Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
53L~5 f
13AC~(;]~C)~Jii- ART
Production of food products by reconstitution of
eorruninuted materials by shaping the coJruninuted materials
with the aid of gurns and gel-forming materials, by
mechanical methods such as extruding and molding, as ~lell as
by thermal treatment such as heating or cooling, are cornrnon
practices in the food industry. Various processes are kno~n
for the production of such shaped food products. Many of
these processes are based on the use of a gel forming system
comprising an alginate an~ a bivalent cation such as the
ealcium ion.
One type of process employing these materials pro-
duces a shaped product encased in a skin, such as a sausage.
For example, U.S. Patent NCJS. 3,650,765 and 3,650,766 dis-
close food products which are l"anufactured in any shape orsize by a process including the steps of forming an extrudable
slurry of a food material, extruding the slurry and forrning
a gel-like skin around the extruded proauct. The skin is
formed by subjecting gelable materials such as alginates to
the action of gelation agents such as al~aline earth ions,
at the surface of the extrusion product. U.S. Paten-t
Nos. 3,891,776; 3,922,360; 4,117,172 and 3,676,158 also
disclose similar processes whereby a shaped food product en-
cased in a s~in is formed. Some- of these processes produce
a peelable, self-supporting skin When the s~in is peeled
off and the resulting produet is again su~jected to a bivalent
cation solution, a s~in is again formed.
Other processes basea ~n the use of alginates and
calciurn ions prodl~ce a stabilized food product ~here the
alginate contained in the slurry used for proc3uction is
con~erted throughout into a c~mplete ad~ranced gel. For
e~aJnple, ~.S. Patcnt Mo. ~,791,50B discloscs a ~roccss Ior
producing reconstituted food prGducts coln~rising initially
fonrling a thi,:otropic scJnl-c3e~ e SU]JSt~n~~r~ di_~erSinCJ .
comminuted, powdered, c3ranulated or shredded foodstuff in a
water solution of an edible hydrophilic colioid in ~hich
- the dispersed foodstuff is present as discree-t particles
more or less completely enclosed in a matrix of the
colloid gel. ~lginates are disclosed as useful hydrophilic
colloids. In addition, a gelation agent such as calcium
carbonate must be added to the dispersed foodstuff and
hydrophilic colloid to institute gelation. The time at
which the gelation agent is added to the dispersion of
foodstuff and hydrophilic colloid is critical since ~7hen
the gelation agent is added, it liberates calcium ions
hich rapidly react with the colloid thereby forming a gel.
Since this gelation occurs rapidly, it is necessary to
quic~ly transfer -the substahee to an extruding feed pipe
wherein the final advanced gel s-tructure is formed. The
feed pipe must be of such a lenyth that the ensuing mixture
becomes an advance gel substantially simultaneous ~Jith its
exit. This is a major disadvantage since if the gelation
agent is added too soon, the mixture will become an advanced
gel before it exits the extruder thereby creating a blockage
in the extruder mechanism. If, on the other hand, the
gelation agent is added too late, the mixture will not be-
come an advanced gel when it eY.its the extruder, thereby
preventing the formation of ~ shaped food product.
Thus, the above prior art processes may result in
both production and product difficulties, such as undesired
skin formation, undesired finished produc-t texture, and
difficulties duriny extrusion.
Accordingl~, it is ~nonc3 the objects of the
present invention to provide an improved process ~or prr-
ducing shaped Iood products ,7hich ~.~ill insure bot}l a smooth
produc-tion run and a cor!trol Gf the dcsired characceristics
of the finished product.
DISCLOSURE OF THF. INVENTION
It has been found in accordance with the present
invention that prepa.red fcod products having any desired
size or shape may be formed from a slurry of comminuted
food particles and additives including a binder and a
time reaction system comprising a gelling agent such as
an alginate and a bivalent ion releasing material. The
slurry employed in the process accordlng to the inven~ion
has the required rheological properties for shaping and
shape retention making possible a continuous production
process based on either extrusion, molding or the like.
The consistency of tne slurry is such that the shaped
product is easily rele~sed Erom the shaping or forming
device.
Thus, the invention provides a process for
the production of shaped food products from comminuted 9
granulated or chopped foodstuffs comprising (13 prepar-
ing a slurry of one or more foodstuffs with a binder,
a gelling agent and a bivalent ion releasing material,
the amounts of binder, gelling agent and bivalent ion
releasing material being sufficient to permit a degree of
interaction between the gelling agent and the bivalent ion
releasing material after a predetermined period of time
after the slurry is prepared; (2~ preparing a shaped food
product by shaping the slurry by means of a shaping and
forming device; and (3) processing the shaped food product
into a final product~
The method of the present invention may be
applied to a wide variety of foodstuffs including vege-
tables, fruits, proteinaceous substances such as meats
and fish products, shrirnp products and the li~r;e and is
.~,~&
5~5
not dependent ~pon the acidity oE the ~oods or upon
temperature. The slurry may be formed from one or more
of the comminul~:ed foodstuffs referred to above, a binder
comprising, for example, a cellulose ether alone or
together with a gum such as guar gum~ an alginate, a
bivalent ion releasing material such as calcium carbonate,
which reacts wi~h the alginate to form a gel, an extender
such as flour and/or starch, and optionally a pH control
agent such as citric acid or any other weak physiologi-
cally acceptable acid, a suitable sequestring agent,
such as a metaphosphate, and other additives, such as
salt, sweeteners and colorants.
