Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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A METHOD OF FORMING A BUTTER/MARGARINE BLEND
BACKGROUND OF THE INVENTION
The present invention generally relates to a method of forming
butter-based products, such as a butter/margarine blend, and to butter-based
products that are prepared by this method. More specifically, the present
invention
relates to a method of concentrating interfacial butter solids of butter, to a
method
of incorporating the interfacial butter solids in butter-based products, and
to butter-
based products that contain a concentrated amount of the interfacial butter
solids.
Butter preparation methods represent some of the oldest
techniques for utilizing fat components that are found in milk. Butter
manufacture
has been accomplished in one form or another for over 4500 years. Over the
centuries, butter has been used in sacrificial worship ceremonies, for
medicinal and
cosmetic purposes, and as a human food.
Butter production techniques generally evolved into more
sophisticated techniques as new forms and uses of equipment developed. For
example, the barrel churn made its appearance toward the end of the 18th
century
when non-wooden manufacturing materials entered widespread use in creaming and
butter making equipment. These advances led to advances in cream separation
techniques and, by 1879, continuous operation cream separators were known in
Sweden, Denmark, and Germany. Likewise, butter production evolved from an
individual farm activity to a factory based technique with the introduction of
milk
pooling systems for creamery operation in the 1870s. Later advances in fat
quantification techniques, pasteurization, refrigeration, and bacterial
culture usage
further advanced the art of butter production.
Advances in butter production technology helped make butter a
staple item in the kitchen. Certain components of butter, such as interfacial
butter
solids, give butter-based baked goods properties that are not achievable by
margarines and presently available butter/margarine blends. For example,
butter
melts somewhat evenly in the mouth to yield a smooth, rich mouth-feel that is
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characteristic of butter. As another example, the protein and lactose
components
of butter give desirable browning characteristics to baked goods that
incorporate
butter. Also, the phospholipid portion of butter gives body to baked goods and
gives the baked goods the characteristic rich flavor long associated with
butter.
Phospholipids, proteins, and sugars, such as lactose, are each components of
interfacial butter solids.
Despite these highly desirable taste and baking properties
associated with butter, butter consumption came under attack by nutritionists
and
the medical profession during the 1970s and 1980s because of links thought to
exist
between butter consumption and certain health conditions. Also, butter prices
tend
to be relatively volatile over the long term. These factors led to increasing
use of
butter substitutes, such as margarine and butter/margarine blends, that
included fat
sources in addition to, or other than, butterfat. Existing butter/margarine
blends are
typically based on butter; other fat sources, such as soybean oil, cottonseed
oil,
1 S canola oil, and other types of vegetable oils; water; and emulsifying
agents, such as
monoglycerides and diglycerides. Margarines are typically based on various
combinations of water and vegetable oils and may include or exclude butterfat,
depending upon the formulation of the particular margarine.
However, even present margarines that include butterfat and
present butter/margarine blends that include butter do not have the
characteristic
mouth-feel of butter and typically do not give baked goods the browning
properties
and body-yielding properties that are characteristic of butter. This is true
even
though numerous artificial butter flavoring compounds have been developed and
incorporated into margarines and butter/margarine blends over the years.
Thus, even though these alternatives to pure butter have helped
to reduce the amount of saturated fats and calories in the human diet and have
helped to stabilize the cost of supplying nutritionally necessary fat in the
human
diet, these advances have come at the cost of losing butter-like baking
properties,
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such as the browning and baking characteristics yielded by butter, and the
rich
flavor and characteristic mouth-feel exhibited by butter. Thus, consumers,
including household consumers and commercial baking concerns alike, long for
an
improved butter/margarine blend that accommodates ' health concerns about
butterfat while achieving baking properties, mouth-feel properties, and flavor
and
taste that equal or even exceed those exhibited by butter.
BRIEF SUMMARY OF THE INVENTION
The present invention concerns a method of forming a butter-
based product, such as a butter/margarine blend, that includes removing water
or
butterfat from a feed material that includes butter to yield an intermediate,
combining a non-dairy fat with the intermediate to form an intermediate blend,
and
processing the intermediate blend to form the butter-based product. The
present
invention further includes a method of forming a concentrated butter. The
method
of the present invention additionally includes a concentrated butter, a butter-
based
product, and a concentrated butter product.
BRIEF DESCRIPTION OF THE DR.AW1NG
The Figure is a schematic of a process for producing a butter-
based product, such as a butter/margarine blend, in accordance with the
present
invention.
DETAILED DESCRIPTION
The present invention generally relates to a method of forming
butter-based products, such as a butter/margarine blend, and to butter-based
products that are prepared by this method. More specifically, the present
invention
relates to a method of concentrating interfacial butter solids of butter, to a
method
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of incorporating the interfacial butter solids in butter-based products, and
to butter-
based products that contain a concentrated amount of the interfacial butter
solids.
A process for preparing the butter-based product, such as the
butter/margarine blend, of the present invention is generally depicted at 10
in the
Figure. First, a feed material 12, such as butter or a mixture of butter and
one or
more additional components, is heated using a heat exchange mechanism 14, such
as a steam jacketed pipe, to form a liquid feed material 16, such as melted
butter
or a liquid composition containing melted butter, and thereby remove all
crystallization memory of the butter. The liquid feed material 16 is placed in
an
agitated and heated tank 18. Mixed liquid feed material 20 is then transferred
from
the tank 18 to an evaporator 22 to concentrate the mixed liquid feed material
20 by
removing water 24 from the mixed liquid feed material 20 under controlled
vacuum
and temperature conditions.
A reduced water-content material 26 that is derived in the
evaporator 22 is then transferred to a separator 28 and separated into
butterfat 30,
byproduct butterfat 3 l, and a butter solids intermediate 32. The byproduct
butterfat
31 exits the process 10 for further processing or for sale to customers as
butterfat.
The ratio of butterfat removed from the process 10 as byproduct butterfat 31
versus
butterfat remaining in the process 10 as the butterfat 30 may be adjusted to
provide
products produced using the process 10 with different butterfat contents and
concentrations. As an alternative to removing the byproduct butterfat 31
directly
from the separator 28, excess butterfat beyond the butterfat required to
produce the
butter-based products of the present invention may be removed from the process
10
by removing byproduct butterfat from the butterfat 30 after separation of the
butterfat 30 and the butter solids intermediate 32 in the separator 28.
The butterfat 30 is placed into a holding tank 34 and the butter
solids intermediate 32 is placed into a holding tank 36. If any byproduct
butterfat
is removed from the butterfat 30, the byproduct butterfat removal may occur
either
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before or after the butterfat 30 has been placed in the holding tank 34. The
holding
tank 34 and/or the holding tank 36 may be heated, as necessary, to maintain
the
butterfat 30 as a liquid and/or to maintain the butter solids intermediate 32
as a
liquid. Additionally, the tanks 34, 36 may be agitated to maintain the
homogeneity
5 of the butterfat 30 and the homogeneity of the butter solids intermediate
32,
respectively. The composition of the butterfat 30 may be left unchanged in the
holding tank 34, and the composition of the butter solids intermediate 32 may
be
left unchanged in the holding tank 36.
On the other hand, an emulsifying agent may optionally be added
to the tank 34 and thereafter may be dispersed within the butterfat 30. The
ratio of
emulsifying agent to butterfat 30 in the tank 34 may be selectively adj usted
to attain
desired properties in butter-based products, such as the butter-margarine
blend, that
may be produced using the process 10. Likewise, food grade salt may optionally
be added to the tank 36 and thereafter may be dispersed within the butter
solids
intermediate 32. The ratio of salt to butter solids intermediate 32 in the
tank 36
may be selectively adjusted to attain desired properties in butter-based
products,
such as the butter-margarine blend, that may be produced using the process 10.
The butterfat 30 is metered from the holding tank 34 as butterfat
38 into a weigh and mix tank 42, and the butter solids intermediate 32 is
metered
from the holding tank 36 as butter solids intermediate 40 to the weigh and mix
tank
42. Non-dairy fat 44, such as vegetable oil, may optionally also be metered
into the
weigh and mix tank 42. The ratio of butterfat 38 to butter solids intermediate
40
to non-dairy fat 44 in the weigh and mix tank 42 may be selectively adjusted
to
attain desired properties in butter and butter-based products produced using
the
process 10. The butterfat 38, the butter solids intermediate 40, and the non-
dairy
fat 44 are mixed together in the weigh and mix tank 42 to form a water-in-fat
dispersion, namely an intermediate blend 46.
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The intermediate blend 46 along with optional additives) 48 are
combined, blended, and agitated in a blend tank 50 to form a liquid
butter/margarine blend 52. The liquid butter/margarine blend 52 may then be
conventionally processed in traditional margarine and butter crystallization
equipment, such as a chill roller or a swept surface heater exchanger 54, to
form a
solidified butter/margarine blend 56. The solidified butter/margarine blend 56
may
be packaged in conventional butter and margarine packing equipment, such as a
packing unit 58, to yield a packaged butter/margarine product 60.
The butter-based product that exits the blend tank 50 is
subsequently referred to primarily in terms of the butter/margarine blend 52.
Nonetheless, it is to be understood that the butter-based products that exit
the tank
42 and the tank 52, along with any derivatives of these butter-based products,
may
alternatively be butter, a reduced-fat butter, a butter-based spread, or any
other
water-in-fat dispersion that includes interfacial butter solids from the
butter of the
feed material 12 and may also include some water and/or butterfat from the
butter
of the feed material 12.
In the process 10, the feed material 12 may be or may include any
butter. As used herein, all references to "butter" are to be understood as
refernng
to a dairy product prepared by churning, or equivalently processing, milk,
cream,
or a combination of milk and cream, though other optional ingredients beyond
milk
and/or cream may optionally be included before, during and/or after the butter
production. The churning or equivalent processing may be accomplished in
either
batch-wise or continuous fashion. The source of the milk and/or cream that is
used
to form the butter may be bovine, ovine, caprine, or the like. The butter that
makes
up some or all of the feed material 12 may generally take any form, such as
semi-
solid, pumpable butter that exits the churning process; chilled solid butter;
or butter
that has been melted to form liquid butter.
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Non-dairy ingredients, preferably other minor non-dairy
ingredients, such as salt, a coloring agent, and/or vitamins, may optionally
be
included in the milk and/or cream that is churned to form the butter or may
optionally be added to the milk and/or cream during the churning process.
S Preferably, however, salt, if added, is added at the tank 36, and other
minor non-
dairy ingredients, such as vitamins, lactic acid, and/or the coloring agent,
are added
at the blend tank 50 to simplify operational considerations for the evaporator
22 and
the separator 28.
Non-dairy fat may also optionally be added to the milk and/or
cream that is processed to form the butter or may be added to the milk and/or
cream
during the butter production process. Non-dairy fat is preferably not added to
the
milk and/or cream either before or during processing of the milk and/or cream
to
form the butter, since some of any such added non-dairy fat would likely be
present
in the buttermilk byproduct of the butter forming process and would reduce the
value of the byproduct buttermilk. Also, non-dairy fat is preferably not added
to the
milk and/or cream either before or during processing of the milk and/or cream
to
form the butter, since any such addition of non-dairy fat would prevent the
butter
being formed from being labeled as butter, and would prevent butter-based
products
that exit the tank 42 and the tank 52, along with any derivatives of these
butter-
based products, from being labeled as butter-based products, such as the
butter/margarine blend, under the present dietary labeling standards of United
States
regulatory authorities, such as the U.S. Department of Agriculture (U.S.D.A.).
Churning of milk and/or cream initially causes fractionation of
the milk and/or cream into (1) an aqueous phase that yields a buttermilk
byproduct
and (2) a fat phase that includes milk fat globules. The churning process also
causes aggregation of milk fat globules that, with the aid of various
interfacial
butter solids such as phospholipids, entrap water molecules from the aqueous
phase
to form the water-in-fat dispersion that predominantly or exclusively exists
in
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butter. It is believed that the water-in-fat dispersion of butter is not a
true emulsion,
but instead represents a surface absorption phenomena in which water is
absorbed
within a matrix of milk fat globules. Additionally, it is believed that the
solids
leaving as part of the aqueous buttermilk byproduct of the churning process
are
qualitatively different in nature than the solids remaining in the butter
produced by
churning, since the taste of this aqueous buttermilk byproduct is
qualitatively quite
different from the taste of the aqueous layer resulting when butter is melted
and
stratified into a fat layer and an aqueous layer.
