a flexible metallized
film
known in the art. Any number of individually wrapped cereal bars can be
packaged
in a secondary container or carton. In one embodiment, a single pouch is
placed in
an individual carton, such as for use in fast food restaurants, airplanes, and
so forth.
It is also possible to ship individual pouches without placing them in
individual
cartons. In a particular embodiment, small, regular or king-sized cereal bars
are
packaged to be individually dispensed in a vending machine. In one embodiment,
six (6) pouches are packaged together in a consumer-sized container. In
another
embodiment, less than six (6) pouches are placed in a carton. In yet another
embodiment, seven (7) to 12 pouches or more are placed in a carton. In one
embodiment, the consumer-sized container is about 2,000 to 5,000 cc and holds
more than one pouch. In another embodiment, a large slab of layered cereal
bar,
such as about 25 cm by 35 cm (about ten (10) in by 14 in), is packaged in a
flexible
metallized film for use in a food service facility where it is cut into
individual
servings to be sold at a later time.
[0082] According to known international standards, a single serving of
most
cereals is considered to be about 30 g, which corresponds to a volume of from
about
=
0.2 to 0.3 Liters (L) (about 0.75 to 1.25 cups). (A single serving of denser
cereals,
such as a granola, muselix, or fruit and nut bran cereals, is about 50 to 55
g). A
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single serving of cereal provides about one (1) to two (2) g of protein. When
combined with about 0.1 L (about 1/2 cup) of milk having about four (4) g of
protein, a bowl of cereal with milk averages about six (6) g of protein. In
one
embodiment, the layered cereal bar of the present invention provides the
"nutrition
of a bowl of cereal with milk," i.e., up to about six (6) g of total protein.
[0083] The label for the layered cereal bar can include nutritional
information that includes a statement that each cereal bar has "the nutrition
of a
bowl of cereal and milk" or "the nutrition of a bowl of cereal with milk." The
details
on the nutritional content of the cereal bars can be presented both on the
outside
carton as well as on each individually wrapped layered cereal bar. In one
embodiment, the information on a nutrition label might read as follows:
[0084] INGREDIENTS: Cereal [Whole Grain Oats (includes the oat bran),
brown rice flour, corn meal; sugar; wheat starch; honey; salt; calcium
carbonate;
partially hydrogenated soybean oil; barley malt extract; trisodium phosphate;
almond meal; wheat flour, vitamin E (mixed tocopherols) added to preserve
freshness]; milk filling [milk; sugar; lactose; palm kernel oil; partially
hydrogenated soybean oil; soy lecithin; mono and diglycerides; natural and
artificial
flavor, freshness preserved by BHT]; soy flour; corn syrup, soy protein
isolate; rice
flour; fructose; high fructose corn syrup, sugar, partially hydrogenated
soybean oil;
glycerin; maltodextrin; tricalcium phosphate; sorbitol; almonds; malt extract;
color
added; gelatin; salt; honey; natural flavor; freshness preserved by BHT.
[0085] VITAMINS AND MINERALS: Zinc and Iron (mineral nutrients); a
B vitamin (niacinarnide); vitamin C (sodium ascorbate); vitamin A (palmitate);
vitamin D, vitamin B6 (pyridoxine); vitamin B2 (riboflavin); vitamin B1
(thiamin
mononitrate); vitamin B12; a B vitamin (folic acid).
[0086] CONTAINS: milk, soy, almond, and wheat ingredients.
[0087] In the above label, cereal, present in the largest quantity, is
listed
first. The second ingredient is a milk filling. Milk is the first ingredient
of the milk
filling, which is in the form of milk powder as discussed below. A suitable
label
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also contains all of the nutritional information required by law, including
the %
daily value (DV) of various components, including information on the total fat
(including saturated fat, polyunsaturated fat, monounsaturated fat),
cholesterol,
sodium, potassium, total carbohydrate (including dietary fiber, sugars, other
carbohydrates) and protein. A statement to the effect that, "the % DV is based
on a
2,000 calorie diet, and an individual's daily values may be higher or lower
depended
on calorie needs," can also be present on the label. This can be accompanied
by a
table showing the total content of fat, including saturated fat, cholesterol,
sodium
potassium and total carbohydrates, including dietary fiber, in a single
serving, based
on a calorie intake of 2000 and 2500 calories. Information on various vitamins
and
minerals, such as vitamin A, vitamin C, iron, vitamin D, thiamin, riboflavin,
niacin,
vitamin B6, folic acid, vitamin B12, calcium, phosphorus, magnesium, zinc and
copper can also be on the label.
[0088] In one embodiment, there are about four (4) to five (5) g of total
fat
in a 40 g bar, of which about 1.8 to two (2) g is saturated fat. In one
embodiment,
the total carbohydrate level is about 65%, by weight, of the layered cereal
bar. The
total carbohydrate level is comprised of about 3 to 4% dietary fiber, 50 to
60%
sugar, and about 36 to 47% complex carbohydrates. In a 40 g cereal bar, for
example, there is about 25.6 g of total carbohydrates, of which about 0.8 to
one (1) g
is dietary fiber, about 12.8 to 15.4 g is sugar and about 9.2 to 12 g are
complex
carbohydrates. In another embodiment, additional fiber in any suitable form,
such
as an invisible fiber is added to increase the total fiber percentage to about
5 to 10%.
In one embodiment, inulin is added.
Methods and Apparatus for Making Layered Cereal Bars
[0089] The present invention provides methods and apparatus for making
layered cereal having a visible filling layer comprising mixing a binder with
a cereal
composition having identifiable cereal pieces to form an amorphous mass or
mixture, compressing the amorphous mass into a first layer and a second layer,
applying a filling layer on the first layer, combining the first layer and
filling layer
with the second layer, and pressing the first layer, filling layer and second
layer
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together to form pressed layers, wherein the pressed layers are cut into
individual
cereal bars having identifiable cereal pieces.
[0090] Fig. 2A shows one embodiment of a milk filling process 200 for
preparing a milk filling for the filling layer of the present invention. In
this
embodiment, milk powder 201, sweeteners 202 and any minor dry ingredients 203,
such as dry colors, flaked emulsifiers, and so forth, are combined and refined
in a
refiner 204 to reduce their particle size. These components enter the process
200 at
ambient temperature, which can be as high as 38 C (190 F) or more in a
manufacturing plant. The refined ingredients are then combined with fats 205
and
any minor wet ingredients 206, such as oil-based colors, emulsifiers, and so
forth, in
a heated mixing "filling" kettle 207 to produce the filling, i.e., milk
filling 114. In
one embodiment, flavors 208 are also added to the filling kettle 207 at any
suitable
time. In a particular embodiment, flavors 208 are added last to avoid any
adverse
affects from prolonged exposure to heat.
