Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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W O 97/1)2760 PCT~EP96/03060
Forrnulated Fm~ ion Product ~nd Process
This invention relates to a process for the production of a formulated
emulsion product which has a meat-like appearance. The invention also relates to5 products s~ produced. The formulated emulsion products are particularly suitable
for use as p,et foods.
Coagulated meat emulsions, in the form of loaf-like products, are
commonly used as pet foods because they are easily manufactured, readily
digested by the ~nim~I~, very palatable to the animals, and are readily formulated
10 to contain necessary nutrients and trace elements. A disadvantage is that these
coagulated emulsions do not have a striated and chunky meat-like appearance.
~owever, for pet foods, a meat-like appearance can greatly enhance consumer
acceptability.
A formulated meat emulsion which has a meat-like appearance is
described in US patent 4,781,939. This formulated meat emulsion is produced by
fLrst forming a meat emulsion from a meat source. Dry ingredients such as dry
proteinaceous materials (for example wheat gluten, soy flour), vit;~min~, minerals
and the like are then mixed into the meat emulsion to provide a viscous emulsion.
The viscous emulsion is then run through a high-speed emulsion mill in which
the emulsion is rapidly heated to a temperature in the range of 1 02~C to l l 8~C.
The emulsion leaving the emulsion mill is fed to a holding tube where the protein
in the emulsion coagulates to form a solid emulsion product. This solid emulsionproduct is tl1en formed into chunks. The chunks are highly striated and resembleniatural meat chunks in appearance and te~ture.
The lproduct produced by the process has been successfully used in pet
foods for many years. However in recent times, mainly to reduce costs, there hasbeen a move to increase the moisture content of the meat emulsions. Ho-vever, ifthe amount of moisture becomes too high, the emulsion is not viscous enough to
form acceptable chunks. Consequently proteinaceous materials must be added to
the emulsion prior to forming into chunks
A s;milar process is disclosed in US patent 5,132,137. However, in this
process the viscous emulsion is heated to a temperature of 40 to 70~C in the
emulsion mill; which is much lower than that in the process disclosed in US
patent 4,781,939. The heated emulsion takes longer to coagulate and is thereforeheld in a holding tube for a longer time. The emulsion is then formed into skands
and baked in an oven at a core temperature of 70 to 95~C. The patent is deficient
CONFIRMATION COPY
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in specific teaching of the contents of the emulsion but it is very likely that
proteînaceous components such as gluten would be needed and that the moisture
content would need to be low. This is particularly so since only partial
coagulation occurs in the emulsion mill.
Therefore there is a need for a process of producing a formulated emulsion
product which has a meat-like appearance and texture and yet which may have a
higher moisture content.
In one aspect, this invention provides a process for the production of a
forrnulated emulsion product which has a meat-like appearance, the process
comprising:
emulsifying a protein source for providing an emulsion;
adding alkaline to the emulsion to raise the pH to above about 8;
rapidly heating and comminuting the emulsion using mechanical energy
~or causing protein in the heated emulsion to at least partially coagulate;
allowing the heated emulsion to coagulate and form striations; and
forming the coagulated emulsion into chunks for providing a formulated
eI:nulsion product.
Surprisingly, it is found that the addition of the alkaline greatly increases
the viscosity of the emulsion and permits the production of a form~ ted
ennulsion product of higher moisture content. Also, if desired, components such
as gluten may be reduced in amount or omitted entirely. Further, the emulsion
need not be produced from a traditional meat source; instead an animal protein
source such as plasma, blood proteins, whey, or casein may be used.
Consequently, a formulated emulsion product with a meat-like appearance may
be produced at lower cost.
Further, it is also surprisingly found that the formulated emulsion product
has much thinner and more pronounced layers giving it a highly striated and moremeat-like appearance. Also the product has an improved, chewy texture.
The protein source may be of animal or vegetable origin, or a mixture of
both. Conveniently the protein source may comprise at least about 80% by weight
of animal protein; the remaining protein being of vegetable origin. For example,the protein in the emulsion may comprise about 95% to 100% by weight of
protein of animal origin. Alternatively, the protein in the emulsion may comprise
about 95% to 100% by weight of protein of vegetable origin.