Unless otherwise indicated, all references to "interfacial butter
solids" are to be understood as referring to the solid particles and/or semi-
solid
particles that tend to congregate proximate the interface of the aqueous phase
and
the fat phase of melted butter (1 ) when the temperature of the melted butter
is in the
range of about 80 °F (about 26.7 °C) to about 145 °F
(about 62.8 °C) and (2) when
the aqueous phase and the fat phase are permitted to separate under the
influence
of gravity or when the aqueous phase and the fat phase are forced to separate,
such
as by processing the melted butter in a centrifuge. Some components of the
"interfacial butter solids", such as proteins and sugars, tend to exist in the
aqueous
phase of the melted butter proximate the interface, while other components of
the
"interfacial butter solids", such as phospholipids, tend to exist proximate
the .
interface of the fat phase and the aqueous phase of the melted butter in both
the fat
phase and the aqueous phase of the melted butter.
Consequently, the "interfacial butter solids" includes those solid
particles and/or semi-solid particles that tend to congregate proximate the
interface
of the aqueous phase and the fat phase of the melted butter under the
influence of
gravity or physical separation, no matter whether those solid particles and/or
semi-
solid particles are in the aqueous phase, the liquid phase, or both the
aqueous phase
and the liquid phase of the melted butter. Additionally, solid particles
and/or semi-
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solid particles of the interfacial butter solids may be dissolved
(solubilized) in the
aqueous phase and/or the fat phase of the melted butter.
The term "interfacial butter solids" includes all solid particles
and/or semi-solid particles that tend to congregate proximate the interface of
the
aqueous phase and fat phase of melted butter, rather than only solid particles
and/or
semi-solid particles that actually have congregated proximate the interface of
the
aqueous phase and the fat phase of melted butter. The term "interfacial butter
solids" excludes any non-dairy additives, such as salt, that are added to the
milk
and/or cream that is processed to form the butter and also excludes any non-
dairy
additives that are added to the milk and/or cream during the butter production
process or that are added to the butter after the butter production process.
The term
"interfacial butter solids" also excludes any non-dairy fat that is added to
the milk
and/or cream that is processed to form the butter, any non-dairy fat that is
added to
the milk and/or cream during the butter production process, and any non-dairy
fat
that is added to the butter after the butter production process. Additionally,
unless
otherwise-indicated, the term "non-dairy" means not a dairy material and not
derived from a dairy material. Milk, cream, whey, cheese, and butter are some
non-
exhaustive examples of dairy materials.
As noted, some components of the "interfacial butter solids",
such as proteins and sugars, tend to exist in the aqueous phase of the melted
butter
proximate the interface. Therefore, these protein and sugar components of the
interfacial butter solids will predominantly, if not nearly exclusively,
remain in the
aqueous phase upon separation of the aqueous phase from the melted butter.
Also
as noted, other components of the "interfacial butter solids", such as
phospholipids,
tend to exist proximate the interface of the fat phase and the aqueous phase
of the
melted butter with part of each phospholipid molecule typically located in the
aqueous phase of the melted butter and with another part of each phospholipid
molecule typically located in the fat phase of the melted butter. Nonetheless,
upon
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removal of the aqueous phase from melted butter, most, if not essentially all,
of the
phospholipids tend to stay with the aqueous phase; this tendency of the
phospholipids to stay with the aqueous phase instead of with the fat phase
upon
removal of the aqueous phase from the melted butter is believed to occur
because
5 the attraction of each phospholipid molecule portion present in the aqueous
phase
to the aqueous phase tends to be stronger than the attraction of each
corresponding
phospholipid molecule portion present in the fat phase is to the fat phase.
Despite
this observation, when separating the aqueous phase and the fat phase of the
reduced water-content material 26 into the butterfat 30, the byproduct
butterfat 3 l,
10 and the butter solids intermediate 32, some butterfat may be allowed to
stay with
the aqueous phase (butter solids intermediate 32) to maximize the amount of
the
phospholipid component of the interfacial butter solids that remains in the
butter
solids intermediate 32.
Additionally, unless otherwise indicated, all references to
"butterfat" are to be understood as referring to dairy (milk) fat that is both
(1)
present in butter and (2) present in the liquid dairy material, such as milk,
cream,
or combination of milk and cream, that is processed to form the butter.
Consequently, unless otherwise indicated, the term "butterfat" excludes non-
dairy
fats, including, but not limited to, any non-dairy fat that is added to, or
as, feed
components of the butter production process; any non-dairy fat that is added
to the
butter production process during butter manufacture; and any non-dairy fat
that is
added to the butter after the butter production process.
The feed material 12 preferably contains, and more preferably
consists of, butter that is recognized as butter in the United States by
regulatory
authorities, such as the Department of Agriculture (U.S.D.A.). The U.S.D.A.
defines butter as follows:
The food product usually known as butter, and
which is made exclusively from milk or
cream, or both, with or without additional
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coloring matter, and containing not less than
80 percent by weight of milkfat, all tolerances
having been allowed for.
7 C.F.R. ~58.305(a), revised January 1, 1997. Generally, however, the feed
material 12 may contain or may consist of any butter, such as butter formed by
churning. This means that butter present in the feed material 12 will
typically have
a butterfat concentration of at least about 60 weight percent, based on the
total
weight of the butter leaving the butter production process, since the
aggregation of
milk fat molecules into the "butterfat" matrix that entraps water molecules
will
typically not form if the milk fat concentration of the in-process dairy
material that
is transformed into butter is less than about 60 weight percent, based on the
total
weight of the in-process dairy material.
For purposes of marketing the butter solids intermediate 32 (as
concentrated liquid butter), the intermediate blend 46, the liquid
butter/margarine
blend 52, and/or the solidified butter/margarine blend 56 to American
consumers,
the butter that forms, or is part of, the feed material 12 is preferably based
upon
dairy material that is produced by or derived from dairy cattle in the United
States,
since the palates of American consumers are accustomed to dairy material that
is
produced by or derived from dairy cattle in the United States. Dairy animals,
such
as dairy cattle, in other regions of the world are often fed or grazed upon
different
feeds than dairy cattle in the United States. For example, dairy cattle in New
Zealand are typically grazed on clover which gives butter a unique flavor that
is
typically not appreciated by American consumers. '
For purposes of marketing the butter solids intermediate 32 (as
concentrated liquid butter), the intermediate blend 46, the liquid
butter/margarine
blend 52, and/or the solidified butter/margarine blend 56 to consumers in
countries
other than the United States, the butter that forms, or is part of, the feed
material 12
may be based upon dairy material that is produced by or derived from dairy
cattle
in countries other than the United States, while realizing that consumers in a
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particular country will typically prefer dairy products that are based upon
dairy
material produced by or derived from dairy cattle in that particular country.
The time between formation of the butter and introduction of the
butter into the process 10 as the feed material 12 or as a component of the
feed
material 12 is preferably minimized to maximize the "fresh churned" butter
taste
of products produced in accordance with the present invention. Though not
wishing to be bound by theory, it is believed that air entrained in butter
during the
churning process causes or contributes to degradation of flavor components in
freshly-churned butter that are responsible for the difference between the
taste of
freshly churned butter and the taste of butter that can no longer be
considered to be
fresh churned.
Therefore, the butter that forms, or is part of, the feed material 12
is preferably freshly churned butter that has been produced no more than about
8
hours prior to being incorporated in the process 10. In one particularly
preferred
embodiment, the butter that forms, or is part of, the feed material 12 is
introduced
into the process 10 in semi-solid form directly from the churning process to
minimize the time between formation of the butter and feeding of the butter to
the
process 10 as the feed material 12 or as a component of the feed material 12.
Additionally, in the process 10, the feed material 12, the liquid
feed material 16, the mixed liquid feed material 20, the reduced water-content
material 26, the butterfat 30, the byproduct butterfat 31, the butter solids
intermediate 32, the intermediate blend 46, the liquid butter/margarine blend
52, the
solidified butter/margarine blend 56, the packaged butter/margarine blend 60,
and
derivatives of any of these are each preferably handled carefully in the
process 10
to minimize damage to these streams or to any components of these streams.
Careful handling entails minimizing, and preferably eliminating, exposure of
these
streams to temperatures above about 160°F (above about 71.1 °C).
Though the
mixed liquid feed material 20 may be exposed to a temperature of about
200°F
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(about 93.3°C) to about 210°F (about 98.9°C) prior to and
immediately after
entering the evaporator 22, this high temperature exposure is brief, since the
material 20 rapidly cools to approximately 140°F (approximately
60°C), or less,
soon after entering the evaporator 22. Also, all processing and handling of
these
streams in the process 10 is preferably done under conditions that minimize
the
potential for oxidation of these streams, or of components of these streams,
such as
by blanketing these streams with an inert gas, such as nitrogen. Furthermore,
transfer of these streams within the process 10 is preferably accomplished
using a
positive displacement pump, such as a lobe-type pump or a high pressure piston
pump of the type typically used in dairy homogenizers.
Although the feed material 12 preferably consists of only butter,
the feed material 12 may permissibly include one or more other materials in
addition to butter. When other materials) in addition to butter are included
in the
feed material 12, the concentration of butter in the feed material 12 is
preferably at
least about 50 weight percent, more preferably at least about 75 weight
percent, and
still more preferably at least about 90 weight percent, based on the total
weight of
the feed material 12. Butter is preferably the major, more preferably the
predominant, and most preferably the only component of the feed material 12,
since
the interfacial butter solids that are present in butter and that are
concentrated in
accordance with the present invention provide the desirable, enhanced baking,
flavor, and mouth-feel properties that are achieved in products that are
produced in
accordance with the present invention.
Nonetheless, in place of some or all of the butter, the feed
material 12 may optionally include any butter material that is derived from
butter,
so long as the butter material includes interfacial butter solids. In addition
to
interfacial butter solids, the optional butter material may optionally also
include
butterfat, water, or any combination of water and butterfat in any
concentration.
Also, in addition to butter and the optional butter material, the feed
material 12 may
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permissibly, though preferably does not, include any edible non-dairy fat,
such as
lard, beef tallow, vegetable oil, and/or shortening; water; any food grade
coloring
agent(s); any food grade emulsifying agents) such as lecithin, a
monoglyceride, or
a diglyceride; or any combination of any of these. Added food grade
emulsifying
agents) are preferably not included with the butter in the feed material 12,
since the
presence of added food grade emulsifying agents in the feed material 12, under
some operating conditions, may complicate removal of water via the evaporator
22
and/or separation of the butterfat 30 and byproduct butterfat 31 from the
butter
solids intermediate 32 in the separator 28.
If the optional butter material is included in the feed material 12,
the interfacial butter solids concentration in the butter material is
preferably about
the same as the concentration of interfacial butter solids in the butter that
is used as
part of the feed material 12. This preference is based upon the fact that
centrifugal
separation equipment that may be used as the separator 28, at some operating
conditions, has been found to sometimes lose some amount of interfacial butter
solid during U.S.D.A. mandated "burping" of the centrifugal separation
equipment.
It is believed that the interfacial butter solids losses from the centrifugal
separator
will tend to increase, as a percentage of the total interfacial butter solids
in the feed
material 12, as the concentration of interfacial butter solids increases in
the feed
material 12. Thus, while it is entirely desirable to have interfacial butter
solids in
the feed material 12, the concentration of interfacial butter solids included
in the
optional butter material is preferably about the same as the concentration of
interfacial butter solids in the butter of the feed material 12 to avoid
enhancing the
relative amount of interfacial butter solids lost due to U.S.D.A.-mandated
burping
of any centrifugal separator that is used as the separator 28.
Likewise, the content of solids other than interfacial butter solids
in the feed material 12 is preferably minimized to minimize loss of
interfacial butter
solids during the U.S.D.A.- mandated burping of any centrifugal separator used
as
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the separator 28. For this reason, and to minimize the potential for corrosion
in the
evaporator 22, the butter that is used in or as the feed material 12 is
preferably
unsalted butter, since any desired salt may be added later in the process 10
to the
tank 36.