[0091] The milk powder 201 in the milk filling 114 can have any fat
content
desirable. In one embodiment, whole milk powder having about 25 to 30% fat is
used. In another embodiment, milk powder having less than about 25%, down to
about 4% fat is used. In yet another embodiment, skim milk powder having a
maximum fat content of about 1.25% is used. In one embodiment, skim milk
powders processed under low heat conditions, i.e., "low-heat" powders are
used.
Such powders have a relatively bland flavor without any cooked notes from
scorched flavor or odors. In another embodiment, high-heat powders are used
which are typically more stable than low-heat powders. Further, off-flavors
don't
occur as fast when the milk powder is subjected to higher heat at the
beginning of
processing, and high-heat milks typically have a more cooked flavor as a
result. In
one embodiment, combinations of low-heat and/or high-heat skim and whole milk
powders in about a 1:1 ratio are used.
[0092] The sweeteners 202 in the milk filling 114 can be any suitable
types
of sweeteners. In one embodiment, carbohydrate sweeteners are used, including,
but not limited to any type of sugar or sugar combination, corn syrup solids
and/or
maltodextrins, or a combination thereof. Any suitable type of fats 205 can be
used
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in the milk-filling layer 114. In one embodiment, hydrogenated vegetable oil
is
used. In a particular embodiment, palm kernel oil and soybean oil are used in
a ratio
of about 1:1. Palm kernel oil has a sharp melting point and is a relatively
inexpensive and common source of fat.
[0093] The components can be combined according to any suitable ratio.
For example, for approximately every 45 kg (100 lbs) of milk filling 114
produced,
about 11.4 kg (25 lbs) of milk powder 201, 20.5 kg (45 lbs) of sweeteners 202,
and
13.6 kg (30 lbs) of fats 205 are used. In one embodiment, of the 20.5 kg (45
lbs) of
sweeteners 202 used, about nine (10.5) kg (23 lbs) is sugar, while the
remainder is
lactose. Further, in most embodiments, less than about 0.45 kg (one (1) lb) of
the
minor ingredients 203 and 206 are added.
[0094] In one embodiment, the heated mixing kettle 207 is a swept surface
tank. In another embodiment, separate kettles are used for mixing and holding
the
milk filling 114. In a particular embodiment, the flavors 208 are added
separately to
the holding or "use" kettle, rather than to the "mixing" kettle. The mixture
is heated
for any suitable time, depending on the mixing speed. In one embodiment, the
mixture is heated for less than about three (3) to four (4) hours or more. Any
suitable temperature can be used in the "filling" kettle 207. In one
embodiment, the
temperature is greater than about 38 C (about 100 F). The resulting milk
filling
114 has a viscosity of about 10,000 to 15,000 cp. In another embodiment, the
filling
ingredients are combined without the refining and/or heating step to produce a
confection.
[0095] The binder is prepared according to a batch binder process, such as
the process shown in Fig. 2B. The process begins by stirring in soy protein
212
with pre-heated shortening or fat 214 in a heated mixing "protein" kettle or
vessel
216. Any suitable source of soy protein can be used, such as soy protein
concentrates or soy protein isolates. In a particular embodiment, soy protein
isolates
from Arthur Daniel Midland (ADM) Co. in Decatur, Illinois or PTI in St. Louis,
Missouri, are used. The soy protein 212 is suspended in fat rather than water
to
avoid the formation of a gel. Any suitable amount of soy protein 212 can be
added
to the fat 214. In one embodiment, the soy protein 212 and fat 214 are
combined in
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a ratio of about 3:2. For example, for every 150 kg (330 lbs) of soy protein
212
(dwb) added, about 100 kg (220 lbs) of fat 214 is used. In one embodiment, a
soy
protein isolate is used having an initial viscosity of about 1,000 to 3,000 cp
and soy
oil is used for the fat 214, having an initial viscosity of about 1,000 cp.
The soy
protein 212 and fat 214 can be heated and mixed in any suitable type of
vessel. In
one embodiment, the components are heated and mixed together in a swept
surface
tank. The mixture is heated for any suitable time, depending on the mixing
speed.
In one embodiment, the mixture is heated for less than about three (3) to four
(4)
hours. In another embodiment, the mixture is mixed with a high-speed mixer or
liquefier for less than about three (3) minutes. Any suitable temperature can
be used
in the protein kettle 216. In one embodiment, the temperature is greater than
about
32 C (about 90 F). After being heated and mixed, the resulting slurry 218 is
flowable, but can have a viscosity of up to about 3000 cp.
[0096] In a separate step, syrups, glycerin and sugars can be combined to
form a sugar solution in a heated mixing make-up kettle 226. In the embodiment
shown in Fig. 2B, the sugar solution 228 is comprised of liquid syrups and
glycerin
220, dry sugars, such as a sucrose/fructose combination 222, and other minor
dry
ingredients 224, although the invention is not so limited. In one embodiment,
the
sucrose and fructose are combined in a ratio of about 1:175. In other
embodiments,
alternate combinations are used, such as various amounts of dextrose, maltose,
xylose, trehalose, and/or other sugars for a portion of the sucrose and/or
fructose
and/or sucrose/fructose blend.
[0097] In one embodiment, the ratio of wet to dry ingredients is about
2:1,
or in some embodiments, about 2.2:1. For example, with a 908 kg (2,000 lb)
batch
of heated sugar solution 228, there are about 627 kg (1,380 lbs) of wet
ingredients,
and about 281 kg (620 lbs) of dry ingredients. The mixture can be heated for
any
suitable time at any suitable temperature, depending on the batch size, kettle
size,
and so forth. In one embodiment, a 908 kg (2,000 lb) batch is heated from
ambient
temperature to about 88 C (190 F) in about 35-45 minutes. The viscosity of
the
heated sugar solution 228 is about 10,000 to 100,000 cp, depending on the
temperature of the mixture. In the embodiment shown in Fig. 2B, the heated
sugar
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solution 228 then passes through one or more heat exchangers 229 in order to
reduce the temperature of the heated sugar solution 228 to avoid denaturing
protein
present in the cooling binder kettle 249. In one embodiment a swept surface
heat
exchanger made by Waukesha Cherry-Burrell, A United Dominion Co., Louisville,
Kentucky, is used to reduce the temperature of the heated sugar solution 228
from
about 88 C (190 F) to about 130 F. In another embodiment a Contherme Swept
Surface Heat Exchanger made by Alfa Laval Contherm, Inc., in Newburyport,
Massachusetts, is used.