The alkaline which is added to the emulsion may be any suitable alkaline
which is acceptable in food. For example, the alkaline may be NaOH, KOH or
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Ca(OH)2, or mixtures thereof. Preferably, however, the alkaline is NaOH.
Preferably sufficient alkaline is added to raise the pH of the emulsion to a range
of about 9 to about 12; for example about 9 to about 11. This amount preferably
results in thle formulated emulsion product containing less than about 5% by
5 ~eight alkaline; more preferably less than about 2% by weight.
The formulated ernulsion product preferably has a moisture content of
about 45% to about 85% by weight; more preferably about 55 to about 65% by
weight. If necessary water may be added up to an amount of about 60% by
~eight to obtain this level of moisture. However, if the protein source contains10 sufficient moisture, the addition of further moisture is not necessary. Additional
ingredients such as fats, sugars, salts, spices, seasonings, flavorants, minerals, and
the like may also be added to the emulsion. The amount of additional ingredientsused is preferably such that they make up about 1% to about 35% by weight of
the formulated emulsion product.
The protein source may include whey. This embodiment has the
advantage that sugars in the whey may react with amino acids in the emulsion.
The Maillard reaction products which result provide the chunks with "meaty"
flavor notes which may increase palatability.
The alkaline may be added to the emulsion during emulsification of the
protein source, or may be added to the emulsion immediately prior to the heatingand commi~ ting of the emulsion, or may be added to the emulsion during the
heating and comminuting of the emulsion. Preferably, the emulsion is deaerated
after emulsification.
Preferably the emulsion is rapidly heated and comminuted by forcing the
emulsion between a pair of spaced-apart plates; at least one of which is rotating at
high speed. If necessary, the emulsion may be further heated by injecting
superheated steam into it. Preferably the emulsion is heated to a temperature
above about 1 00~C, for example within the range of about 1 02~C to about 120~C.~.lternatively, the emulsion may be rapidly heated to a lower temperature
providing ~lat the temperature is sufficient to cause at least partial coagulation of
the protein; for example at least to about 45~C.
The ]heated emulsion is preferably allowed to coagulate and form striations
for a time in the range of about 30 seconds to about 10 minlltes; more preferably
albout 1 minute to about 6 minlltes.
The invention alsc provides a formulated emulsion product produced by
the process defined above.
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In another aspect, this invention provides a formulated, striated emulsion
product having a meat-like appearance, the product comprising protein, fats and
about 45% to 85% by weight moisture and having a pH of above about 8.
Preferably the formulated emulsion product comprises about 55% to about
5 6~% moisture. Also, the formulated emulsion product preferably has a pH in the range of about 9 to about 12.
The protein content of the formulated emulsion product is preferably about
10 to about 25 % by weight; for example about 12 to about 22 % by weight. The
protein may include whey.
The formulated emulsion product preferably comprises about 5% to about
25% by weight of fat.
Preferably at least about 50% of the striations of the formulated emulsion
product have a thickness less than about 50~1m. Further, the formulated emulsionproduct preferably has an elasticity recovery of greater than about 40%; more
preferably greater than about 50%. For example, the formulated emulsion
product may have an elasticity recovery of about 55% to about 65%. This
provides the product with an excellent chewy texture.
The invention also provides a pet food comprising chunks of a form~ ted
ernulsion product as defined above, in combination with an acidic carrier to
neutralize the basicity of the chunks. The carrier may be an acidic sauce or
gravy, or may be a coagulated meat emulsion.
Embodiments of the invention are now described, by way of example
only, with reference to the drawing which illustrates schematically the process of
producing the formulated emulsion product.
Referring to the drawing, a protein source 2, water 4 and an additive
mixture 6 are mixed together in a mixer 8 to provide a primary emulsion 10.
The protein source 2 which is fed to the mixer 8 may be any suitable meat or
vegetable protein source, or both.