5 Furthermore, the feed material 12 preferably does not include any
edible non-dairy fat, since addition of non-dairy fat as part of the feed
material 12
would increase the expense and the amount of work needed to concentrate the
interfacial butter solids using the evaporator 22 and the separator 28. Also,
any
non-dairy fat added as part of the feed material 12 would diminish the market
value
10 of any byproduct butterfat 31 and any butterfat 30 that is removed from the
holding
tank 24 as by-product, rather than being used as butterfat 38 that is added to
the
tank 42. Likewise, the feed material 12 preferably does not include any added
water beyond water present in the aqueous phase of butter, since addition of
extra
water as part of the feed material 12 would also increase the expense and the
15 amount of work needed to concentrate the interfacial butter solids using
the
evaporator 22.
Additionally, the feed material 12 preferably does not include any
food grade emulsifying agent(s), since it has been found that the interfacial
butter
solids from the feed material 12 typically supply most, if not all, of the
blending
power necessary to form a stable water-in-fat matrix in the concentrated
liquid
butter, the intermediate blend 46, the liquid butter/margarine blend 52, and
the
solidified butter/margarine blend 56 that may be produced in accordance with
the
present invention. This observation about the interfacial butter solids from
the feed
material 12 typically supplying most, if not all, of the blending power
necessary to
form a stable water-in-fat matrix depends upon at least the following factors:
( 1 ) the
concentrations of interfacial butter solids in the butterfat 38 and in the
butter solids
intermediate 40, (2) the ratio of the butterfat 38, the butter solids
intermediate 40,
and the optional non-dairy fat 44 to each other in the intermediate blend 46,
(3) the
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16
nature of the non-dairy fat 44, (4) the fat profile of the butterfat 38 or of
the blend
of the butterfat 38 and any optional non-dairy fat 44 and (S) mixing
conditions
(such as mixing severity and component temperatures) in the tank 42.
Ultimately,
- food grade emulsifying agents) are preferably not added during processing of
the
feed material 12, and derivatives thereof, in accordance with the present
invention,
such as in the process 10, though it is nevertheless permissible to include
emulsifying agents) as an additive to the butterfat 30 in the tank 34 or as a
component of the additives) 48.
The tank 18 in the process 10 functions as an accumulation tank
for the liquid feed material 16 and balances differences between the flow rate
of the
feed material 12 and the flow rate of the mixed liquid feed material 20. When
the
tank 18 is included in the process 10, the liquid feed material 16 is
subjected to
mild agitation, only, in the tank 18 that is sufficient to prevent
stratification of
components of the liquid feed material 16 and thereby avoid significant
variations
1 S in the composition of the mixed liquid feed material 20 that is sent to
the evaporator
22. As yet another alternative, the tank 18 may be left out of the process 10
in favor
of a balance tank for the feed material 12, prior to heating of the feed
material 12.
Preferably, however, the feed material 12 balance tank or the tank
18 is included to provide an option of returning a portion of the reduced-
water
content material 26, a portion of the butterfat 30, and/or a portion of the
byproduct
butterfat 31 to the feed material 12 balance tank or the tank 18 for
subsequent reflux
in the evaporator 22 to enhance flavor development in the light butter 62. As
discussed more fullybelow, it is believed that hydrolytic and/or hydrolysis
reactions
occurring during reflux contact between the butterfat and aqueous components
in
the evaporator 22 may enhance flavor development in the liquid
butter/margarine
blend 52 and derivatives thereof.
The evaporator 22 may be or include any type of evaporation
equipment, such as a vacuum can, a triple effect evaporator, a vacuum
distillation
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17
tower, or any combination of any of these, that is capable of removing water
24
from the mixed liquid feed material 20. Preferably, the evaporator 22 allows
components that are present in the mixed liquid feed material 20 to quickly
cool to
about 140°F, or less, soon after these components enter the evaporator
22 to
minimize degradation of these components that become part of the reduced water-
content material 26. As one non-exhaustive example, the evaporator 22 may
consist of one or more vacuum cans (not shown) arranged either in series or in
parallel, where a vacuum is created in the vacuum cans) by a vacuum source,
such
as a vacuum pump. One suitable example of the evaporator 22 is a SENIORTM
vacuum chamber that is available from Kussel Equipment Company of Watertown,
Wisconsin. An ELMO~-P vacuum pump that may be obtained from Siemens
Aktiengesellschaft of Munich, Germany may be used as the vacuum source for the
SElVIORTM vacuum chamber.
Water 24 may be sequentially removed by multiple passes
through the evaporator 22 or may be removed in one pass through the evaporator
22 by permitting a longer residence time of the mixed liquid feed material 20
in the
evaporator 22. The purpose of removing water 24 in the evaporator 22 is to
concentrate the interfacial butter solids of the butter that is used in or as
the feed
material 12. Therefore, the evaporator 22 preferably removes water 24 from the
mixed liquid feed material 20 without removing any interfacial butter solids
from
the mixed liquid feed material 20.
Any technique that is capable of removing water from the feed
material 12 or the mixed liquid feed material 20 may be substituted in place
of the
evaporator 22, so long as the technique is capable of minimizing, and
preferably
eliminating, removal of interfacial butter solids from the feed material 12 or
from
the mixed liquid feed material 20. For example, as an alternative to the
evaporator
22, the feed material 12 or the mixed liquid feed material 20 may be subjected
to
freeze-drying or spray drying to reduce the concentration of water in the feed
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18
material 12 or in the mixed liquid feed material 20. However, the process 10
preferably employs the evaporator 22 instead of freeze drying, since water
removal
using the evaporator 22 is less complicated than freeze drying and relies on
equipment conventionally used in the dairy industry for water removal. Also,
the
process 10 preferably employs the evaporator 22 instead of spray drying, since
spray drying would be excepted to cause undesirable oxidation of one or more
components of the mixed liquid feed material 20.
The separator 28 may be any piece of equipment (not shown),
such as gravity separation equipment (a settling tank, for example) or
mechanical
separation equipment (a centrifuge, for example), that permits the aqueous
phase
and the butterfat phase of the butter to separate into substantially distinct
layers and
thereby permits separation of the reduced water-content material 26 into the
butterfat 30, the byproduct butterfat 31, and the butter solids intermediate
32. The
butterfat 30 and the byproduct butterfat 31 primarily contain butterfat. The
butterfat
1 S 30 and the byproduct butterfat 31 may also contain a small amount of
aqueous
phase material of the type that forms the majority of the butter solids
intermediate
32, though the amount of aqueous phase material in the butterfat 30 and the
byproduct butterfat 31 is preferably minimized. The butter solids intermediate
32
primarily contains water and water-soluble components along with the majority
of
the interfacial butter solids. The butter solids intermediate 32 may also
contain a
small amount of butterfat and butterfat-soluble components to maximize capture
of interfacial butter solids, such as phospholipids, in the butter solids
intermediate
32, though the amount of butterfat in the butter solids intermediate 32 is
preferably
minimized to a degree that is consistent with maximizing recovery of
interfacial
butter solids, such as phospholipids, in the butter solids intermediate 32.
Furthermore, multiple pieces of equipment may be provided that
collectively operate as the separator 28. For example, the separator 28 may
include
a pair of settling tanks (not shown) that are arranged in series. In one of
the tanks,
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19
the reduced water-content material 26 may be separated into a butterfat
component
(not shown) and the butter solids intermediate 32. Thereafter, the butterfat
component may be separated into the butterfat 30 and the byproduct butterfat
31.
Of course, alternative separation equipment, such as a centrifuge, may be
S substituted in place of one or both of these tanks.
Preferably, stratification of the butterfat phase and the aqueous
phase of the butter occurs in the separator 28 to a substantial degree to
maximize
separation of butterfat 30 and interfacial butter solids in the separator 28.
When the
separator 28 is a gravity separator, such as a settling tank, it has been
determined
that operating temperatures above about 14S°F (above about
62.8°C) in the
separator 28 tend to reduce separation efficiency and consequently may cause
. undesirably high amounts of interfacial butter solids to be retained in the
.butterfat
30 and/or the byproduct butterfat 31.
One example of a suitable piece of equipment that may serve as
1 S the separator 28 or as a component of the separator 28 is the BMRPX-S314
centrifuge that may be obtained from Alfa-Laval Separation, Inc. of
Warminster,
Pennsylvania. The BMRPX-S314 centrifuge may have a bowl speed of about 5,000
revolutions per minute (rpm), though the bowl is preferably powered by a
variable
speed drive that permits adjustment of the bowl speed to minimize, and
preferably
eliminate, loss of interfacial butter solids due to the afore-mentioned
U.S.D.A.-
mandated "burping" of the separator 28. For the BMRPX-5314 centrifuge, the top
of the separator bowl is preferably maintained at a temperature above the
melting
point of butter, using a warm water bath, to prevent butterfat from
solidifying and
plugging the outlet for the aqueous phase (intermediate butte solids 32). If
any
2S clumps of solidified butterfat begin to form in the BMRPX-S314 centrifuge,
these
clumps may plug the outlet for the aqueous phase and cause loss of some of the
aqueous phase (intermediate butte solids 32), and thus loss of some of the
interfacial butter solids, to the butterfat 30 and/or the byproduct butterfat
31.
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As a general guideline, the degree of interfacial butter solids
separation into the butter solids intermediate 32 versus interfacial butter
solids
separation into the butterfat 30 and/or the byproduct butterfat 31 may be
gauged by
the visual clarity of the butterfat 30 and/or the byproduct butterfat 31. If
the
S butterfat 30 and/or the byproduct butterfat 31 are cloudy in appearance, it
is likely
that a significant amount of the interfacial butter solids has wound up in the
butterfat 30 and/or the byproduct butterfat 31, as opposed to the butter
solids
intermediate 32. On the other hand, if the butterfat 30 and/or the byproduct
butterfat 31 are each fairly clear (though colored) in appearance, most, if
not all or
10 predominantly all, of the interfacial butter solids have been separated
into the butter
solids intermediate 32, as opposed to the butterfat 30 and/or the byproduct
butterfat
31.
The purpose of the separator 28 is to permit splitting of the
reduced water-content material 26 into the butterfat 30, the byproduct
butterfat 31,
15 and the butter solids intermediate 32. Operation of the separator 28
preferably
maximizes the concentration of interfacial butter solids in the butter solids
intermediate 32 and minimizes the concentration of interfacial butter solids
in the
butterfat 30 and in the byproduct butterfat 31. More preferably, the butter
solids
intermediate 32 that is discharged from the separator 28 contains at least
about 95
20 weight percent, or more, of the interfacial butter solids originally
present in the feed
material 12, and the butterfat 30 and the byproduct butterfat 31 that exit the
separator 28 collectively contain little, if any, of the interfacial butter
solids, such
as about S weight percent, or less, of the interfacial butter solids
originally present
in the feed material 12.
Still more preferably, the separator 28 causes the butter solids
intermediate 32 to contain at least about 99 weight percent, or more, of the
interfacial butter solids originally present in the feed material 12 and
causes about
1 weight percent, or less, of the interfacial butter solids originally present
in the
CA 02387337 2002-04-12
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21
feed material .12 to be in the butterfat 30 and in the byproduct butterfat 31,
collectively, that exit the separator 28. Most preferably, operation of the
separator
28 causes all of the interfacial butter solids originally present in the feed
material
12 to be in the butter solids intermediate 32 and yields butterfat 30 and
byproduct
butterfat 31 that contain no or only de minimis amounts of interfacial butter
solids.
The interfacial butter solids are predominantly formed of proteins,
sugars (predominantly lactose), and phospholipids. Consequently, unless
otherwise
indicated, all comments and statements that are provided herein about
interfacial
butter solids are equally applicable to proteins, sugars, and phospholipids,
collectively. Thus, as another gauge of the degree of separation of the
interfacial
butter solids into the butter solids intermediate 32, as opposed to the
butterfat 30
and/or the byproduct butterfat 3 l, one may rely on degree of separation of
proteins,
sugars, and phospholipids into the butter solids intermediate 32 versus the
degree
of separation of proteins, sugars, and phospholipids into the butterfat 30
and/or the
1 S byproduct butterfat 31. The amount and concentration of proteins and
sugars in a
particular sample, such as the butter solids intermediate 32, the butterfat
30, or the
byproduct butterfat 31, may be determined using the Solids Non-Fat
determination
procedure that is provided below in the PROPERTY ANALYSIS AND
CHARACTERIZATION PROCEDURE section of this document. Likewise, the
amount and concentration ofphospholipids in a particular sample, such as the
butter
solids intermediate 32, the butterfat 30, or the byproduct butterfat 31, may
be
determined using the Phospholipids determination procedure that is provided
below
in thePROPERTYANALYSISAND CHARACTERIZATIONPROCEDURE section
of this document. The results obtained from the Solids Non-Fat determination
procedure and from the Phospholipids determination procedure may be combined
to determine the amount and concentration of proteins, sugars, and
phospholipids,
collectively, in a particular sample, such as the butter solids intermediate
32, the
butterfat 30, or the byproduct butterfat 31.