[0098] As noted above, macronutrients, i.e., vitamins and minerals, can be
added at any stage of manufacturing. However, some macronutrients are more
heat
sensitive than others, such as certain vitamins, and others may require more
time to
disperse, such as calcium. Alternately, components can be fractionated, or
more
soluble forms of components, such as calcium, can be used. In the embodiment
shown in Fig. 2B, a calcium supplement 225 is also added to the make-up kettle
226. Any form of calcium 225 can be used, such as calcium carbonate (CaCO3),
tricalcium phosphate (Ca3(PO4))2, i.e., TCP), and so forth. CaCO3, however, is
less
concentrated than TCP such that higher amounts of CaCO3 must be added to
obtain
the same level of usable calcium, which can adversely affect the viscosity of
the
sugar solution 228, and ultimately of the binder 238. Furthermore, CaCO3, has
a
grittier and chalkier taste than TCP. In one embodiment, TCP, in the form of a
fine
powder having a mean particle size of between about one (1) to 45 microns in
diameter, is used. In a particular embodiment, about 50% of the particles have
a
micron size less than about 6.5. Any suitable quantity of TCP can be used. In
one
embodiment, the percent of TCP in the sugar solution 228 is about two (2)%.
[0099] In one embodiment, the ratio of TCP to binder 238 is about 1:40 or
about two (2) to three (3)% on a weight basis. For example, for a 908 kg
(2,000 lb)
batch of binder 238, about 23 kg (50 lbs) is TCP and about 880 kg (1,950 lbs)
is the
total weight of the remaining binder ingredients, representing a ratio of
about 1:40
or 2.5% TCP content in the binder 238 on a weight basis. This level of TCP
provides about 25% of the recommended daily value (DV) of calcium per 40 g of
layered cereal bar.
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[001001 In another separate step, conventional powdered gelatin 230 and
sucrose 231 are hydrated in water 232 in a heated mixing "gelatin" kettle 234
to
produce hydrated gelatin 236. This step is similar to the process used to make
gelatin in the home. In one embodiment, the gelatin 230, sucrose 231 and water
232
are combined in the gelatin kettle 234 in a ratio of about 6:4:15. In another
embodiment, no added sucrose 231 is used, and the gelatin 230 and water 232
are
combined in a ratio of about 4:1. Any suitable temperature can be used to
hydrate
the gelatin 230. In one embodiment, the mixture is heated to about 66 to 77 C
(about 150 to 170 F). Temperatures higher than about 77 C can degrade the
gelatin 230. At temperatures below about 66 C, the gelatin 230 will not
dissolve in
the water 232. In one embodiment, the gelatin 230 is not whipped to avoid
creating
the appearance of marshmallow, which is opaque white in color, less dense and
stringier than gelatin, which is not whipped. The resulting hydrated gelatin
236 is
relatively colorless and translucent, which helps to create a chewy, layered
cereal
bar.
[00101] In the embodiment shown, the binder 238 is produced when the
fat/protein slurry 218 is combined together with the heated sugar solution 228
and
hydrated gelatin 236 in the cooling binder kettle 240. (Again, in some
embodiments, no protein is used, such that the fat and heated sugar solution
can be
combined to form a slurry, which is then combined with the hydrated gelatin as
described). In one embodiment, the slurry 218 and hydrated gelatin 236 are
folded
into the sugar solution 228. Using the same 908 kg (2000 lbs) batch of binder
238
as in the example above, the sugar solution 228 containing the calcium 225
comprises about 772 kg (1700 lbs), the protein slurry 218 comprises about
113.5 kg
(about 250 lbs), and the hydrated gelatin 236 comprises about 11.4 kg (about
25
lbs). Minor ingredients, such as flavors, colors, and water can comprise up to
about
20.4 kg (about 45 lbs). The binder 238 can be kept at any suitable
temperature. In
one embodiment, the binder is transferred to a binder use kettle 241 and
stored at a
temperature of between about 49 to 60 C (about 120 to 140 F).
[00102] Additional components that can be added are shown in Fig. 2B.
Specifically, macronutrients 242 can be added at any time in the process to
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nutritionally fortify the layered cereal bars. It is known that the potency of
heat-
sensitive macronutrients, such as vitamin C and vitamin A, can degrade upon
exposure to heat for prolonged periods of time. In one embodiment, vitamin and
mineral macronutrients 242 are combined in a specific vitamin/mineral blend
and
added after all of the other components in the binder 238 have been combined.
Some vitamins may also discolor the final product, but typically such
discoloration
cannot be seen due to the colors of the other components in the cereal layers.
Other
additives include flavorings 244 and colorings 246. Flavorings and colorings
are
typically added last into the binder kettle 240 because they can also be
adversely
affected by heat. In one embodiment, the viscosity of the binder 238 is about
20,000 to 100,000 cp or higher, depending on temperature, protein content, and
so
forth. In a particular embodiment, the binder 238 has a viscosity of about
20,000
cp at about 88 C (about 190 F) and a viscosity of about 100,000 at about 54
C
(about 130 F).
[00103] The binder 238 is combined with other ingredients to make the
layered cereal bars in a layered cereal bar process 310A and 310B, such as in
the
process shown in Figs. 3A and 3B, respectively. In one embodiment, cereal 116,
rice pieces 118 and TVP 120 comprise the cereal composition 312 (which is
sometimes referred to as a cereal "base" for the layered cereal bars, as
distinguished
from the base or slurry used to produce RTE cereals), although the invention
is not
so limited. In one embodiment, the cereal 116, rice pieces 118 and TVP 120 are
combined in a ratio of about 2:1:1. Prior to being added to first and second
heated
mixers ("A" and "B") 350A and 350B, respectively, bulk amounts of each
component of the cereal composition 312 can be placed in their respective tote
dumpers 314, 316, 318. As is known in the art, a tote dumper is a hydraulic
lift that
inverts a tote of ingredients into a hopper or bin. Typically, totes are lined
cardboard boxes holding about 300 lbs of any particular ingredient. The cereal
passes through a cereal hopper 320 onto a cereal conveyor 322. In the
embodiment
shown in Fig. 3A, the cereal 116 next passes through a fines scalper (or
sifter) 324
to remove fines and small particles. Similarly, the rice 118 passes through a
rice
hopper 328 onto a rice conveyor 330. In this embodiment, a rice scalper 332 is
then
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used to remove small particles. Likewise, the TVP 120 passes through a TVP
hopper 336 onto a TVP conveyor 338. Again, in this embodiment the TVP 120 also
passes through a TVP sifter 340 to remove small particles.