A suitable meat protein source is a meat emulsion obtained by grinding
and then emulsifying blocks of a meat material, such as meat or meat by
products. The meat material may be any suitable source of anirnal protein; for
example the muscular or skeletal meat of m~mm~l~, poultry, and fish or meat by-
products such as hearts, liver, kidneys, tongue and the like. The exact
composition may be selected according to cost and the desired flavor. The meat
material conveniently may be in frozen form prior to grinding. Suitable
procedures for processing frozen blocks of meat material into a meat emulsion
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rnixture are described in US patent 4,781,939, the disclosure of which is
incorporatc d by reference. Alternatively or in addition, the animal protein source
rnay be in the form of meat meals such as poultry meal, fish meal, and red meat
rneal; blood proteins; egg solids; casein; plasma; whey and mixtures thereof.
5 ~gain the exact composition may be selected according to cost and the desired
flavor. Mixtures of any of the above may also be used.
Any suitable vegetable protein source may be used; for example grain
flours and legume flours, vegetable protein isolates and concentrates, and
~ egetable proteins. Suitable examples are wheat flours, cottonseed meal, gluten,
10 soy meal, soy protein concentrates and isolates, and mixtures thereof. Preferably
however the vegetable protein source contains reduced amounts of starch; for
example, less than about 20% by weight of starch. Cottonseed meal, gluten, soy
nneal, soy p~rotein concentrates and isolates are therefore particularly preferred.
It is particularly preferred to use a protein source which is a mi~ture of
15 animal and vegetable origin; for example a mixture of meat material, soy protein
isolates or concentrates, and gluten. The total amount of protein in the primaryemulsion must be such that the protein is able to coagulate to provide a firm
emulsion product in a relatively short time; for example in less than 10 minutes.
For example, the primary emulsion 10 may contain from 10 to 22 % by weight of
20 protein.
If desired, whey may be included in the protein source 2, for example in
an amount of about 1% to about 25% by weight of the primary emulsion 10. The
whey is conveniently in powder form. The inclusion of the whey has the
advantage of providing a source of reducing sugars which may react with amino
25 acids to provide Maillard reaction products. These reaction products may
provide flavor notes which can increase the palatability of the formulated
emulsion product.
The additive mixture 6 may be a mixture of dry additives or fats; and
mixtures thereof. The dry additives may be, for example, sugar, salt, spices,
30 seasonings, vit~minc, minerals, flavorants and the like. The fats may be suitable
a:nimal fats; for example tallow, or may be vegetable fats. The total amount of
~ the additive mixture used may be selected as required but will usually be in the
range of 1 to 35% by weight ofthe primary emulsion.
The ,amount of water 4 added is sufficient such that the water comprises
35 fiom about 45% to 85% by weight in the formulated emulsion product. If
sufficient 1noisture is present in the protein source 2 or the additive mixture 6, the
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water 4 may be omitted. Usually an amount of water to make up to about 60%
of the primary emulsion 10 is added.
In the processes described in US patents 4,781,939 and 5,132,137, the
amount of fat in the primary emulsion must be controlled to facilitate processing
5 and to obtain an acceptable product. However the amount of fat is not an
irnportant parameter in this process and the amount can be selected as desired.
Consequently no fat need be added; particularly if the animal protein source 2
contains fats. Conveniently, the amount of fat in the primary emulsion 10 is in
the range of 5% to 25% by weight. Reducing the importance of fat as a
10 parameter in the process is a major advantage of the process.
The protein source 2, the water 4 and the additive mixture 6 are mixed in
any suitable mixer 8. For example, a twin screw mixer, a twin ribbon blender, orarl overlapping paddle mixer may be used. The mixing should be sufficient to
ensure that any dry ingredients are dissolved.
Once mixed, the primary emulsion 10 is preferably fed through a vacuum
stuffer (not shown), or similar deaeration apparatus, to deaerate the primaIy
emulsion 10. This removes air which may otherwise cause disruption of the
formulated emulsion product and reduce its meat-like appearance. However, it is
not essential to deaerate the primary emulsion 10 because, in general, an
20 acceptable product may still be obtained.
Alkaline 12 is injected into the primary emulsion 10 prior to the primary
emulsion 10 being fed into an emulsion mill 14. Sufficient alkaline 12 is injected
so as to raise the pH ofthe primary emulsion 10 to a range of about 8 to about 12.
The alkaline may be any alkaline suitable for use in a food product.