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22
Operation of the separator 28 preferably maximizes the
concentration of proteins, sugars, and phospholipids, collectively, in the
butter
solids intermediate 32 and minimizes the concentration of proteins, sugars,
and
phospholipids, collectively, in the butterfat 30 and in the byproduct
butterfat 31.
More preferably, the butter solids intermediate 32 that is discharged from the
separator 28 contains at least about 95 weight percent, or more, of the
proteins,
sugars, and phospholipids, collectively, that were originally present in the
feed
material 12, and the butterfat 30 and the byproduct butterfat 31 that exit the
separator 28 collectively contain little, if any, of the proteins, sugars, and
phospholipids, such as about 5 weight percent, or less, collectively of the
proteins,
sugars, and phospholipids originally present in the feed material 12.
Still more preferably, the separator 28 causes the butter solids
intermediate 32 to contain at least about 99 weight percent, or more, of the
proteins,
sugars, and phospholipids, collectively, that were originally present in the
feed
material 12 and causes about 1 weight percent, or less, of the proteins,
sugars, and
phospholipids, collectively, that were originally present in the feed material
12 to
be in the butterfat 30 and in the byproduct butterfat 31, collectively, that
exit the
separator 28. Most preferably, operation of the separator 28 causes all of the
proteins, sugars, and phospholipids originally present in the feed material 12
to be
in the butter solids intermediate 32 and yields butterfat 30 and byproduct
butterfat
31 that contain no or only de minimis amounts of proteins, sugars, and
phospholipids.
The purpose of removing water 24 in the evaporator 22 and
removing the butterfat 30 and the byproduct butterfat 31 in the separator 28
is to
maximize the concentration of interfacial butter solids in the butter solids
intermediate 32. The butter solids intermediate 32 serves as a building block
for
creating products that have a higher concentration of interfacial butter
solids than
ordinarily present in butter. Some of the butterfat 30, some optional non-
dairy fat
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23
44, and some optional aqueous-phase material may be combined with the butter
solids intermediate 32 to attain products having an elevated concentration of
interfacial butter solids, a desired butterfat content, a desired non-dairy
fat
concentration, as well as, a desired fat profile.
Ultimately, a major goal of the interfacial butter solids in the
butter solids intermediate 32 via the process 10 is to permit preparation of
butter-
based products, such as butter and/or the butter/margarine blend, that have an
enhanced concentration of interfacial butter solids, as compared to the
concentration of interfacial butter solids ordinarily present in butter. This
enhancement of the interfacial butter solids content in butter and/or
butter/margarine blends that may be produced according to the present
invention
causes the produced butter and/or butter/margarine blends to have improved
butter
taste and butter-baking characteristics, even as compared to the butter that
forms all
or part of the feed material 12.
To maximize the recovery of interfacial butter solids in the butter
solids intermediate 32, some water may be, and typically is, allowed to remain
in
the reduced water-content material 26 that leaves the evaporator 22, and some
butterfat may be allowed to remain in the butter solids intermediate 32 that
exits the
separator 28. Permitting some water to remain in the reduced water-content
material 26 typically helps to minimize, or even eliminate, losses of
interfacial
butter solids via the water 24 that exits the evaporator 22 and via the
butterfat 30
and the byproduct butterfat 31 that exit the separator 28, respectively.
Likewise,
permitting a small amount of butterfat to remain in the butter solids
intermediate
32 may help to minimize, or even eliminate, losses of interfacial butter
solids via
the butterfat 30 and the byproduct butterfat 31 that exit the separator 28,
respectively.
Also, water 24 may optionally be removed without removing any
butterfat 30 and/or any byproduct butterfat 31, or butterfat 30 and/or
byproduct
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24
butterfat 31 may be removed without removing any water 24, if desired, to
attain
particular properties in the butter solids intermediate 32 (as concentrated
butter), the
intermediate blend 46, the liquid/margarine blend 52, and/or the solidified
butter/margarine blend 56. However, the concentration of water and the
concentration of butterfat in the butter solids intermediate 32 is preferably
minimized, to the extent possible, consistent with the goal ofpreferably
maximizing
the amount of interfacial butter solids retained in the butter solids
intermediate 32
versus the amount of interfacial butter solids originally present in the feed
material
12. Furthermore, ifbutterfat 30 and/or byproduct butterfat 31 are removed
without
removing any water 24, addition of the optional emulsifying agents) may be
required to obtain the desired water-in-fat dispersion of the intermediate
blend 46
and the liquid butter/margarine blend 52.
Though the separator 28 is depicted as being located after the
evaporator 22 in the process 10, some or all removal of the butterfat 30
and/or the
byproduct butterfat 31 may optionally occur prior to water 24 removal. This
scenario would offer the advantage of reducing the amount of fluid needing to
be
heated to evaporate the water 24 in the evaporator 22. However, it is
presently
believed that evaporation of the water 24 prior to any butterfat 30 removal
and any
byproduct butterfat 31 may cause some added flavor development as a result of
short chain fatty acid cleavage from hydrolytic and/or hydrolysis reactions
occurring
during reflux contact between the butterfat and aqueous components of the feed
material 10 in the evaporator 22. It is thought that the short chain fatty
acids
resulting from this cleavage may add to the potent flavor profile realized in
butter
and butter/margarine blends produced according to the present invention.
Therefore, based upon this present understanding, it is preferred that most,
and
more preferably all, butterfat 30 removal and/or byproduct butterfat 31
removal
occurs after water 24 removal.
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After the reduced water-content material 26 has been split into
the butterfat 30, the byproduct butterfat 31, and the butter solids
intermediate 32,
the butterfat 30 is placed into the holding tank 34, which primarily functions
as an
accumulation tank. The composition of the butterfat 30 is typically not
modified
5 in the holding tank 34 and nothing is typically combined with the butterfat
30 in the
holding tank 34. The holding tank 34 is preferably jacketed and equipped with
a
temperature controller to permit heating and/or cooling of the tank 34
contents and
consequent maintenance of the butterfat 30 in the tank 34 as a liquid in a
desired
temperature range, such as at a temperature in the range of about 105°F
(about
10 40.6°C) to about 120°F (about 48.9°C).
After the reduced water-content material 26 has Been split into
the butterfat 30, the byproduct butterfat 31, and the butter solids
intermediate 32,
the butter solids intermediate 32 is placed into the holding tank 36, which
primarily
functions as an accumulation tank. The holding tank 36 is preferably jacketed
and
1 S equipped with a temperature controller to permit heating and/or cooling of
the tank
36 contents and consequent maintenance ofanybutterfat content ofthe butter
solids
intermediate 32 in the tank 36 as a liquid at an appropriate temperature; such
as at
a temperature in the range of about 105°F (about 40.6°C) to
about 120°F (about
48.9°C).
20 The composition of the butter solids intermediate 32 is typically
not modified in the holding tank 36 and nothing is typically combined with the
butter solids intermediate 32 in the holding tank 36. Nonetheless, salt may
optionally be added to, and dispersed within, the butter solids intermediate
32 in the
tank 36 to give the subsequently prepared intermediate blend 46 a desired salt
25 content that is typically in the range of about 1.2 weight percent salt to
about 1.8
weight percent salt, based on the total weight of the intermediate blend 46.
The salt
may be any food-grade salt, such as sodium chloride. The optional salt is
preferably
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26
added as part of an aqueous salt slurry to assist in homogeneously dispersing
the
salt within the butter solids intermediate 32.
After separation of the water 24, the butterfat 30, and/or the
byproduct butterfat 31 in the process 10, the butterfat 38, the butter solids
intermediate 40, and the optional non-dairy fat 44 may be selectively metered,
in
batchwise fashion, into the weigh and mix tank 42 at any ratio relative to
each
other. The relative amounts of butterfat 38, butter solids intermediate 40,
and non-
dairy fat 44 that are added to the weigh and mix tank 42 may be adjusted as
desired
to selectively attain desired properties in butter and butter-based products
produced
using the process 10. Preferably, however, the relative amounts of butterfat
38,
butter solids intermediate 40, and non-dairy fat 44 are selected to increase
the
concentration of interfacial butter solids in the liquid butter/margarine
blend 52,
relative to the concentration of interfacial butter solids in the butter used
as, or as
part of, the feed material 12.
The butterfat 38, the butter solids intermediate 40, and the
optional non-dairy fat 44 are preferably added to the tank 42 in a particular
sequence to avoid the potential of forming a fat-in-water emulsion since,
absent
proper sequencing, formation of a fat-in-water emulsion may occur even at high
liquid fat concentrations of 80 weight percent, or more, and low moisture
concentrations of 20 weight percent, or even less. To form the desired water-
in-fat
dispersion, rather than the undesired fat-in-water emulsion, the butterfat 38
and the
optional non-dairy fat 44 are preferably added to the tank 42 and placed at an
appropriate temperature, such as within the range of about 105 °F
(about 40.6°C)
to about 120 °F (about 48.9 °C), to maintain the butterfat 38
and any warm, optional
non-dairy fat 44 as liquids. The agitator (not shown) in the tank 42 is
activated to
homogeneously mix the warm butterfat 38 and the optional non-dairy fat 44.
With
the agitator still activated, the butter solids intermediate 40 is then
preferably added
to the mixture of the butterfat 38 and the optional non-dairy fat 44, under
high shear
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27
agitation, to form the intermediate blend 46. The butter solids intermediate
40
addition rate should be slow enough and the mixing conditions in the tank 42
should be aggressive enough to cause formation of the intermediate blend 46 as
the
water-in-fat dispersion, preferably with the preferred continuous liquid fat
phase.
The temperatures of the butterfat 38, the optional non-dairy fat
44, and the butter solids intermediate 40 may be selected to achieve a mixture
temperature in the tank 42 of about 105°F (about 40.6°C) to
about 120°F (about
48.9 °C) unless precrystalization of some fat is desired in the
intermediate blend 46.
Maintaining a lower temperature in each tank 42 on the order of about
80°F (about
26.7°C) to about 92°F (about 33.3°C) will typically cause
a small amount of
crystallizable fat in the intermediate blend 46 to be precrystalized as solid
fat
crystals in the continuous fat phase of the intermediate blend 46. When such
precrystalization is desired, the solid fat crystals preferably form to a
degree in the
continuous fat phase of the intermediate blend 46 that increases the viscosity
of the
continuous fat phase and consequently permits the continuous fat phase to
hinder,
and more preferably eliminate, coalescence of aqueous droplets. The
precrystalized
fat acts as nuclei that promote an increased rate of crystallization in the
crystallization equipment, such as the swept surface heat exchanger 54.
Alternatively, the intermediate blend 46 containing pre-crystalized fat, after
passing
through the blend tank S0, may be placed in tote or barrel packages for
subsequent
quiescent crystallization.
The butterfat 38, the optional non-dairy fat, and the butter solids
intermediate 40 that are added to the tank 42 are each heated to temperatures
that,
upon addition of the butter solids intermediate 42 to either the butterfat 38
or the
fat blend of the butterfat 38 and the optional non-dairy fat 44, (1) will
permit
uniform dispersion of the butter solids intermediate 40 in the butterfat 38 or
in the
fat blend and (2) will cause formation of the intermediate blend 46 as the
stable
water-in-fat dispersion that is preferably based on the continuous fat phase.