[00104] Any type of conveyor known in the art can be used for the conveyors
322, 330, 338. In one embodiment a cleated inclined belt conveyor is used.
After
exiting their respective scalpers 324, 332, 340, the components fall into
individual
feeders 342, 344, 346, respectively, and then onto a common conveyor 348. Any
type of feeders known in the art can be used. In one embodiment, loss-in-
weight
feeders are used which can deliver a constant weight of ingredient per unit
time. In
a particular embodiment, a Model 300 K-Tron Feeder made by K-Tron America Co.
in Pitman, New Jersey is used. Any type of conveyor can be used as the common
conveyor 348. In one embodiment, a common dry supply conveyor is used.
[00105] The cereal composition 312 then passes through a divider 354. Any
suitable type of divider 354 that serves to divide the dry cereal composition
312 into
two fractions can be used. In one embodiment, the divider 354 is a gate that
is
flipped back and forth on a timing mechanism, which causes the dry cereal
composition 312 to fall into hoppers 347A and 347B located above each mixer
350A and 350B, respectively. Each hopper 347A and 347B further has means to
control the flow of cereal composition 312 into each mixer 350A and 350B.
[00106] In one embodiment, a constant speed screw is located in the bottom
of each hopper 347A and 347B to keep the flow constant rather than cyclical,
so as
to maintain a constant ratio between binder and dry mix. Without the timing
device
and constant speed screws, the flipping of the gate back and forth would cause
the
ratio of binder and dry material in the stream to constantly vary. In one
embodiment, conventional level sensors, located in each hopper 347A and 347B,
are
in communication with the gate or divider 354 to prevent excess cereal
composition
312 from entering the mixers 350A and 350B. Use of a divider 354 in this
manner,
i.e., prior to adding wet ingredients, is accomplished more easily and
efficiently, as
compared with the dividers described in Figs. 5A and 6A.
[00107] In one embodiment, the cereal composition 312 is first dumped onto
one or more secondary conveyors prior to entering the mixers 350A and 350B,
such
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as cleated inclined belt conveyors. If desired, raisins can be added at any
point in
the process. In one embodiment, (not shown) raisins are first passed through a
"delumper" prior to being passed through a hopper onto a feeder and then onto
the
same secondary conveyor as the cereal composition.
[00108] The binder 238 can be added in any suitable manner to the mixer
316. In the embodiment shown in Fig. 3A, the binder 238 is pumped out of the
binder use kettle 241 (shown in Fig. 2B) with first and second binder pumps,
351A
and 351B, respectively, into first and second binder application manifolds
349A and
349B, respectively. Any suitable types of pumps 351A and 351B can be used that
can maintain product viscosity and provide consistent flow, such as any type
of
positive displacement pump. In one embodiment a "Waukesha" pump is used.
Conventional flow meters (not shown) can also be used to control the flow rate
of
the binder 238 into the manifolds, i.e., "piccolo" tubes 349A and 349B. The
tubes
or manifolds 349A and 349B are stainless steel tubes that are sealed on one
end.
Such tubes are typically about 2.5 cm to 7.6 cm (about one (1) to three (3)
in) in
diameter. Any suitable number of rows of holes can be present in each tube
349A
and 349B, such as about one to three rows of holes drilled at regular
intervals along
the length of the tube. The diameter of each hole can vary from about 0.025 to
0.95
cm (about .01 to .375 in). The holes are spaced such that there are typically
about
twenty holes in a tube that is about 46 cm (about 18 in) in length, up to
about 60
holes in a tube, which is about 0.9 m (about three (3) ft) in length.
[00109] The cereal composition 312 and binder 238 are combined in each
mixer 350A and 350B for a suitable period of time. In some embodiments, other
ingredients, such as dried fruit, reground material, particulates, clusters,
and so
forth, follow the same path to the mixers 350A and 350B in the same manner
described above for the components of the cereal composition 312. Any suitable
type of mixer can be used. In one embodiment, each mixer 350A and 350B is any
type of cooker with an agitator. In another embodiment, the each mixer 350A
and
350B is an inclined helical mixer. The inclined helical mixer is a U-shaped
shell
with a shaft running parallel to its long axis. The mixing is accomplished by
the
moving shaft, which has a steel ribbon in the shape of a helix. The shell
itself is
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jacketed with water to allow temperature control in about the ten (10) to 91
C
(about 50 to 195 F) range. In one embodiment, the operating temperature of
each
mixer 350A and 350B is about 21 to 54 C (about 70 to 130 F). In another
embodiment, the operating temperature is kept at a constant temperature of
about
54 C.
[00110] The temperature of the binder 238 decreases as it flows through
each
manifold 349A and 349B. In one embodiment, the binder 238 enters each manifold
349A and 349B at a temperature of about 54 C (130 F). In one embodiment, the
binder 238 exits the manifold at a temperature of about 52 C (about 125 F).
In
another embodiment, the binder 238 has a temperature of about 49 C (about 120
F)
as it combines with the cereal composition 312. At temperatures above about 54
C
(about 130 F), the binder 238 can develop off-flavors due to protein
degradation.
[00111] The binder 238 and cereal composition 312 are combined in a ratio
of about 1:1 to produce first and second mixtures 352A and 352B, respectively,
having a temperature of about 32 to 38 C (about 90 to 100 F). As noted
above,
prior to combining, the binder 238 can have a bulk density of about one (1) cp
and
the cereal composition can have a bulk density of about 0.3 g/cc, although the
invention is not so limited. In this embodiment, the resulting mixtures 352A
and
352B each have a bulk density of about 0.27 g/cc (about 4.47 cu in). In
another
embodiment, the mixtures 352A and 352B each have a bulk density of about 0.25
g/cc to 0.35 g/cc.
[00112] In an alternative embodiment, enrobers are used instead of the
mixers
350A and 350B. In this embodiment, the cereal composition 312 is coated with
the
binder 238 in each enrober, and then processed in the same manner as discussed
below.
[00113] The first and second mixtures 352A and 352B, respectively, move
onto their respective first and second belts, 360 and 362 and into their
respective
spreaders 364 and 366 where they are essentially formed into "beds." Any
suitable
type of spreaders can be used. In one embodiment, deposition spreaders with
reciprocating rakes are used. The portions 356, 358 are spread out to any
suitable
width and depth before passing through its respective picker wheel 368, 370,
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depending on the particular application. In one embodiment, each portion 356,
358
is spread out to about 97 to 101 cm (about 38 to 40 in) in width, and to about
six (6)
to 17.8 cm (about three (3) to seven (7) in) in depth, before passing through
its
respective picker wheel 368, 370. The picker wheels 368 and 370 serve to level
the
beds, i.e., the first and second mixtures, 352A and 352B, respectively, to
produce a
first leveled bed 371 and a second leveled bed 372. Each picker wheel 368,
370,
has shafts with suitably arranged rows of tines that rotate counter to the
direction of
the flow of the first and second leveled beds 371, 372.