25 Conveniently, NaOH may be used; preferably in solution. The concentration of
the NaOH in solution is conveniently about 25% to 50% by weight. As an
alternative to injecting the alkaline into the primary emulsion 10, the alkalinemay be added into the mixer 8 along with the water 4 and additive mixture 6. As
a further alternative, the alkaline may be injected into the primary emulsion 10 as
30 it enters the emulsion mill 14.
The emulsion mill 14 is a high speed mill which subjects the emulsion to
rapid mechanical heating and shearing. Any suitable emulsion mill 14 may be
used, for example the emulsion mill disclosed in US patent 5,132,137, the
disclosure of which is incorporated by reference. Other suitable emulsion mills
35 14 are commercially available under the tr~(len~me of Trigonal and may be
obtained from Siefer Machinenfabrik GmbH & Co KG, Bahnhofstrasse 114,
j
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.Postfach 1l31008, Velbe1~ 1, Germany. These emulsion mills usually comprise a
pair of plal;es which are closely spaced apart. One of the plates rotates at high
xpeeds. The emulsion is fed between the plates and the mechanical energy
imparted to the emulsion rapidly raises its temperature. The heated emulsion 16
~eaves the emulsion mill in a thin stream which packs onto earlier streams to form
layers or striations
The temperature of the primary emulsion 10 is raised to the desired
coagulation temperature in the emulsion mill 14 in a few seconds. For example,
the temperature may be raised to from about 100~C to about 120~C.
~lternatively, the temperature may be raised to in the range of about 45~C to
about 75~C as described in US patent 5,132,137. Usually the mechanical energy
generated in the emulsion mill 14 will be sufficient to heat the emulsion 10 butthis may be supplemented by the injection of superheated steam.
The heated emulsion 16 leaving the emulsion mill 14 is then transferred to
a holding tl1be 18. Holding tubes 18 such as described in US patents 4,781,939
and 5,132, ] 37 may be used. In the holding tube 18, the heated emulsion 16
coagulates while moving slowly along the holding tube 18. The residence time
of the heated emulsion 1~ in the holding tube 18 is sufficient for the emulsion to
hlave coagulated into a film emulsion product upon reaching the exit of the
holding tube 18. Residence times of about 30 seconds to about 10 minutes are
sufficient; the actual time depending upon the temperature to which the primary
emulsion 10 was heated. Longer or shorter residence times may also be used but
disadvantages arise. If desired, the holding tube may be equipped with a suitable
valve at its end to m~int~in a desired pressure in it.
The firm emulsion product 20 leaving the holding tube 18 is then
transferred to a cutter 22 where it is cut into chunks 24 of size suitable for use in
a pet food. ~lternatively, if it is desired to produce chunks of a more natural
appearance, steam may be intermittently injected into the holding tube 18 to
cause disruption of the firm emulsion product 20 into chunks as it leaves the
holding tube 18. This procedure is described in US patent 4,781,939.
If desired, the chunks 24 may be baked by passing them through an oven
as describecl in US patent 5,132,137. However, if the meat emulsion 10 was
hleated to above 100~C in the emulsion mill 14, this is unnecessary.
The chunks 24 are then allowed to cool and are collected. If desired, the
collected chunks are stored for later use or are simply transferred to a c~nningo;peration. Prior to canning, the chunks 24 may be flaked if desired. In the
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c~nning operation, the chunks are filled into cans along with a gravy or sauce.
The gravy or sauce may contain an acid, such as citric acid or phosphoric acid,
which is acceptable in foods to neutralize the alkaline in the chunks. The cans
are then sealed and sterilized. In this case, the product produced is a chunk-in-
5 gravy type product. ~lternatively the chunks may be combined with a meatemulsion which forms a loaf-type product. In this case, the meat emulsion may
contain a similar acid to neutralize the chunks. The cans are then sealed and
sterilized. In this case, the product produced is a chun~-in-loaf type product.
The chunks 24 have a highly striated appearance which provides a very
10 good simulation of meat. This greatly increases the consumer acceptability of the
product. Also, the chunks 24 have a chewy texture which requires the ~nim~lc to
chew them; much as ~nim~ls would chew fresh meat. This offers the advantage
o:E being beneficial to the ;lnimzll.s' teeth.
Although the invention has been described with reference to pet foods, it
15 will be appreciated that the process may also be used to produce foods intended
for human consumption.