When
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28
precrystalization in the intermediate blend 46 is desired, the two objectives
noted
above along with the desired precrystalization may typically be achieved with
the
butterfat 38 or the fat blend at a temperature ranging from about 110°F
(about
43.3 °C) to about 125 °F (about 51.7 °C) and with the
butter solids intermediate 40
at a temperature ranging from about 60°F (about 15.6°C) to about
80°F (about
26.7 °C). Mixing the butterfat 38 or the fat blend and the butter
solids intermediate
40 that are within these temperature ranges will typically yield the
intermediate
blend 46 at a temperature ranging from about 80°F (about 26.7°C)
to about 92°F
(about 33.3°C) at typical blend ratios of the butterfat 38 or the fat
blend to the
butter solids intermediate 40. When precrystalization in the intermediate
blend 46
is not desired, the two objectives noted above along with the desired lack of
precrystalization may typically be achieved with the butterfat 38 or the fat
blend at
a temperature ranging from about 120 ° F (about 48.9 ° C) to
about 140 °F (about
60°C) and with the butter solids intermediate 40 at a temperature
ranging from
about 100°F (about 37.8°C) to about 120°F (about
48.9°C). Mixing the butterfat
38 or the fat blend and the butter solids intermediate 40 that are within
these
temperature ranges will typically yield the intermediate blend 46 at a
temperature
ranging from about 105 °F (about 40.6 °C) to about 120 °F
(about 48.9 °C) at typical
blend ratios of the butterfat 38 or the fat blend to the butter solids
intermediate 40.
Of course, the exact temperatures selected for the butter solids
intermediate 40, the butterfat 38 or the fat blend of the butterfat 38, and
the optional
non-dairy fat 44, respectively, to achieve (1 ) uniform dispersion of the
butter solids
intermediate 40 in the butterfat 38 or in the fat blend and (2) formation of
the
intermediate blend 46 as the stable water-in-fat dispersion depend upon at
least the
following factors: (1) the concentration of interfacial butter solids in the
butterfat
38 and in the butter solids intermediate 40, (2) the ratio of the butterfat
38, the
butter solids intermediate 40, and the optional non-dairy fat 44 to each other
in the
intermediate blend 46, (3) the nature of the non-dairy fat 44, (4) the fat
profile of
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29
butterfat 38 or of the blend of the butterfat 38 and any optional non-dairy
fat 44, (5)
mixing conditions (such as mixing severity and component temperatures) in the
tank 42, and (6) the concentration of any optional emulsifying agent in the
butterfat
38 or in the fat blend.
The weigh and mix tank 42 is preferably jacketed to permit
heating and cooling of the tank 42 to attain and maintain a desired
temperature of
components that are added to, and blended together in, the mix tank 42. The
process 10 may include a plurality of the tanks 42 that are arranged in
parallel with
each other. This permits filling and mixing to occur in one of the tanks 42
while
the contents of another of the tanks 42 are being transferred to the blend
tank 50 for
further processing. In one embodiment, each tank 42 has a capacity of about
600
gallons (about 2271 liters) and includes a center post agitator with agitation
enhancement baffles that are attached within the tank. Any conventional
agitation
mechanism may be employed in each tank 42, so long as mixing that is adequate
1 S to insure creation of the desired water-in-fat dispersion may occur in
each tank 42.
Additionally, each tank 42 preferably has a slanted, cone-shaped bottom to
permit
complete emptying of the tanks) 42. One suitable example of the tanks) 42 is
the
WPDA (600 gallon/2271 liter capacity) process tank that is available from
Waukesha Cherry-Burrell of Delavan, Wisconsin.
For the purpose of modifying the fat profile of the intermediate
blend 46, the optional non-dairy fat 44 may be substituted in the weigh and
mix
tank 42 for some of the butterfat 38 that would ordinarily be added to attain
a
particular concentration of fat in the intermediate blend 46. Thus, in
addition to
creating a product with an increased concentration of interfacial butter
solids, as
compared to the concentration of interfacial butter solids ordinarily present
in
butter, the process 10 may also be utilized to change the fat profile in the
product
from the fat profile originally present in the butter of the feed material 12.
Some
non-exhaustive examples of suitable non-dairy fats 44 include animal fats,
such as
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lard and beef tallow; plant fats, such as shortening, vegetable oil, and
tropical oils;
marine oils, such as kelp oil and seaweed oil; fish oil, such as menhaden oil;
and
any of these in any combination. Some non-exhaustive examples of suitable
vegetable oils include corn oil, peanut oil, soybean oil; canola oil, olive
oil, and any
S of these in any combination. Some non-exhaustive examples of suitable
tropical
oils include coconut oil, palm oil, palm kernel oil, and any of these in any
combination.
Any of the components of the non-dairy fat 44, if normally in the
liquid phase at a particular temperature, may be hydrogenated to harden the
non-
10 dairy fat 44 and thereby modify the viscosity and phase of the non-dairy
fat 44, as
desired. Furthermore, the non-dairy fat 44 may be selected to achieve desired
properties in the liquid butter/margarine blend 52 and in the solidified
butter/margarine blend 56. For example, the non-dairy fat 44 may be selected
to
achieve, upon mixing with the butter solids intermediate 40 and any added
butterfat
1 S 38 and subsequent processing in the process 10, a particular amount of
hardness or
softness iri the solidified butter/margarine blend 56 or to permit the liquid
butter/margarine blend 52 to serve as the final product of the process 10.
Thus,
after concentrating the interfacial butter solids in the butter solids
intermediate 32,
the non-dairy fat 44 may be selectively chosen and added to the tank 42 to
achieve
20 particular properties in the liquid butter/margarine blend 52 and/or in the
solidified
butter/margarine blend 56 that are desired by a particular customer or that
are more
suitable for a particular application of the liquid butter/margarine blend 52
or the
solidified butter/margarine blend 56.
Though it is permissible to add non-dairy fat 44 to the butter
25 solids intermediate 40 and any butterfat 38 that is added to the tank 42,
it is likewise
also permissible to add butter solids intermediate 40 and butterfat 38,
without
adding any non-dairy fat 44, to the tank 42. This alternative would produce
the
intermediate blend 46 with a concentrated level of interfacial butter solids,
as
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31
compared to the concentration of interfacial butter solids in the butter of
the feed
material 12, while maintaining the original fat profile of the butter of the
feed
material 12.
Though not depicted, it is permissible to add the non-dairy fat 44
S prior to the weigh and mix tank 42. For example, some or all of the non-
dairy fat
44 may be included as part of the feed material 12. Preferably, however, the
non-
dairy fat 44 is not included as part of the feed material 12, since this would
increase
the volume of the feed material 12 needing to be heated to effect evaporation
of the
water 24. Also, the non-dairy fat 44 may be added prior to removal of the
butterfat
30. However, the non-dairy fat 44 is preferably not added prior to removal of
the
butterfat 30, since this would increase the size needed for the separator 28
and
would make it challenging, if not impossible, to remove byproduct butterfat 31
in
the separator 28 without removing any non-dairy fat 44. Removal of a combined
fat stream containing both byproduct butterfat 31 and non-dairy fat 44 would
1 S typically be expected to diminish the market value of any byproduct
butterfat 31.
Similar considerations would apply if byproduct butterfat were removed from
the
butterfat 30 after separation of the butterfat 30 and the butter solids
intermediate 32
in the separator 28.
The weigh and mix tank 42 is ordinarily only used for blending
the butterfat 38, the butter solids intermediate 40, and the optional non-
dairy fat 44.
However, it is permissible to add aqueous ingredients and ingredients in
aqueous
solution at the weigh and mix tank 42, preferably after addition of the butter
solids
intermediate 40, so that these aqueous ingredients and aqueous solutions of
ingredients are incorporated as part of the water-in-fat dispersion that exits
the
weigh and mix tank 42 as the intermediate blend 46. One example of a suitable
aqueous ingredient is water. Some non-exhaustive examples of aqueous solutions
of ingredients include sweeteners, such as molasses and malt syrup.
Furthermore,
small amounts of liquid dairy materials, such as milk, cream, whey, whey
protein
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32
concentrate, and any combination of any of these, may be added to the weigh
and
mix tank 42 for incorporation into the water-in-fat dispersion for any desired
purpose, such as modifying the viscosity of the water-in-fat dispersion that
exits the
tank 42 as the intermediate blend 46.
After exiting the weigh and mix tank 42, the intermediate blend
46 is combined with the additives) 48 in the blend tank 50. Some non-
exhaustive
examples of the additives) 48 include coloring agent(s); vitamins and
minerals,
such as Vitamin A and betacarotene; other conventional additives to margarines
and
fat-based spreads; and any of these in any combination. The additives) 48 may
include any individual component or any combination of any of the components
at
any concentration. The combination of the intermediate blend 46 and the
additives) 48 is subjected to mild agitation in the blend tank 50 to blend the
additives) 48 into the water-in-fat dispersion (intermediate blend 46)
previously
formed in the tanks(s) 42.
The blend tank 50 is preferably jacketed and equipped with a
temperature controller to permit heating and cooling of the tank 50 and
consequent
maintenance of the components that are added to, and blended together in, the
blend
tank SO at a desired temperature. In the process 10, though only one of the
tanks
SO is typically required, two or more of the tanks 50 may be employed if
multiple
tanks 42 are used, since filling of the tank 50, processing of the components
in the
tank S0, and emptying of the tank SO ordinarily takes more time than each
cycle of
filling the tank 42 and forming the water-in-fat dispersion in the tank 42
that is
preparing the next batch for the tank S0. In one embodiment, the tank 50 has
the
same configuration as the tank 42 and has a capacity of about 600 gallons
(about
2271 liters. Therefore, one suitable example of the tank 50 is the WPDA (600
gallon/2271 liter capacity) process tank that is available from Waukesha
Cherry-
Burrell of Delavan, Wisconsin.
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After being formed in the tank 50, the liquid butter/margarine
blend 52 may be transferred to the crystallizing equipment, such as the swept
surface heat exchanger 54. In the swept surface heat exchanger 54, the liquid
butter/margarine blend 52, under heavy mechanical treatment and rapid cooling,
is
S supercooled and crystalized to transform the water-in-fat dispersion created
in the
tank 42 and maintained in the tank 50 into a water-in-fat matrix and to
stabilize and
work the water-in-fat matrix. One suitable example of the swept surface heat
exchanger 54 is the Votator~ 672DE swept surface heat exchanger that is
available
from Waukesha Cherry-Burrell of Delavan, Wisconsin. Though the swept surface
heat exchanger 54 is depicted in the process 10, any equipment, such as a
chilled
roller type of exchanger, that is capable of supercooling the water-in-fat
dispersion
from the tank 50 and causing crystallization of fat in the water-in-fat
dispersion to
form the water-in-fat matrix may be substituted in place of the swept surface
heat
exchanger 54.
As yet another alternative, the liquid butter/margarine blend 52
may be sent directly to the packing equipment 58, without undergoing the
cooling
and crystallization in the swept surface heat exchanger 54, in those
applications
where it is desired for the final packaged product to be in a liquid form. As
another
example, where the tank 42 has been operated at a lower temperature to attain
some
precrystalization of fat in the intermediate blend 46, and where this
precrystalization has been maintained or enhanced in the tank 50, fat in the
liquid
butter/margarine blend 52 may be permitted to complete the desired amount of
crystallization after being placed in packaging in the packing equipment 58.
The method of the present invention, such as the method utilized
in conjunction with the process I 0, permits conversion of the feed material I
2 that
is butter with a certain weight percent Y of interfacial butter solids, based
upon the
total weight of the butter, into concentrated butter having an interfacial
butter solids
concentration that has been increased, relative to the concentration of
interfacial
butter solids originally present in the butter, to any multiple, such as 1.1,
2.0, 2.5,
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34
3.0, 3.5, 4.0, etc., of the Y concentration of interfacial butter solids in
the butter of
the feed material 12. This is accomplished by removing sufficient water 24
and/or
butterfat 30 from the feed 12 followed by addition of a select amount of
butterfat
38 and/or non-dairy fat 44 to a select amount of the butter solids
intermediate 40 in
the weigh and mix tank 42.
Likewise, where the feed material 12 includes one or more
components in addition to butter, the method of the present invention, such as
the
method utilized in conjunction with the process 10, permits conversion of the
feed
material 12 containing a certain weight percent Z of interfacial butter
solids, based
upon the total weight of the feed 12, into a butter/margarine blend having an
interfacial butter solids concentration that has been increased, relative to
the
concentration of interfacial butter solids in the feed material 12, to any
multiple,
such as 1.1, 2.0, 2.5, 3.0, 3.5, 4.0, etc., of the Z concentration of
interfacial butter
solids in the feed material 12. This is similarly accomplished by removing
sufficient water 24 and/or butterfat 30 from the feed material 12 followed by
addition of a select amount of butterfat 38 and/or non-dairy fat 44 to a
select
amount of the butter solids intermediate 40 in the weigh and mix tank 42.