[00114] Each respective leveled bed, 371 and 372, then passes through a
series of compression rolls or rollers, i.e., first compression rollers 373
and second
compression rollers 374, to form a bottom layer 375 and top layer 376,
respectively.
Any suitable number of compression rollers can be used, such as one or two. In
one
embodiment, there are three to six or more compression rollers in each of the
first
and second series of compression rollers, 373 and 374.
[00115] Each leveled bed 371 and 372 can be compressed to any suitable
dimension, dependent on the desired thickness of the cereal bar for a
particular
application. In one embodiment, the resulting bottom and top layers, 375 and
377,
respectively, are compressed to about 0.64 to 1.3 cm (about 0.25 to 0.5 in).
Following compression, the density of the cereal composition 312 is increased.
In
one embodiment, the bulk density of the cereal composition 312 after
compression
is about 1.5 to two (2) times the bulk density of the cereal composition 312
before
compression. In an exemplary embodiment, the cereal composition 312 has a bulk
density of about 0.25 to 0.35 g/cc before compression and a bulk density after
compression of about 0.45 to 0.55 g/cc.
[00116] Referring now to Fig. 3B, the milk filling 114 (discussed in Fig.
2A)
is passed through a filling pump 396, which can be any suitable type of pump,
such
as a positive displacement pump. At this point, the bottom layer 375 has
cooled to a
temperature of about 21 to 32 C (about 70 to 90 F). In order for the bottom
layer
375 and layer of milk filling 114 to bond and form bonded layers 379 (and
later, for
the top layer 376 to bond adequately to the bonded layers 379), it is
important that
the temperature of the milk filling 114 be properly controlled as it is
applied to the
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bottom layer 375. This can be accomplished through use of a filling heat
exchanger
397, which can be any suitable type of heat exchanger, such as the Contherm
Swept Surface Heat Exchanger described above. In one embodiment, the filling
heat exchanger 397 cools the milk filling 114 to about 130 F or less.
[00117] Upon exiting the filling heat exchanger 397 the cooled filling is
formed into a continuous sheet or layer of filling 114 on top of the bottom
layer 375
as it flows through a filling applicator 377. In one embodiment, the filling
applicator 377 is an extrusion head or sheeting nozzle. In another embodiment,
the
pump 396 feeds the filling applicator 377 with a vacuum assist in order to
prevent
air locks or bubbles in the filling 114. In one embodiment, the filling
applicator 377
is capable of delivering the appropriate width of material, such as about 35
to 40 in,
or 20%, by weight, of the final product. In a particular embodiment, a Vemag
500
Filling Applicator, made by Robert Reiser & Co., Inc. in Canton,
Massachusetts, is
used.
[00118] The milk filling 114 is applied at a temperature of at least about
28 to
31 C (about 82 to 88 F). Below the melting point of the milk filling, which
is
about 29.4 C (85 C) in one embodiment, the viscosity of the milk filling 114
changes dramatically from about 10,000 to about 100,000 cp. Even after it
cools,
the milk filling 114 is still deformable, similar to the "soft ball" stage of
candy.
Controlling the temperature in this manner also controls the amount of
filling, i.e.,
cooler temperatures deposit thicker, yet less filling while warmer temperature
deposit a larger amount of a thinner filling. The lamination, i.e., softening,
is
observable when the appearance of the milk filling 114 changes from a matte
finish
to a glossy finish, i.e., just above the melting point or glass transition
temperature of
the fat in the filling. This change typically occurs at a temperature of about
31 to 35
C (about 88 to 95 F). Once lamination of the milk filling 114 occurs, the two
layers are adequately bonded, thus forming the bonded layers 379.
[00119] In another embodiment, the milk filling 114 is not chilled prior to
being applied to the bottom layer 375. In yet another embodiment, the
temperature
of the bottom layer 375 is adjusted higher or lower, as needed, in order to
facilitate
application of the milk filling 114. In one embodiment, a conventional chilled
roller
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(not shown) is used to apply the milk filling 114. Chilling the milk filling
114 in
this way may also aid in applying it to the bottom layer 375.
[00120] In still other embodiments, the filling layer is a low water
activity
fruit filling having a water activity value ranging from about 0.4 to 0.5,
preferably
about 0.45. In commercial operation, the fruit filling is supplied in bulk
quantities
at finish moisture content and water activity values ranging from about 0.4 to
about
0.5, preferably about 0.45 to 0.5, typically in 55 gal drums or 100 lb plastic
lined
totes or other suitable and convenient bulk packaging. The fruit filling is
preferably
aseptically processed and can be supplied and stored at ambient temperature in
view
of the low water activity and acidity levels. A drum pump can be inserted into
the
drum or other suitable pump for a tote that discharges the fruit from the drum
to the
filling supply line. A secondary or metering pump can be used to convey the
fruit
filling in the fruit supply line to an application nozzle or extrusion head
that is
configured to dispense the fruit filling as a layer or sheet to the first or
lower cereal
layer at ambient temperature.
[00121] It will be appreciated that in the preferred embodiment, little or
no
heat is applied to the fruit filling layer material whether prior to or after
forming the
filling layer whereby degradation of the fruit filling layer material is
minimized. By
selecting a thixotropic fruit filling material, the fruit filling ingredient
can be
conveyed from its supply source (such as from supply drums) conveniently by
conventional pumps without need for a heating step to make the fruit filling
material
fluid for pumping such as when a temperature setting gelling agent is
employed.
Also, in the preferred embodiment, by selecting a low water activity fruit
filling
material that can be applied at final moisture content, a post fabrication bar
baking
step can be eliminated that in the past was used to lower the moisture content
of the
fruit filling to shelf stable levels.
[00122] Moreover, once the fruit filling material is applied as a fruit
filling
layer, the thixotropic nature of the fruit filling material at rest provides
that the fruit
filling remains in place without running. Also, gel setting additives addition
and
mixing steps can be eliminated. (e.g., a calcium ion source when calcium ion
setting
gelling agents are employed). Moreover, the thixotropic nature of the fruit
filling
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conveniently allows for the fruit filling upon application to the lower cereal
layers to
reach into any voids or cavities of the irregular surface of the cereal layer
and can
function as adhesive that binds the upper and lower cereal layers together to
minimize undesirable delamination of the finished multi-layered product.