~ - 4a -
s~s
The ~inder used in the slurry main-tains a
certain degree of rigidity and shape oE the product,
and the gradual gelling of the alginate results in
a certain setting of the product.
The pH control agent in combination with
tne sequestring agent results in a predetermined rate
of release of the calcium ions, which results in the
controlled gelling of the alginate. In certain cases
the pH of the comminuted food product is such that
either the acid or the acid and se~uestring agent need
not be added. For example, in the case of comminuted
food products which release acid such as onions the
pH control agent and sequestring agent need not be
added to the slurry.
In each case the slurry must be adjusted
in such a manner that the gelling takes place at a
predetermined time interval. In general, the slurry
is left standing for a predetermined period of time
of from about 5 to about 30 minutes before the actual
shaping and further processing is commenced. This
allows sufficient time for the gelling to take place.
The ratio of, and quantity of the various ingredients
in the slurry determines the consistency and characteristics
of the final product.
The actual shaping is carried out with an
extruder, cutter or molding device. As mentioned above,
the easy and fast release of the shaped food product
from the ex'cruder, cutter or molding device is important
for an efficient continuous production prGccss. Such
\
rele3se may be facili~atca by a continuous rinsing
of the extrusion head, cu-tter or mold wit~l a liquid
sud, water or with an aqueous solution of bivalent
ions such as calcium ions which prevents the shaped
product from sticking to the shaping device. i~hen
a solution such as calcium chloride solu-tion is used
~or the rinsing, there results a smooth slippery surface
which has a very low friction coefficient and which will
be easily released from the shaping device. This rinsing
solution is used in a small quantity and concentration,
and is intended only to facilitate the easy release of the
product, and does not result in the formation of a
shape-retaining or self-supporting film or skin.
The shaped product may be further processed
by contacting i~ with either a floury material or a normal
batter and breading. If added adhesion of the ba-tter
coating to the product is desired, a small quantity of
gelling agent can be added to the batter which will in-
teract with alginate in the upper layer of the product.
The shaped food products may also be coated,
ZO cooked, fried, ~rozen and packed. When such frozen products
are heated, they retain their shape, te~ture, eating
qualities.
The components used for the process of the
instant invention are reasonable in price, and thus
the product can be produced on an economical basis.
,..~,..
S~:~5
DETAILED DESCRIPTION O~ THE INVENTION
. . . _,
As indicated hereinabove, the shaped foods of
this invention are produced by first forming a slurry of
a comminuted food product and other additives, thereafter
shaping the slurry by means of extrusion, molding or the
like, followed by final processing which may include
batter application, breading, cooking, such as frying,
freezing and packaging. According to the present in-
vention, the slurry contains one or more comminuted
food products, a ~inder, a gelling agent, a compound
releasing bivalent ions for reacting with the gelling
agent, extenders, and optionally a pH control agent, a
sequestring agent and additives such as salt, spices,
sweetening agents, and coloring materials.
Suitable binders for use in the present invention
include edible cellulose ethers which are non-toxic and
water soluble. Examples of suitable cellulose ethers are
alkyl, hydroxyalkyl and carboxyalkyl ethers, wherein the
alkyl group contains lw3 car~on atoms. Specific examples
oL the cellulose ethers are sodium carboxymethyl cellulose
methyl cellulose, ethyl cellulose, hydroxy me-thyl cellu-
lose, hydroxy ethyl cellulose 9 hydroxypropyl cellulose,
hydroxypropyl methyl cellulose and combinations thereof.
These cellulose ethers may be employed in combination
with gums such as a guar gum, gum tragacanth, gum karaya,
xanthan gum, carageenan gum, furcellaran gum, locust
bean gum, gum arabic or combinations thereof. ~hile any
suitable binder may be employed, it is presently preferred
to employ hydroxypropyl methyl cellulose together ~ith guar
gwn as ~he binder. A particularly preferred hydroxymethyl
propyl cellulose is 100,000 CPS viscosity grade hydroxy-
propyl Methocel ~ K100M manufactured by Do,J Chemical.