Ex~mple 1
An emulsion is formed by mixing 20% plasma, 20% whey powder, 6%
tallow, and 52% water (the percentages being based on the total weight of the
chunk ingrediel1ts). The emulsion is transferred to a batch blender and 2% of a
solution containing 50% by weight of NaOH is added. The pH of the emulsion
increases to about 11.
The emulsion is run through an emulsion mill (a Trigonal Mill obtained
f~om Siefer Machinenfabrik GmbH & Co KG). The emulsion leaving the
ernulsion mill is at a temperature of 103 to 105~C and is discharged into a holding
tube. The residence time in the holding tube is less than 6 minutes. The
coagulated emulsion leaving the holding tube is cut into chunks of about 10 mm
si:ze. The chunks have a highly striated, meat-like appearance. Some meat-like
browning, due to Maillard reactions bet~,veen amino acids in the plasma and
su.gars in the whey, is noticeable.
A loaf product mix is prepared from about 53% by weight of meat and
meat by-products, about 44.5% water and about 2.5% flavoring agents. The
mixture is cooked in a batch mixer/cooker and filled, with the chunks, into cans.
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The mass ratio of loaf ingredients to chunks is about 78:22. The cans are sealedand sterilized.
A can is opened, a representative sample of the product is taken and the
pH is determined to be about 6.5 to 7Ø Further product is fed to dogs and is
freely eaten.
~_x~mple 2
Chunks are produced as described in example 1. A gravy is then prepared
by mixing together 5.5% starch, 1% phosphoric acid, less than 0.5% condiments,
and water making up the remainder (all percentages being by weight). The
chunks an~ gravy are combined in a mass ratio of about 45:55 and filled into
cans. The cans are sealed and sterilized.
A ccm is opened, a representative sample of the product is taken and the
pH is determined to be about 6.3 to 6.6. Further product is fed to dogs and is
freely eaten.
Fxample 3
Frozen meat and meat by-products obtained from a local source are
ground and then emulsified. An emulsion mixture is then formed by mixing 2%
plasma, 2% whey powder, 1% condiments and 93% emulsified meat and meat
by-products (the percentages being based on the total weight of the chunk
ingredients). The emulsion mixture is transferred to a batch blender and 2% o~ asolution cont~ining 50% by weight of NaOH is added. The pH of the emulsion
mixture increases to about 11.
The emulsion mixture is run through an emulsion mill (a Trigonal Mill
abtained from Siefer Machinenfabrik GmbH & Co KG). The emulsion leaving
the emulsicn mill is at a temperature of 103 to 105~C and is discharged into a
holding tube. The residence time in the holding tube is less than 6 minutes. Thecoagulated emulsion leaving the holding tube is cut into chunks of about 10 mm
size. The chunks have a highly striated, meat-like appearance. Some meat-like
browning, due to Maillard reactions between amino acids in the plasma and
sugars in the whey, is noticeable.
A gravy is then prepared by mixing together 5.5% starch, 1% phosphoric
acid, less th~an 0.5% condiments, and water; the water m~king up the rem~inder
-
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-10-
(all percentages being by weight). The chunks and gravy are combined in a mass
ratio of about 45:55 and filled into cans. The cans are sealed and sterilized.
A can is opened, a representative sample of the product is taken and the
pH is determined to be about 6.3 to 6.6. Further product is fed to cats and dogsS and is freely eaten.
Fxample 4
Frozen meat and meat by-products obtained from a local source are
10 ground and then emulsified. The emulsion is placed in a blender and 10% by
weight wheat gluten, 4% by weight soy protein concentrate, 3% condiments and
18 % by weight water are added to provide an emulsion mixture (the percentages
being based on the total weight of all chunk ingredients). Two % by weight of a
solution cont~ining 50% by weight of NaOH is added then added and the
15 emulsion mixture blended until uniform. The pH of the emulsion mixture
increases to about 12.
The emulsion mixture is run through a Trigonal emulsion mill and
discharged into a holding tube at a temperature of about 11 0~C to about 1 1 5~C.
The holding tube is equipped with a pinch valve to m~int~in back pressure. The
20 coagulated emulsion leaving the holding tube is cut into chunks of about 10 mm
size. The chunks have a shredded, stringy, meat-like appearance.