[00123] The top layer 376 is transported via a lowering conveyor 380 to the
top of the layer of milk filling 114. Due to the previous heating of the milk
filling
114, as described above, the top layer 376 can now also adequately bonded to
the
layer of milk filling 114. The resulting combined layers 381 pass through one
or
more polishing rollers 382 to form a layered stream 383, i.e., pressed layers.
The
polishing roller 382 provides relatively light compression so that the layers
bond
properly. In embodiments having a fruit filling layer, those skilled in the
art would
also consider such a layer to be bonded to the top and bottom layers at this
point,
even though the fruit filling layer was not heated and the bar has been cold
formed.
In one embodiment, about 2.3 to 4.5 kg (about five (5) to ten (10) lbs) of
pressure is
applied to the layers (i.e., the bonded layers 379 and the top layer 376),
comparable
to the pressure used with a home rolling pin. The compression causes the
layers to
compress about 0.16 cm (about 0.06 in) to about 2.2 cm (about 0.88 in) in
total
height, thus setting the final height. Essentially, the polishing roller 382
removes
most of the surface irregularities that may exist from transfer of the top
layer to the
bottom layer. The layered stream 383 can be any suitable width depending on
the
equipment being used. In one embodiment, the layered stream 383 is about 89 to
114 cm (about 35 to 45 in) wide. In a particular embodiment, the layered
stream
383 is about 99 cm (about 39 in) wide.
[00124] At this point, the layered stream 383 passes through a first cooler
or
cooling tunnel 384, which is maintained at a temperature of about 10 to 15.6
C
(about 50 to 60 F). The layered stream 383 cools from about 32 to 12.7 C
(about
90 to 55 F) in the first cooler 384. The layered stream 383 then passes
through a
slitter 385 where it is slit or cut into individual pieces to form layered
ribbons 386.
Any suitable type of slitter 385 can be used. In one embodiment, the slitter
385 is
comprised of any number of rotating blades, such as about 30 or more rotating
blades. The layered stream 383 can be cut into any suitable number of strips.
In one
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embodiment, the layered stream 383 is cut into about 30 to 40 strips that can
be any
suitable width, such as from about 1.9 to 5.7 cm (about 0.75 to two (2) in).
In a
particular embodiment, the layered stream 383 is cut into strips that are
about 3.8
cm (about 1.5 in) wide.
[00125] The trim pieces 387 produced by the slitter 385 along the outside
edges of the layered stream 383 are either used as recycled material 388 or
scrapped
as waste 389. In one embodiment, about 30 to 90% of the trim pieces 387 are
saved
as recycled material 388. The exact proportion of recycled material 388 to
waste
389 depends on how various addition rates affect the final product, as the
recycled
material 388 does contain some milk filling 114. In most cases, the recycled
material 388 is returned to one or both of the mixers ("A" and/or "B") 350A
and/or
350B where it is combined with the other ingredients. In one embodiment, the
first
and second mixtures (352A and 352B in Fig. 3A) each comprise about zero (0) to
five (5)% trim 386. In most embodiments, the recycle rate into each mixer 350A
and 350B is about the same.
[00126] The layered ribbons 386 then pass through a cutter 390 which cuts
the layered ribbons 386 into highly dense individually-sized layered cereal
bars 391
weighing about 40 to 50 g. Any suitable cutter 390 can be used. In one
embodiment a reciprocating guillotine cutter is used. The cutter 390 can
operate at
any suitable speed. In one embodiment, the cutter 390 completes about 30
cycles
per minute, i.e. makes one cut about every two (2) seconds. After being cut,
the
individual layered cereal bars 391 are separated in a separator 392. In one
embodiment, the separator is a conveyor belt that runs slightly faster than
the belt
under the cutter 390. As the cereal bars 391 make the transfer to the faster
conveyor
belt, they separate slightly along the axis of travel.
[00127] The individually sized layered cereal bars 391 pass through a
second
cooler or cooling tunnel 393 that operates at about 10 to 12.7 C (about 50 to
55 F).
The temperature of the cereal bars 391 is reduced from about 12.7 to 10 C
(about
55 to 50 F) in the second cooler 393. In the embodiment shown in Fig. 3B, the
bars
can optionally pass through a cinnamon duster 398 where a cinnamon mixture 399
is applied prior to entering a separator 392. In one embodiment, the cinnamon
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mixture 399 is comprised of a mixture of about five (5) - ten (10)% cinnamon,
90-95% sugars, and a small amount, such as about 0.025%, of flow agent as a
process aid. In one embodiment, the flow agent is silicon dioxide available
from
any commercial source, such as McCormick-Schilling Co. The sugars can be
comprised of a mixture of sugar and fructose ranging from about 50% to 50% up
to
about 80% to 20%, respectively. The cinnamon duster 398 can be any suitable
type
of flour sifter, such as a flour sifter made by Spray Dynamics, Inc.
[00128] After passing through the separator 392, the cereal bars 391 can
then
travel along a conveyor belt to a packager 394 where they are individually
wrapped.
In one embodiment, a surger or conveyor belt (not shown) is located prior to
the
packager 394 so that the cereal bars 391 can accumulate if the packager is
temporarily not operating for any reason (See, e.g., Fig. 6B). The resulting
individually wrapped layered cereal bars 395 can then be packaged in a
secondary
carton in any suitable quantity. In one embodiment, six (6) individually
wrapped
cereal bars 395 are packed in a container. The product is then distributed in
any
marmer known in the art, such as in any food service facility (e.g., grocery
store,
restaurant, movie theatre, airport, hospital, school, and further including
any
location where food is sold), vending machine, by mail order, including over
the
Internet, and so forth.
[00129] Regarding apparatus used in the cereal bar process discussed in
Figs.
3A and 3B, any conventional devices known in the art can be used. For example,
with regard to the compression rollers 373 and 374 discussed in Fig. 3A, any
known
rollers used in conventional milling processes can be used. In another
embodiment,
one or more compression rollers 373 and 374 are used to gradually compress the
first and second leveled beds, 371 and 372, rather than compressing the beds
in one
step. In this way, fewer whole cereal pieces are crushed and/or broken. In a
particular embodiment three (3) "ganged" or "grouped" compression rollers are
each
set at an incline to gradually reduce the thickness of the layer, such that
there are six
(6) compression steps.