The water 24, the butterfat 30, and the byproduct butterfat 31 may
be removed in any ratio, relative to each other, to achieve a desired
concentration
of the interfacial butter solids in the butter solids intermediate 40.
Thereafter, the
butter solids intermediate 40 and the butterfat 38 may be blended together in
the
tank 42 in any ratio that is effective to achieve a desired concentration of
the
interfacial butter solids in the butter solids intermediate 40 that is
preferably greater
than the concentration of interfacial butter solids in the feed material 12.
Furthermore, if desired, non-dairy fat 44, such as any of the afore-mentioned
non-
dairy fats, may be added with the butterfat 38 or substituted in place of some
of the
butterfat 38 to modify the fat profile of the intermediate blend 46, as
compared to
the fat profile of the feed material 12.
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The net result is that butter-based products, such as concentrated
butter and butter/margarine blends, that contain a higher concentration of
interfacial
butter solids than in the feed material 12 may be produced using the process
10.
This is important, because it has been found that the phospholipids portion of
the
5 interfacial butter solids enhances the body of baked goods during the baking
process
and gives the rich characteristic "butter" flavor and mouthfeel to products
incorporating the intermediate blend 46 or products derived from the
intermediate
blend 46, without using any artificial flavoring to simulate the "butter"
taste.
Indeed, the ability to concentrate the interfacial butter solids in products
produced
10 in accordance with the present invention enhances the body yielding
capabilities,
beyond the enhancement provided by butter alone, during baking and enhances
the
butter taste and characteristic mouth-feel beyond that contributed by butter
alone,
prior to processing of the butter in accordance with the present invention.
Furthermore, the protein and lactose components of the interfacial
15 butter solids enhance the browning properties of products that include the
interfacial butter solids. Therefore, increasing the interfacial butter solids
concentration in the intermediate blend 46 and derivatives of the intermediate
blend
46, as compared to the concentration of interfacial butter solids present in
butter
prior to processing in accordance with the present invention, enhances the
browning
20 properties of goods incorporating butter-based products, such as
concentrated
butters and butter/margarine blends, that are prepared in accordance with the
present invention. Additionally, the ability to modify the fat profile and to
likewise
control the softness/hardness of butter-based products of the present
invention, such
as butter/margarine blends, by incorporating the non-dairy fat 44 in place of
some
25 of the butterfat originally present in the feed material 12, while
concentrating the
interfacial butter solids content compared to the original feed material 12,
generates
innumerable flexible use opportunities for butter-based products, such as
concentrated butters and butter/margarine blends, that are prepared in
accordance
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36
with the present invention, while retaining the enhanced butter flavor,
baking, and
browning properties of the butter/margarine blends of the present invention.
Finally, the ability to create butter-based products, such as
concentrated butters and butter/margarine blends, that exclude preservatives
and
include only natural ingredients, such as butter, salt, natural coloring
agents, and
natural, non-dairy fat, such as vegetable oil, permits marketers of butter-
based
products produced in accordance with the present invention to market these
butter-
based products as natural products having only natural ingredients on the
ingredient
list. When marketing these improved butter-base products, such as concentrated
butters and butter/margarine blends, there is often no need to include long
chemical
names for artificial ingredients, emulsifying agents, such as monoglycerides
and
diglycerides, and preservatives, such as potassium sorbate and sodium
benzoate,
since the concentrated butters and butter/margarine blends of the present
invention
may often be, and preferably are, produced without adding artificial
ingredients,
such as monoglycerides, diglycerides, potassium sorbate and sodium benzoate.
PROPERTY ANALYSIS AND CHARACTERIZATION PROCEDURE
Unless otherwise indicated, all determinations of moisture
concentration, fat concentration, salt concentration, and solids non-fat
concentration
are made in accordance with the following procedure. This procedure involves
the
sequential determination of moisture concentration, then the fat
concentration, then
the salt concentration, and finally the solids non-fat concentration on a
particular
sample. Specifically, a weighed sample is first heated to evaporate moisture
and
then is re-weighed to measure the moisture lost. Then, fat is extracted from
the
sample using petroleum ether, and the solids remaining in the sample are then
re-
weighed to determine the fat concentration. Next, the remaining sample is
dissolved in hot water and the salt concentration is determined by titration.
Finally,
the moisture concentration, the fat concentration, and the salt concentration
that
have been determined for the sample are subtracted from 100% to determine the
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37
solids non-fat concentration of the sample. These procedures for moisture
concentration, fat concentration, salt concentration, and solids non-fat
concentration
determination are detailed more fully below.
All samples are refrigerated at 4°C, unless being prepared for
sample analysis. Samples that are being prepared for analysis must first be
tempered to room temperature (about 20 ° C to about 25 ° C)
prior to sample analysis.
MOISTURE DETERMINATION
To determine the moisture concentration of an original sample,
a clean, dry aluminum beaker that has been tempered to room temperature (about
20°C to about 25 °C) is weighed on an analytical balance with a
sensitivity of 0.1
milligrams. The material to be sampled is then warmed and mixed to permit a
representative sample to be taken. This warming of the material to be sampled
may
be done by heating the material to be sampled in a water bath at a temperature
t5 between about 32°C and about 35°C. Care must be taken to
avoid any phase
separation in the sample. Phase separation of liquid butter will typically not
occur
initially and will be delayed for a period of time if the temperature of the
water bath
is held below about 43°C. Alternatively, the material to be sampled may
be
warmed at room temperature until the material reaches a consistency that
permits
mixing and subsequent sampling of the material.
About 10 grams of a well mixed sample (the "original sample")
is placed into the aluminum beaker and accurately weighed on the analytical
balance. The sample in the aluminum beaker is then heated on a hot plate or an
equivalent heat source, while swirling the sample continuously to avoid
spattering
and burning of any milk solids contained in the sample. Heating is continued
to
cause evaporation of water from the sample until all foaming and bubbling of
the
sample has stopped and any milk solids contained in the sample appear light
brown
in color.
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38
For oil and butterfat samples that contain little moisture,
evaporation of any moisture content may only take between about 30 and about
60
seconds. Care should be taken to obtain a uniform color between each sample
being analyzed for water concentration. If a dark brown color appears in the
sample
that is being heated, the milk solids content of the sample have been burned
and this
sample should be rerun.
After evaporation on the hot plate has been completed, the
aluminum beaker is cooled to room temperature (about 20°C to about
25°C).
Thereafter, the aluminum beaker and its contents are weighed on the analytical
balance and the weight is recorded as the "weight ofbeaker+ moisture-free
residue.
The weight percent of moisture in the sample, based on the total
weight of the sample, may be determined in accordance with the following
calculations:
1 S Weight of Original Sample = (Weight of beaker + original sample) - weight
of beaker)
(Weight of beaker + original sample) - (Weight of beaker + moisture free
residue)
Moisture =
_______________________________________________________________________________
___________________ X / 00
2o Weight of Original Sample
FAT ANALYSIS
The fat concentration of the original sample is then determined
by placing the aluminum beaker containing the moisture-free residue from the
25 moisture-determination step in a slanted beaker holder under an exhaust
hood.
Then, 100 milliliters of petroleum ether is measured into the aluminum beaker.
Next, the mixture of the sample and the added ether is stirred using a rubber
policeman to dissolve the fat contained in the sample. Stirring is then
stopped and
the sample is allowed to rest for at least about 3 minutes to penuit any
solids in the
30 sample to settle. Thereafter, using a vacuum source, the cther/fat mixture
is
carefully suctioned from the beaker, while being careful not to suction any of
the
milk solids that have dropped to the bottom of the beaker.
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39
Then, 75 milliliters of petroleum ether is measured into the beaker
and the contents of the beaker are again stirred with the rubber policeman to
dissolve additional fat. Stirnng is again stopped and the beaker is allowed to
rest
at least 3 minutes to permit solids to settle to the bottom of the beaker. The
vacuum
S source is again applied to suction the mixture of ether and fat from the
beaker,
while being careful not to suction any milk solids from the beaker.
Fifty milliliters of petroleum ether is placed into the beaker and
stirred again with the rubber policeman to dissolve any fat remaining in the
sample.
The beaker is allowed to rest at least three minutes to permit settling of any
solids
in the beaker. The vacuum apparatus is again applied to carefully suction the
mixture of fat and ether from the beaker, while again being careful not to
suction
any milk solids from the beaker.
The beaker is allowed to dry under the fume exhaust hood until
the beaker and its contents attain a constant weight, as determined by
measurement
1 S on the analytical balance. After the beaker has attained a constant
weight, the
weight of the beaker and its contents is determined and this weight is
recorded as
"weight of beaker + fat-free residue". Then, the weight percent of fat in the
original
sample, based upon the total weight of the original sample, is calculated
using the
following formula:
~ Fat = Weight of beaker-+ Moisture free residue)=- (Weight of beaker + fat
free residue) X l 00
Weight of Original Sample
SALT ANALYSIS
Reverse osmosis/distilled water is heated to a temperature of
about 65 °C to about 70°C. One hundred fifty (150) milliliters
of the heated water
is measured into the beaker containing the fat-free residue obtained in the
fat
analysis procedure. A rubber policeman is used to stir the contents of the
beaker
to dissolve the salt in the hot water. The beaker and its contents are allowed
to cool
to room temperature (about 20°C to about 25°C). A twenty-five
milliliter sample
of the water/salt mixture in the beaker is withdrawn and pipetted into a 125
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milliliter Erlenmeyer flask. To prevent withdrawal of milk solids from the
beaker,
the tip of the pipet must be held off of the bottom of the beaker while
withdrawing
the water/salt sample. Two to three drops of potassium chromate indicator are
placed in to the Erlenmeyer flask. The contents of the Erlenmeyer flask are
then
5 titrated with .01711N (normal) silver nitrate solution until the first
reddish-brown
color lasting 30 seconds is obtained in the sample being titrated. Thereafter,
the
weight percent of salt, based upon the total weight of the original sample, is
determined using the following formula:
milliliters of silver nitrate (AgN03)
10 % Salt = __________________________________________ X 100
Weight of Original Sample
SOLIDS NON-FAT DETERMINATION
15 After the weight percent of moisture, fat, and salt in the original
sample have been determined, these percentages are plugged into the following
formula to determine the weight percent of solids non-fat, based on the total
weight
of the original sample, that is contained in the original sample:
Solids non fat = 100% - (% Moisture + % Fat + % Salt)
GENERAL COMMENTS ABOUT THE FAT, MOISTURE, SALT, AND
SOL>DS NON-FAT DETERMINATIONS
The detection limit of this method for moisture, fat, salt, and
solids non-fat is 0.01 weight percent. Any results less than 0.01 weight
percent
should be reported as "less than 0.01 weigh percent". At least one duplicate
analysis that includes moisture, fat, salt, and solids non-fat should be
conducted
each day the analysis is performed. Also, at least one in every twenty samples
should be analyzed in duplicate for moisture, fat, salt, and solids non-fat.
Suitable
differences between duplicates are listed below:
Moisture: 0.30 weight percent
Fat: 0.40 weight percent
Salt: 0.10 weight percent
Solids non-fat: 0.10 weight percent
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PHOSPHOLIPIDS DETERMINATION
Unless otherwise indicated, all determinations of phospholipids
concentration are determined in accordance with the rapid high performance
liquid
chromatography (rapid HPLC method) that is set forth in the article entitled
Phospholipids in Milk and Dairy Products by W.W. Christie, R.C. Noble, and G.
Davies that appears in Volume 40, Number 1 of the Journal of the Science
ofDairy
Technology dated February, 1987. This Phospholipids in Milk and Dairy Products
article is consequently incorporated by reference in its entirety. All samples
to be
analyzed in accordance with this Phospholipids Determination procedure are
refrigerated at 4°C, unless being prepared for sample analysis. Samples
that are
being prepared for analysis in accordance with this Phospholipids
Determination
procedure should first be tempered to room temperature (about 20 ° C to
about
25 °C) prior to sample analysis.