'9
In general, the binder is employed in an amount
of from about 0.10% to about 6.0~ by weight based on the
weight of the comminuted food product. When the binder is
composed of both a cellulose ether and a gum, the cellulose
ether is present, for example, in an amount of from about
20~ to about 30% by weight of the binder, and the gum is
present, for example, in an amount of from about 70% to
about 80% by weight of the binder.
While any suitable gelling agent may be employed,
it is presently preferred to employ an alginate such as
sodium alginate or potassium alginate. A particularly
preferred alginate is a sodium alginate having the trade
name Protanal ~ SF~120 distributed by Multi-Kem Corp.
and produced by Protan and Fagertun of Norway. The
alginate is generally present in the slurry in an amount
of from about 0.1% to about 1.0% by weight based on the
weight of the comminuted food product.
Compounds which release bivalent ions for reacting
with the alginate to produce a gel include calcium carbon-
ate, calcium phosphate and the like. Calcium carbonate
is, however, presently preferred. The calcium ion releas-
ing compounds react with the alginate tG produce a calcium
alginate gel. The ion releasing compound is generally
present in an amount of from about 0.001% to about 0.Q04% by
weight based on the weight of the comminuted food product.
Suitable pH control agents include weak organic
acids such as citric acid, maleic acid and tartaric acidO
The pH con~rol agent may be omitted from the slurry when
the comminuted food product that is being used releases a
weak acid. Onions are an example of such a food product.
When the pH control agent is employed, it is generally
present in an amount of from about 0.001% to about 0.05% by
~ ~5~L~5
weigh-t based on -the weight oI comminuted ~ood product.
While any suitable se~uestering agent may
be employed together with the p~l control agent, according
to the present invention it is presently preferred to use
a metaphosphate such as sodium hexametaphosphate. The
sequestering agent is usually employed only when a p~l
control agent is employed. In general, when the sequester-
ing agent is employed, it is present in an amount of from
about 0.001% to about 0.05% by weight based on the weigh-t
of the comminuted food product.
Suitable extenders which may be employed in the
slurry according to the present invention include starch
and flour which are usually used together. In general,
the starch is presènt in an amount of from about 3% to about
12% by weight based on the weight of the comminuted food
product. It is, however, presently preferred to use
starch in an amount of from about 5.5% to about 6.5% by
weight. The flour is generally present in an amount of
from about 3% to about 12% by weight based on the weight
of comminuted food product. A preferred amount is of
from about 7.5 to about ~.5 by weight.
The slurry may also contain one or more optional
additives such as salt, spices, sweetening agents, and
coloring materials. In general, when such materials are
present in the slurry they are present in an amount of
from about 0.01~ to about 1.0~ by weight based on the
weight of the comminuted food par-ticles~
As stated above, the food products which
are suitable for use in -the present invention include
vegetables, fruits, proteinaGeous substances, such as
meat and fish products, shrimp product and the li~e.
The process according to the present invention is parti-
~i~S~
cularly suitable for use with comminuted or shredded ~oodproducts such as fresh onions, rehydrated onions, cauli-
flower, mushrooms, peppers, apples, poulkry meats, meat,
fish, shrimps and calamari. A preferred product is onion
rings, which require a very well defined consistency in
order to an acceptable and saleable product. The food
products are shredded, diced or comminuted by con~entional
means known in the art.
The slurry is prepared by mixing together all
of the materials which make up the slurry excepting the
comminuted or shredded food product. When the dry blend
of these materials is mixed together, they are then added
and mixed with the comminuted or shredded food product for
2 to 5 minutes at room temperature so as to ~orm a slurry.
The resultant slurry which has a very high viscosity is
allowed to stand for a period of from about 5 to about 30
minutes so as to allow the release of ions such as calcium
ions from calcium carbonate which forms a calcium alginate
gel. The slurry is then fed into a shaping apparatus such
as an extruder or molding deviceO While any such suitable
device may be employed, it is presently preferred to pump
the slurry through an extruder with cutting heads. When
making onion rings, one can employ an Autoprod ~ /Food
extruder manufactured by Autoprod, Inc. ~,lith cutting heads
which generate a ring-shaped product of approximately 10
to 12 grams. The same extruder can be used with different
cutting heads to extrude other snapes such as balls,
crescent, rods, etc.
Desirably a bivalent ion containing rinse solution
is used to wash the extruder cutters or molding plate
to facilitate the easy release oE the shaped product
- -- 10 --
,~.
5~5
~rom the cutters or molding plate. It is presently preferred
to employ an aqueous calcium chloride solution (0.2% to 5.0%).
The ext uder shaped products then fall individually
on a mesh conveyor belt that carries the products to a batter
unit wherein batter is applied. If more adhesion of the batter
to the product is desired, a small quantity of a suitable
alginate, e.g., sodium alginate, can be added to the batter
which will then interact with the calcium ions on the surface
of the product. This process step is normally followed by a
breading unit wherein the products are breaded. The breaded
product is then usually cooked, and in the case of onion rings,
deep fried for a short period of time for example about 30
seconds at 400F, and then indiYidually quick frozen and
packaged.