[00130] These compression rollers 373 and 374 rotate in the same direction
as the conveyor belt below on which the first and second leveled beds, 371 and
372,
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respectively, are traveling. In some instances, this may be the same conveyor
belt
on which the product has been traveling since exiting the divider 354, or
there may
actually be a series of conveyor belts onto which the product is transferred
during
manufacturing, depending on the particular operation.
[00131] In the embodiment shown in Fig. 4, it is assumed that the first
leveled bed 371 is still on the first belt 360 (See Fig. 3A). As Fig. 4 shows,
the first
compression rollers 373 can be comprised of three rollers 373a, 373b and 373c,
although the invention is not so limited. Any suitable number of rollers, up
to about
six or more can be used in series. Although the rollers 373a, 373b and 373c
travel
in the same direction as the first belt 360, they are designed to rotate about
10 to
40% faster, up to about 80% faster than the forward speed of the first belt
360. In a
particular embodiment, the rollers 373a, 373b and 373c travel at about 1.8 to
3.7 m
(about six (6) to 12 ft/ min), but maintain a speed of at least about 0.6
m/min (about
two (2) ft/ min) faster than the first belt 360.
[00132] The rollers 373a, 373b, 373c in Fig. 4 are not wrapped in any type
of
belt, as with conventional rollers. Operating the rollers without a belt and
at a
slightly higher speed than the product below helps to keep the rollers cleaner
than
conventional compression rollers. The rollers, in essence, operate much like
the
rollers or track on a military tank, albeit, without the belts. Further, by
drawing the
product, i.e., the first leveled bed 371 through on two planes (i.e., on the
first
conveyor belt 360 below and the rollers 373a, 373b and 373c above), the
surface of
the product is more polished, and has a smoother appearance. This roller
arrangement also improves compression of the product while reducing breakage
of
individual cereal pieces. In one embodiment plastic rollers are used. In
another
embodiment, ultra high molecular weight (UHMW) polyethylene rollers are used.
The rollers can each be of any suitable dimensions, depending on the
particular
operation, and can each have varying diameters, if desired. In one embodiment,
the
rollers have a diameter of about ten (10) to 20.3 cm (about four (4) to eight
(8) in)
and are about 25 to 152 cm (about ten (1) to 60 in) in length, depending on
the
particular application. In one embodiment, any suitable height adjusting
mechanism
is connected to each of the rollers 373a, 373b and 373c, so that the height of
each
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roller can be adjusted accordingly. In this way, beds of varying heights can
be
accommodated and/or the final product can be designed to have a higher or
lower
density, as desired.
[00133] As Fig. 4 shows, each roller 373a, 373b and 373c has a central
shaft
402 that can be of any suitable dimensions. Suitable bearings 404 and mounting
plates 406 are located on the ends of each roller 373a, 373b and 373c, as is
known
in the art. All of the rollers 373a, 373b and 373c are connected to suitable
drive
mechanisms known in the art, although for simplicity, only the first roller
373a is
shown in limited detail. A conventional drive chain 408 is attached to one end
of
the central shaft 402. The drive chain is powered by a suitably sized motor
410,
such as a variable speed drive motor. The motor 410 is connected to the drive
chain
408 as shown in Fig. 4.
[00134] Figs. 5A and 5B show an alternative method for making layered
cereal bars 395. This method is similar to the method shown in Figs. 3A and 3B
in
many respects. However, in this embodiment the filling heat exchanger 397 is
replaced with a heated air source 378, such as a heat gun or air curtain. The
heated
air source 378 operates at a temperature of between about 27 to 31 C (about
80 to
85 F). Using the heated air source 378 from on top of the layer of milk
filling 114
as it passes by, causes it to become laminated or bonded with the bottom layer
375.
Depending on the travel speed of the conveyor belt on which the milk filling
114 is
located, the heated air source 378 is applied for only one (1) to three (3)
seconds or
more. The lamination, i.e., softening, is observable when the appearance of
the milk
filling 114 changes from a matte finish to a glossy finish. This change
typically
occurs at a temperature of about 31 to 35 C (about 88 to 95 F). Once
lamination
of the milk filling 114 occurs, the two layers are adequately bonded, thus
forming
the bonded layers 379, as described above.
[00135] This embodiment also differs in that there is only one heated mixer
350. The components enter the heated mixer 350 directly from the common
conveyor 348 to form a mixture 352, which is then divided with an alternate
divider
554 into first and second mixtures, 352A and 352B, respectively. Any suitable
type
of divider 554 can be used. In one embodiment, a twin helix wet stream
divider,
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which is a symmetrical hopper with two helical screws, is used. In this
embodiment, the mixture 352 floods the helixes and is divided by differential
screw
speed.
[00136] Additionally, since there is only one mixer 350, there is need for
only
one pump 351 and one binder application manifold 349 to supply binder 238 to
the
mixer 350. In this embodiment, no cinnamon mixture 399 is being added,
although
the invention is not so limited.
[00137] Figs. 6A and 6B show another alternate method for making layered
cereal bars 395. Fruit 602, such as dried fruit, which is also shown as a
component
in the cereal composition 312, can also be used in any of the aforementioned
embodiments, together with any other suitable additives and/or particulates,
clusters,
and so forth. As shown in Fig. 6A, the fruit 602 passes through a fruit tote
dump
604, fruit hopper 606, fruit conveyor 608, fruit scalper 610 and fruit feeder
612 prior
to entering the common conveyor 348, in the same manner as the other
components,
i.e., cereal 116, rice pieces 118 and TVP 120.
[00138] In this embodiment, an alternate divider 654 is used to divide the
mixture 352 into two portions, namely 352A and 352B. The alternate divider 654
is
comprised of a suitably-sized inverted stationery sheet metal piece placed
approximately in the center of the discharge stream of the mixer 350, i.e.,
the
mixture 352, as it is traveling along a suitable conveyor belt. Essentially,
the
alternate divider 654 relies on the stable discharge flow from the mixer 350
to
divide the stream. The alternate divider 654 can be adjusted as to location at
any
suitable time. In one embodiment, the alternate divider 654 is adjusted at
start-up to
be in the geometric center of the flow, thereby dividing the stream, i.e.,
mixture 352,
into approximately two equal parts. In one embodiment, the alternate divider
654 is
u-shaped.
[00139] The resulting first and second portions or mixtures, 352A and 352B,
respectively, travel along their respective conveyors or belts to first and
second
smooth rollers, 673 and 674, respectively. In one embodiment, each smooth
roller
is comparable to the rollers used in an old-fashioned ringer-type washing
machine.