EXAMPLES
The present invention is more particularly described in the
following Examples which are intended as illustrations only since numerous
modifications and variations within the scope of the present invention will be
apparent to those skilled in the art.
EXAMPLE 1
This example illustrates use of the process of the present
invention to transform a blend of salted butter and unsalted butter into a
butter/margarine blend. First, a butter mixture with a weight of about 3596
grams
that contained about 59 weight percent salted butter and about 41 weight
percent
unsalted butter, based on the total weight of the butter mixture, was placed
in a
heavy-bottom, stainless steel pan. The stainless steel pan was slowly heated
to melt
the blend of salted butter and unsalted butter. The moisture concentration of
the
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42
melted butter blend was determined to be about 17.2 weight percent, based on
the
total weight of the melted butter blend.
After determining the moisture concentration of the melted butter
blend, the stainless steel pan was further heated on low to bring the melted
butter
blend to a rolling boil. The boiling butter blend was agitated with a Type
RZR3 lab
mixer that may be obtained from Caframo, Ltd. of Wiarton, Ontario, Canada. The
Caframo lab mixer was operated at set point S. The Caframo lab mixer had a
four
blade mixer with an overall mixer blade diameter of 1-7/8 inches (4.76
centimeters). The four blade mixer was operated at about 1520 revolutions per
minute (rpm). While being agitated, the temperature of the boiling butter
blend
ranged from about 208°F (about 97.8°C) to about 218°F
(about 103.3°C). The
butter blend was agitated and boiled to remove water until the concentration
of
water in the boiling butter blend reached about 8.7 weight percent, based on
the
total weight of the boiling butter blend. Thus, about 326 grams of the
original 601
grams of water in the initial butter blend were removed, leaving about 276
grams
of water in the concentrated butter blend that resulted from boiling the
initial butter
blend.
The concentrated butter blend obtained by evaporating water was
then cooled and frozen overnight to help separate the aqueous phase of the
butter
blend from the fat phase of the butter blend. The following day, the frozen
concentrated butter blend was slowly reheated in the stainless steel pan to
liquify
the fat until the fat layer and aqueous layer fully stratified. Then, 2783
grams of
butterfat were extracted from the stratified concentrated butter blend to form
a
butter solids intermediate that contained primarily water, interfacial butter
solids,
butterfat, and salt. Thereafter, 755 grams of Cargill CV-65 canola oil
available
from Cargill Corporation of Minnetonka, Minnesota and 761 grams of the
withdrawn butterfat were combined and mixed to form a homogeneous fat mixture.
Next, under conditions of high shear mixing, the butter solids intermediate
was
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43
slowly added to the homogeneous fat mixture of the butterfat and canola oil to
form
a water-in-fat dispersion with a continuous fat phase.
After addition of the butter solids intermediate to the canola oil
and the butterfat, the water-in-fat dispersion was agitated while being cooled
to
S permit formation of the water-in-fat matrix characteristic of margarines and
butter
and to permit crystallization of the fat in the completed butter/margarine
blend.
Specifically, the mixture of the butter solids intermediate, the canola oil,
and the
butterfat was placed into a stainless steel beaker. The stainless steel beaker
was
then placed in an ice water bath. The Caframo type RZRI lab mixer was then
positioned proximate the beaker with the mixer blade located in the beaker.
The
mixer was then turned on at set point S at approximately 1520 rpm to convert
the
mixture into a water-in-fat dispersion and crystallize the butterfat. The
beaker was
rotated in a direction counter to the direction of the mixer blade rotation
and a
stainless steel spatula was used to continuously sweep solidified fat from the
inside
1 S surface of the beaker. This process was maintained until sufficient fat
had
solidified to form a fairly homogeneous mass.
The starting composition of the salted/unsalted butter blend and
the final composition of the completed butter/margarine blend, along with
component removal and additional details, are presented in Table l, which
appears
later in this example. Again, during the initial evaporation phase, 326 grams
of
water were removed from the aqueous phase of the melted butter blend.
Thereafter,
2783 grams of butterfat were removed and 755 grams of canola oil and 761 grams
of the withdrawn butterfat were added back to the in-process blend. Though no
data was obtained on the amount of interfacial butter solids initially present
in the
salted/unsalted butter blend or in the completed butter/margarine blend, it is
believed that all, or essentially all, of the interfacial butter solids
originally present
in the salted/unsalted butter blend remained in the butter/margarine blend,
since no
solids were removed during evaporation of the water and since no solids were
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44
visually observed to have been removed during extraction of the butterfat from
the
salted/unsalted butter blend.
TABLE 1
Feed Butter Components Product
Added
To
ComponentsButter
Composition RemovalSolids Composition
Intermediate
IngredientComponent (grams) Component
Wt Grams IngredientGrams Wt Grams
% %
Butter Water 17.20601.3325.5 a Water 14.48275.7
~
Butterfat80.292807 2783 Butterfat761 Butterfat41.25785
Salt 0.83 28.9 i ~ Salt 1.52 28.9
I"
SNF* 1.68 58.6 SNF* 3.08 58.6
~
l
Canola 755 Canola 39.67755
Oil Oil
TOTAL 100.003495.8 TOTAL 1516 TOTAL 100.001903.2
I
*: Solids Non-Fat
Samples of butter and samples of the butter/margariile blend
produced in accordance with this example were taste tested by a panel of
tasters.
The panel of tasters oveiwhelmingly preferred the taste of the
butter/margarine
blend to the taste of the butter because the butter/margarine blend had a
richer
butter taste than did the butter itself. This is believed due to the higher
interfacial
butter solids concentration in the butter/margarine blend, versus the
interfacial
butter solids concentration in the butter considered by the taste panel. The
taste
panel's preference of the butter/margarine blend over butter alone occurred
even
though the butter/margarine blend of this example, and thus the interfacial
butter
solids, were somewhat process abused during processing to form the
butter/margarine blend, since the butter was actually boiled to effect
evaporation of
water. Processing at reduced temperature conditions would be expected to
further
enhance the preference of the taste panel for the butter/margarine blend.
EXAMPLE 2
This example illustrates removal of butterfat and moisture from
unsalted butter along with subsequent addition of vegetable oil and salt to
form a
butter/margarine blend. First, 3500 pounds (about 1588 kilograms) of unsalted
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butter were melted in a steam jacketed melt tank at a temperature ranging from
about 120 °F (about 48.9 ° C) to about 140 °F (about 60
° C). The unsalted butter had
the composition listed in Table 2 below. The melted, unsalted butter was then
passed through a vacuum can that was maintained at about 28 inches (about 71
5 centimeters) of mercury vacuum. The melted unsalted butter was introduced
into
the vacuum can at a temperature of about 200°F (about 93.3 °C).
The vacuum can
had a capacity of about 100 to about 150 gallons (about 378 to about 568
liters) and
was a SENIORTM vacuum chamber that may be obtained from Kussell Equipment
Co. of Watertown, Wisconsin. Only about 20% of the volume of the vacuum can
10 was occupied by the melted unsalted butter at any one time. About 276
pounds
(about 125 kilograms) of water were removed from the melted unsalted butter in
the vacuum can.
The reduced-water content unsalted butter produced in the
vacuum can was then sent to a separator and permitted to separate into
butterfat and
15 butter solids intermediate. In this example, the separator was the BMRPX-
S314
separator that is available from Alfa- Laval Separation, Inc. This centrifuge
had a
bowl speed of about 5,000 revolutions per minute (rpm). Steam was injected
into
the reduced-water content unsalted butter prior to the separator to maintain a
minimum temperature of about 150°F (about 65.6°C) at the inlet
to the separator.
20 This steam injection was determined to have added about 27 pounds (about
12.2
kilograms) of water to the reduced-water content unsalted butter prior to the
separator.
In the separator, the reduced-water content unsalted butter
(including the added 27 pounds (about 12.2 kilograms) of steam injection
water)
25 was split into about 2,832 pounds (about 1285 kilograms) of butterfat and
about
419 pounds (about 190 kilograms) ofbutter solids intermediate. The butterfat
and
butter solids intermediate were each routed to separate storage tanks.
Thereafter,
800 pounds (about 363 kilograms) of HM 1019 oil blend and 800 pounds (about
363 kilograms) of the withdrawn butterfat were combined in a mix tank and were
30 mixed to form a homogeneous fat mixture. HM-1019 oil blend is a blend of
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46
partially hydrogenated soybean oil and partially hydrogenated cottonseed oil
that
is available from Harvest States Coop of Mankota, Minnesota. Next, under
conditions of high shear mixing in the mix tank, about 352 pounds (about 160
kilograms) of the butter solids intermediate (about 306 pounds (about 138
S kilograms) of water (and phospholipids) and about 46 pounds (about 20.8
kilograms) of solids non-fat} was slowly added to the homogeneous fat mixture
of
the butterfat and the HM 1019 oil blend to form a homogeneous water-in-fat
dispersion with a continuous fat phase. Then, about 35.8 pounds (about 16.2
kilograms) of salt were combined with the water-in-fat dispersion in the mix
tank.
In this example, the high shear mixing was accomplished using a center post
agitator and side mounted baffles that were mounted within the mix tank.
Additionally, about 2.7 grams ofbetacarotene and about 29 grams
of Vitamin A were added to the mix tank. The contents of the mix tank were
maintained at a temperature of about 115 °F (about 46.1 °C) and
blended in the mix
tank using the agitator to attain the homogeneous water-in-fat dispersion.
This
dispersion was transferred from the mix tank to a blend tank where the
dispersion
was maintained using an agitator and baffle like those in the mix tank.
Additionally, the dispersion was maintained at a temperature of about 115
°F (about
46.1 °C) in the blend tank. a
The dispersion was pumped from the blend tank through a two-
barrel swept surface heat exchanger, a Votator~ 672DE swept surface heat
exchanger that is available from Waukesha Cherry-Burrell, to more fully
develop
the water-in-fat dispersion, crystalize fat, and thereby form a
butterJmargarine blend
in accordance with the present invention. The swept surface heat exchanger had
both a lower barrel and an upper barrel. The lower barrel predominantly
accomplished crystallization of fat in the water-in-fat dispersion, and the
upper
barrel thereafter worked the product of the lower barrel. The exit temperature
of
the lower barrel was about 80°F (about 26.7°C) and the exit
temperature of the
upper barrel, after working, was set at about 60 °F (about 15.6
°C). The lower barrel
was operated at about S50 to about 600 revolutions per minute, whereas the
upper
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barrel was found to cause minimal lumping and produce a smooth product at an
operating speed of about 510 revolutions per minute.
The composition of the butter used as feed in this example and
the composition of the butter/margarine blend product produced in this
example,
along with details about component removal from the butter feed and component
addition to the butter solids intermediate are present in Table 2 below:
TABLE 2
Feed Pounds Components Product
of Added
To
Butter Butter
Solids
Intermediate
Composition Component Composition
IngredientComponent Removal Component
Wt Pounds(kg) IngredientPounds Wt Pounds
/ %
(kg) (kg) (kg)
ButterWater 17.75612.5276 Water 15.40306.25
(-278)(-125) (-)
Butterfat82.102832 2832 Butterfat800 Butterfat40.24800
.
(-1285)(-1284) (-363) (-363)
Salt 0.00 0 Salt 35.8 Salt 1.81 35.8
(0) (-16) (-16)
SNF* 0.15 55.1 SNF* 2.31 46
(--25) (-21
)
Oil** 800 Oil** 40.24800
(-363) (-363)
TOTAL 100.003499.6 TOTAL 1636 TOTAL 100.001988.05
-.
(-1588)~ ~ (_742)I I (-902)
* : Solids Non-Fat
** : HM 1019 oil blend
In addition to the details provided in Table 2, it was determined that the
interfacial
butter solids produced at the separator weighed about 419 pounds (about 190
kilograms) and included about 55.5 pounds (about 25.2 kilograms) of solids non-
fat
and about 336.5 pounds (about 152.6 kilograms) of water (and phospholipids).
Of
this 419 pounds (about 190 kilograms) ofbutter solids intermediate, only about
352
pounds f about 46 pounds (about 20.8 kilograms) of solids non-fat and about
306
pounds (about 139 kilograms) ofwater (and phospholipids)} were added to the
mix
tank. The remaining 67 pounds (about 30.3 kilograms) ofbutter solids
intermediate
produced at the separator and about 2,030 pounds (about 921 kilograms) of
butterfat produced at the separator were discarded and not used in forming the
butter/margarine blend product of this example.