The final shaped product before batter and breading
is applied according to the present invention comprises, for
example, a cellulose ether in an amount or from about 0.10% to
about 2.5% by weight, a gum in an amount of from about 0% to
about 2.5% by weight, alginate salt in an amount of from about
O.OS to about 0.80% by weight, an extender in an amount of from
about 6.0% to a~out 15.0% by weight and a foodstuff in an
amount of from about 80% to about 90% by weightO A preferred
example is 0.2% cellulose ether, 0.9% guar gum, 0.36% alginate
salt, 12.0% extender, and 86.0% foodstuff (onion).
As stated above, ingredients in the dry blend prior
to the addition of the comminuted or shredded food product
comprise the following materials, the weight percent (based on
the weight of materials in the slurry before the addition oE
the foodstuff) indicated for each material representing the
broad range which could be used and preferred amounts.
/, -- 11 --
,, ,, -
Materials Preferred Range
Corn Starch 37% 30-60
Wheat Flour 49 30-60
Hydroxypropyl methyl sellulose 1.5 1-15
Guar Gum 6.0 0-15
Sodium Alginate 2.5 0.5-5
Calciurn Carbonate .012 .006-. 02
Sugar (optional) 4.4 0.-10
Salt (optional) 0.9 0-5
10 Citric Acid (as required) 0 0-.02
Sodium Hexametaphosphate
(as required) 0 0-.02
The ratio of the diced fresh and/or rehydrated onion
to the dry blend mix system is preferably 6.0 to 1, but can
range from about 5:1 to about 10:1.
Specific examples of some preferred formulations are
illustrated in the following examples. These examples are by
way of illustration only and are not to be construed in a
non-limitative manner.
EXAMPLE 1: Production of Onion Rings
A dry blend of the following was prepared (parts by weight):
16 parts corn starch
25 parts wheat flour
0.8 parts sodium alginate (KELTONE, Kelco Co.)
0.003 parts calcium carbonate
3.2 parts hydroxypropyl methyl cellulose, 100,000 CPS
viscosity grade (hydroxypropyl methocel R-1000.t~l, Dow Chem-
ical)~
This mix was added to 250 parts of 1/4"-diced, resn onions in
a ribbon mixer and rnixed for three minutes at room ternperature
so as to form a slurry.
12 -
5~5
The resultant slurry had a ~ery high paste-like
~iscosity. The mixture was allowed to stand for 5-15 minutes
so as to allow the release of calcium ions from the calcium
carbonate due to the acid pH created by the onion exudate and
for the consequent reaction of the calcium ions with the algin
molecules to form a calcium alginate gel.
The slurxy was then pumped by a creamery pump through
an ~utoprod Food type extruder with cutting heads generating a
ring-shaped product of approximately 10-12 grams. The cutters
were washed with an aqueous solution of calcium chloride of
five parts to one hundred parts of water by weight. This wash
solution facilitated the release of the formed ring-shaped
product from the cutters.
The extruded onion rings fell individually on a mesh
conveyor belt that carriers the product to a batter unit which
is followed by a breading unit. The breaded product was deep
fried at 400F for 30 seconds, and then individually quick
frozen and packaged~
The finished product, when heat reconstituted for
serving, had the desired juiciness an-~ mouth feel.
EXAMPLE 2: Production of Onion-Rings
Extruded onion rings were prepared according to
Example 1, with the substitution of water-rehvdrated dried
onion pieces which, when reconstituted with water, were approx-
imately 1/4" in size.
The interior texture of the finished cooked product
resembled that of Example 1.
EXAMPLE 3: Production of Onion Rin~s
Dry blend of the following was prepared (parts by
weight):
15.2 parts corn starch
20.~ parts wheat flour
1.0 ~ar~s ~odiu~ alginate
~5
0.004 parts calcium carbonate
0.6 parts hydroxypropyl methyl cellulose
2.5 parts guar gum
0.4 parts salt
1.8 parts sugar
This mix was added to 250 parts of 1/4" diced fresh onions.
The procedure for preparing ~he onion rings was as set forth in
Example 1.
EXAMPLE 4: Production of Apple Rings
Dry blend of the following is prepared (parts by
weight):
parts corn starch
16 parts white flour
0.6 parts sodium alginate
0.003 paxts calcium carbonate
2.3 parts of hydroxypropyl methyl cell~lose
1.1 parts of guar gum
parts of sugar
1 part of salt
This mix is added to 250 parts of 1/4" diced fresh apples. The
remainder of the process is as in Example 1.
Having thus discussed the present invention, what is
desired to be secured by Letters Patent and hereby claimed is:
- 14 -