The smooth rollers, 673 and 674, serve to compress and form each portion into
a
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= relatively uniform sheet or layer, i.e., the bottom layer 375 and top
layer 376,
respectively. The smooth rollers, 673 and 674, essentially take the place of
the
spreaders, picker wheels and compression wheels used in the previous
embodiments. Using additional rolls (or formers) in each smooth roller
provides
added control in compressing and forming the mixture 352. In one embodiment,
each smooth roller is a three-roll smooth roll extruder. In another
embodiment, the
smooth rollers, 673 and 674, have four to six or more rollers. The bottom and
top
layers, 375 and 376, can also be characterized as "endless-mass" slabs having
essentially infinitely variable thicknesses.
[00140] In one embodiment, there are temperature controls on the
smooth
rollers 673 and 674. In another embodiment, there are also temperature
controls on
the actual surface, such as a plate or shoot, on which the resulting bottom
and top
layers 375 and 376 emerge. In one embodiment, a jacketed hopper of an
appropriate width is used to cool the resulting layers. In a particular
embodiment,
Bepex Smooth Roller Formers (Type GP) made by Hosokawa Bepex GmbH in
Leingarten, Germany are used. The layers 375 and 376 may have improved product
identity over previously described methods, such that there are an increased
number
of whole cereal pieces 116. In one embodiment, there are about one (1) to ten
(10)% or more whole cereal pieces 116. In another embodiment, there are over
ten
(10)%, up to about 25% or more whole cereal pieces 116 as compared with the
previously described methods that uses compression rollers, 373 and 374, in
combination with the spreaders and picker wheels. However, this process
appears
to have higher operating costs, at least initially.
[00141] In another embodiment, a height adjuster is also used or
is already a
part of the unit itself, such as with the Bepex model described above. The
rollers are
also able to make a fairly "defined" edge, which reduces the amount of trim
387
(shown in Fig. 6B), thus reducing waste and saving on manufacturing costs. The
resulting top and bottom layers 375 and 376 further have a more consistent
appearance and use of the rollers 673 and 674 further provide for improved
weight
control of the final product, i.e., the individually wrapped layered cereal
bars 395.
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[00142] The resulting bonded layers 379 are then fed through the second
smooth roller 674, together with the top layer 376, as described above, to
form
combined layers 381. The remaining steps in the process are similar to those
described in Fig. 3B. Essentially, the combined layers 381 are passed under a
polishing roller 382, first cooling tunnel 384, slitter 385, cutter 390 and
separator
392, prior to entering a second cooling tunnel 393 and packager 394. In
another
embodiment, the layered cereal bars 391 travel through the second cooler 393
prior
to entering the separator 392. As show in Fig. 6B, there can also be a surger
620 to
collect accumulating cereal bars, should the packaging unit 394 stop for any
reason.
The width and thickness of the layers 375 and 376, as well as the bonded
layers 379,
combined layers 381, and individually layered cereal bars 391 are the same as
what
was described in reference to Figs 3A and 3B above.
[00143] Any of the aforementioned commercial devices can include a system
controller. The system controller can be coupled to various sensing devices to
monitor certain variables or physical phenomena, process the variables, and
output
control signals to control devices to take necessary actions when the variable
levels
exceed or drop below selected or predetermined values. Such amounts are
dependent on other variables, and may be varied as desired by using the input
device of the controller. The non volatile memory may comprise a disk drive or
read
only memory device which stores a program to implement the above control and
store appropriate values for comparison with the process variables as is well
known
in the art. Such sensing devices may include, but are not limited to, devices
for
sensing temperatures, pressures and fluid flow rates, and transducing the same
into
proportional electrical signals for transmission to readout or control devices
may be
provided for in all of the principal fluid flow lines. Furthermore, means for
sensing
temperature, pressure and fluid flow rates in all of the fluid flow lines may
also be
accomplished by suitable manual means.
[00144] It will be understood by those skilled in the art that the
apparatus for
manufacturing the layered cereal bars includes all known apparatus for moving
components into, through and out of a food processing system. This includes,
but is
not limited to, various types of pumps, filters, strainers (such as magnetic
strainers,
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decline dual strainers, etc.), flow meters, heat exchangers (such as plate
type swept
surface heat exchangers), drains, level indicators, grate magnets, and so
forth. (A
grate magnet is essentially a series of parallel magnetic bars placed in an
ingredient
or product stream to remove magnetic metal particles from the stream as a
consumer
protection measure). Further, although in many instances only the term
"kettle" has
been used herein, it is to be understood that in some embodiments there are
separate
kettles for mixing versus holding, i.e., using.
[00145] It will further be understood by those skilled in the art that all
of the
lines in the system are made from materials that can be either flexible or
rigid,
depending on their location and use. Furthermore, all lines are of a suitable
diameter for their intended purpose, but are preferably between about 1.3 cm
(0.5
in) and about ten (10) cm (four (4) in). in diameter. It will also be
appreciated by
those skilled in the art that flexible lines can include hoses made from
rubber,
plastic or other suitable material, and rigid lines can be made from
galvanized metal,
stainless steel, copper, PVC or other suitable material.
Conclusion
1001461 The skilled artisan will appreciate that in the preferred
embodiment,
the present method does not comprise a baking or other heat or cooking step
that
drives moisture from the filling into the cereal layers. Rather, both the
cereal layers
are formed and the filling layer is applied at substantially their finish
moisture
content and water activity values. Of course, some moisture equilibration will
occur
over extended storage but the consumer eating quality remains a desirable of a
crunchy cereal texture. When the filling layer is a fruit based filling, the
crunchy
texture of the cereal layers is desirably combined with a chewy quality
provided by
the soft filling. Unlike conventional bars containing fruit, such a cereal bar
does not
have a "cooked" flavor, has an excellent shelf life and maintains a crisp
product
texture over time.
[001471 The layered cereal bar described herein essentially provides, in
one
embodiment, the nutrition of a bowl of cereal and milk in portable form. Each
bar is
conveniently sized and individually packaged. Further, the layered cereal bar
is
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larger than conventional food bars. As a result the consumer can now enjoy the
nutritional and organoleptic benefits of cereal and milk essentially anywhere,
at any
time. Unlike some conventional cereal bars, the layered cereal bars of the
present
invention are not baked, but are non-cooked cereal bars formed from pieces of
identifiable cereal pressed together with other components. As such, the
cereal bars
of the present invention do not contain leavening. The cereal bars are
crunchy, yet
chewy, producing few crumbs without being excessively sticky. It has the
further
advantage of having a unique and appealing appearance. Specifically, the RTE
cereal is clearly identifiable and in one embodiment, there is a clearly
defined
creamy milk layer.
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