A gravy is then prepared by mixing together 2.5% starch, 0.5%
condiments, 0.3% hydrocolloid, and water; the water m~king up the remainder
(all percentages being by weight on the basis of gravy ingredients). The chunks
25 and gravy are combined in a mass ratio of about 60:40 and then about 1.75% byweight of phosphoric acid is added and blended in. The mixture is then filled
i~to cans. The cans are sealed and sterilized.
Fx~mple S
An emulsion is prepared by blending 8% by weight wheat gluten, 22% by
weight soy protein concentrate, 0.3% condiments, 5% fat and 62.7 % by weight
water (the percentages being based on the total weight of all chunk ingredients).
Two % by weight of a solution cont~ining 50% by weight of NaOH is added then
35 added and the emulsion mixture blended until uniforrn. The pH of the emulsion mixture increases to about 11.
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The emulsion is then forrnulated into chunks and added to a gravy as
~described iin example 4.
.,
iExample 6
A c;hunk produced according to the process described irl US patent
4,781,939 (Sample A) alld a chunk produced according to example 4 (Sample l)
are frozen at -80~C. The samples are freeze fractured into sections vf 10 to 15
~1m and stained with Sudan III and Harris' Hemato~ylin (J: Dairy Science; 1922,
10 5). The sarnples are then subjected to light microscopy in the frozen state.
Sample 1 is formed of thin layers or striations of protein and fat generally
of thickness less than about 50 ~Lm. Sample A is formed of less well defined
layers or striations of protein and fat of thickness substantially generally greater
than 50 ,um. The results support the visual observation that the chunks of Sample
15 I have an ~ppearance more highly striated then the conventional chunks of
Sample A.
Fx~mple 7
A dough which contains about 62.5% by weight of a mixture of turkey
meat and fish is prepared according to example 4 (without the formation of
chunks). The dough are labeled Sample 2. A similar dough is produced
according to the process described in US patent 4,781,9394 (again without the
formation of chunks). The dough is labelled Sample B. The doughs are then cut
i]~to disks of about 50mm diameter and 10 mm thickness. Twenty disks of
sample 2 are prepared in this way and 20 disks of sarnple B.
Each sample disk is placed in a texture analyzer (TX.XT2 b~ Texture
Technologist Corp, Scarsdale, New York, USA) on a flat disk of 80 mm. The
temperature is about 10 to 1 5~C. A flat bottom probe of 56 mm diameter is
pressed down at a constant speed of 2 mm/s on the sample disk using 10 gram
force and for a distance of 6 mm. The probe is held in this position ~or 60
seconds. The strain at the start of the pressing (initial strain) and the strain after
pressing (fi~nal strain) are determined and recorded. The percentage elasticity
~ recovery of each disk is then determined according to the formula:
reco~very % = 100 - ((final strain - initial strain)/final strain x 100)
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The results are as follows:
r
Sample 2 ~ Sample B
Disk Final Initial % Recovery Disk Final Initial % Recovery
strain strain strain strain
1402 g87 63.3 l 812 223 27.5
2 1475 943 64.0 2 763 208 27.2
3 838 519 62.0 3 543 136 25.0
4 443 272 61.4 4 829 233 28.1
308 196 63.8 5 810 213 26.3
6 610 389 63.7 6 1011 288 28.5
7 930 583 62.7 7 781 216 27.6
8 953 579 60.7 8 616 168 27.3
9 493 309 62.7 9 799 200 25.1
501 314 62.7 10 771 217 28.2
11 462 285 61.7 11 755 207 27.4
12 356 222 62.0 12 509 140 27.5
13 683 429 62.7 13 821 212 25.8
14 425 260 61.2 14 532 141 26.6
lS 492 307 62.4 15 672 181 27.0
16 87 53 60.7 16 53 P~ 151 28.0
17 801 489 61.1 17 843 229 27.2
18 1253 771 61.5 18 695 180 25.8
19 911 567 62.2 19 682 184 27.0
325 194 59.6 20 524 142 27.0
The average % recover.v for the disks of sample 2 is 63.3 while that for the
disks of sample B is 27Ø This indicates that chunks produced from the dough ofSample 2 have a much more elastic (chewier) texture than the conventional
chunks.