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EXAMPLE 3
This example illustrates removal of butterfat and moisture from
lightly salted butter along with subsequent addition of vegetable oil to form
a
butter/margarine blend. First, 2200 pounds (about 998 kilograms) of salted
butter
were melted in a steam jacketed melt tank at a temperature ranging from about
120°F (about 48.9°C) to about 140°F (about 60°C).
The lightly salted butter had
the composition listed in Table 3 below. The melted butter was then processed
through the third effect of a triple effect evaporator that was maintained at
about 25
inches (about 63.5 centimeters) of mercury vacuum. The melted butter was
introduced into the evaporator at a temperature of about 136°F (about
57.8°C).
This third effect of the triple effect evaporator was actually a
finishing effect for small volumes that followed a larger double effect
evaporator.
The double effect evaporator was not used in this example. Only the finishing
effect (the third effect) was used for water evaporation from the melted
butter in
this example. This finishing effect evaporator was a falling film evaporator
that is
available from Marriott Walker Corporation of Birmingham, Michigan. Vacuum
on this falling film evaporator was provided by a thermal compressor that is
available from Croll-Reynolds Company of Westfield, New Jersey. The evaporator
removed approximately 292 pounds (about 132.5 kilograms) to about 300 pounds
(about 136 kilograms) of water from the melted butter.
The reduced-water melted butter was then sent to a separator to
permit splitting of butterfat and a butter solids intermediate. The butter
solids
intermediate contained most of the interfacial butter solids from the reduced-
water
melted butter. The separator in this example was a 500 gallon (1892 liter)
jacketed
steel tank equipped with a cone-shaped bottom. Thus, gravity separation was
used
to split the butterfat and the butter solids intermediate in this example.
Approximately 1,200 pounds (about 544 kilograms) to 1,250 pounds (about 567
kilograms) of butterfat was removed from the separator tank. The butter solids
intermediate that was removed from the separator was routed to a storage tank.
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After the partial butterfat removal, the remaining contents (as
butterfat) of the separator tank were sent to a mix tank. This mix tank had a
cone-
shaped bottom and a capacity of about 500 gallons (about 1892 liters). The mix
tank also had a center-mounted agitator and tank-mounted baffles. In the mix
tank,
244 pounds (about 110.7 kilograms) of HM508 oil blend and 131 pounds (about
59.4 kilograms) of liquid soybean oil were combined with the butterfat
contents
transferred from the separator tank to form a homogeneous fat blend. The HM508
oil blend is a partially hydrogenated soybean oil that is available from
Harvest
States Coop of Mankato, Minnesota. Thereafter, under conditions of high shear
mixing in the mix tank, the butter solids intermediate that was removed from
the
reduced-water melted butter in the separator was slowly added to the
homogeneous
fat blend ofthe butterfat and the HM508 oil blend to form a homogeneous water-
in
fat dispersion with a continuous fat phase. In this example, the high shear
mixing
was accomplished using the center post agitator and side mounted baffles that
were
1 S mounted within the mix tank.
The water-in-fat dispersion was transferred from the mix tank to
a swept surface heat exchanger. In this example, the swept surface heat
exchanger
was a two-barrel Votator~ 672DE swept surface heat exchanger that is available
from Waukesha Cherry-Burrell of Delavan, Wisconsin. Using ammonia as the
cooling medium, the swept surface heat exchanger was operated to crystalize
the
fat in the water-in-fat dispersion to transform the water-in-fat dispersion
into a
water-in-fat matrix and subsequently work the water-in-fat matrix. The
composition of the butter feed and the composition of the product produced in
this
example, along with details about component removal and component addition,
are
presented in Table 3 below.
The water removal number of 219 pounds (about 99.3 kilograms)
in Table 3 does not reflect the actual measured amount of water removed from
the
butter for at least a couple of reasons. First, about 133 extra pounds (about
60.3
kilograms) ofwater were inadvertently added to the melted butter during
processing
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through the evaporator. It is believed that the water was either added to the
melted
butter during transfer of the melted butter to the evaporator or in the
evaporator
itself. Secondly, some of the materials being transferred from the mix tank to
the
exchanger were left in the transfer line after processing was complete in the
5 exchanger. This loss of water during exchanger processing and the gain of
water
proximate the evaporator are believed to be reflected in the 219 pounds (about
99.3
kilograms) of water removal that is shown in Table 3, versus the observed
water
removal of about 292 pounds (about 132.5 kilograms) to about 300 pounds (about
136 kilograms) in the evaporator.
10 Additionally, salt removal and solids non-fat removal are shown
in Table 3. This removal of salt and solids non-fat is believed attributable
to
material remaining in the transfer line from the mix tank to the exchanger
following
production of the butter/margarine blend in the exchanger. Similarly, the fat
removal number of 1,398 pounds (about 634 kilograms) in Table 3 is larger than
15 the observed removal of about 1,200 pounds (about 544 kilograms) to about
1,250
pounds (about 567 kilograms) of butterfat. This difference in butterfat
removal is
likewise believed attributable to line losses similar to the noted line loss
of salt and
solids non-fat.
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TABLE 3
Feed Pounds Components Product
of Added
To
Butter
Butter
ComponentSolids
omposition omposition
Component RemovalIntermediate Component
Ingredient (fig)
Wt% Pounds IngredientPounds Wt/ Pounds
(kg) (kg) (kg)
Butter Water 14.71323.6219 Water 11.09104.6
(-147)(-99) (-47)
Butterfat82.961825 1398 Butterfat427 Butterfat45.29427
(-828)(-634) (-194) (-194)
Salt 0.88 19.4 3.7 Salt 1.67 1
S.7
(-8) (-2) (-7)
SNF" 1.45 32 SNF* 2.18 20.6
(-l4) ('9)
Oil'**131 Oil*** 13.89131
(-60) (--GO)
Oil*'*'244 Oil****25.88244
(-111) ('111)
TOTAL 100.002200 1620.7 TOTAL 802 TOTAL 100.00942.9
('998)(-73S) (-364)I I (--428)
* . Includes approximately 133 pounds (about 60.3 kilograms) of process water
that was inadvertently
added to the cream feed during transfer of the cream feed to the evaporator
** . Solids Non-Fat
1$ *** : liquid soybean oil
****: HM508 oil blend
The butter/margarine blend produced iwthis example was taste
tested by a panel of tasters and was also incorporated into baked goods. The
panel
of taste testers preferred the butter/margarine blend of this example over
Grade AA
salted butter, because the butter/margarine blend had a richer butter taste
than even
the Grade AA salted butter. Also, the taste panel observed that the
butter/margarine
blend had an improved mouth-feel even compared to the mouth-feel of Grade AA
salted butter. Additionally, it was observed that the butter/margarine blend
was
easier to spread on bread than Grade AA salted butter that had not been
presoftened.
Finally, when baking using the butter/margarine blend, it was observed that
the
butter/margarine blend produced enhanced body in baked goods, as compared to
the
body of baked goods that incorporated Grade AA salted butter, and also
increased
the uniformity and rate at which the baked goods browned, as compared to baked
goods incorporating Grade AA butter.
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COMPARATIVE EXAMPLE NO. 1
In this comparative example, an attempt was made to produce
margarine by starting with cream containing 40 weight percent milk fat, based
upon
the starting weight of the cream, instead of starting with churned butter, to
create
a margarine. In Table 4 below, the pounds of water shown for the cream feed
(40
wt% fat) is about 400 pounds (about 181.4 kilograms) greater than for the
cream
feed alone because approximately 400 pounds (about 181.4 kilograms) of process
water was inadvertently added to the cream feed during transfer of the cream
feed
to the evaporator.
The cream was fed to a falling film evaporator, similar to the
falling film evaporator used in Example 3, that is available from Marriott
Walker
Corporation of Birmingham, Michigan. Vacuum on this falling film evaporator
was provided by a thermal compressor that is available from Croll-Reynolds
Company of Westfield, New Jersey. The cream was introduced into the evaporator
at a temperature of about 136°F (about 57.8°C). After water was
removed in the
evaporator, the reduced moisture cream was placed in a mix tank and combined
with some hydrogenated soybean oil and some liquid soybean oil, along with
some
salt.
Thereafter, the mixture of reduced moisture cream and soybean
oil was blended using an agitator in the mix tank to form a homogeneous water-
in-
fat/oil dispersion. The water-in-fat/oil dispersion was then transferred to a
crystalizing exchanger. In this comparative example, the crystalizing
exchanger
was a Votator~ 672DE swept surface heat exchanger available from Waukesha
Cherry-Burrell. The water-in-fat/oil dispersion was processed through the
swept
surface heat exchanger to an outlet temperature of about 58°F (about
14.4°C).
The composition of the cream used as feed in this comparative
example, and the product composition, along with component removal and
addition
details, are presented in Table 4 below. The intended amount of water removal
in
this comparative example was less than the actual amount of water removal that
is
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53
shown in Table 4 as being removed. Approximately 400 pounds (about 181.4
kilograms) of extra water was removed in the evaporator to compensate for the
approximately 400 pounds (about 181.4 kilograms) of process water that was
inadvertently added to the cream feed to the evaporator. Also, some unintended
butterfat removal, along with some unintended water removal, occurred as a
result
of line losses between the mix tank and the crystalizing exchanger.
Furthermore,
some solids non-fat removal likewise occurred due to line losses in the line
connecting the mix tank and the crystalizing exchanger.
TABLE 4
Feed Pounds Components Product
of Added
To
The
Concentrated
Composition ComponentCream Composition
Feed
IngredientComponent Removal Component
Wt Pounds IngredientPounds Wt% Pounds
%
(k8) (kg) (k8) (kK)
Cream* Water 67.98964* 853.2 Water 12.80110.8
(--436)(-296) (-50)
Butterfat28.21400 52 Butterfat0 Butterfat40.19348
(-181)(-24) (0) (-158)
Salt 0.00 0 Salt 13.4 Salt 1.55 13.4
(0) ! r'~~. (-6) (-6)
SNF** 3.81 54 SNF** 5.28 45.7
(-24) (-21)
Oil***226 Oil*** 26.10226
(-102) (-102)
Oil****122 Oil****14.08122
(-55) (-55)
TOTAL 361.4 0 6
I ~ . .
(-643)~ I (-163) I (-392)
I
* . Includes approximately 400 pounds (about 181.4 kilograms) of process water
that was inadvertently
added to the cream feed during transfer of the cream feed to the evaporator
** . Solids Non-Fat
*** : hydrogenated soybean oil
****: liquid soybean oil
This comparative example yielded two striking observations.
First, during processing of the cream in the evaporator, it was observed that
significant fouling and clogging occurred in the evaporator. This is believed
to be
a result of the aqueous phase of the cream containing an excessive amount of
solids
as evaporation of water proceeded, since a much larger percentage of incoming
water must be evaporated from cream containing 40 weight percent fat, as
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54
compared to the amount of water to be evaporated from butter, to achieve a
similar
fat/water ratio in the completed product.
Furthermore, the initial concentration of solids in cream
containing 40 weight percent fat is significantly higher than the
concentration of
comparable solids in butter, since churning of cream to form butter removes,
in the
buttermilk product of the churning process, a significant amount of solids
from the
incoming cream being churned. The evaporator clogging problem significantly
reduced the flow rate of cream through the evaporator as fouling and clogging
increased in the evaporator during the run. Nonetheless, some flow of reduced
water cream through the evaporator did continue so that margarine was
ultimately
able to be formed in the crystallizing exchanger.
When provided to a taste panel, the tasters found that the
margarine produced in this comparative example had a flavor that was not
acceptable. Specifically, the flavor of the margarine, as compared to the
flavor of
butter, was merely milky, had a greatly diminished fatty taste or mouth-feel,
and
virtually no butter flavor, as compared to butter. Thus, this comparative
example
demonstrates that it is not feasible or acceptable to use cream that has not
been
churned into butter, as a substitute for butter, in or as the feed material 12
of the
present invention.
Although the present invention has been described with
reference to preferred embodiments, workers skilled in the art will recognize
that
changes may be made in form and detail without departing from the spirit and
scope of the invention.
