U.S. patent application number 09/776809 was filed with the patent office on 2001-09-27 for low-fat snacks having improved eating qualities and dough compositions used to prepare low-fat fabricated snacks.
Invention is credited to Brower, S. Michelle, Reed, Jada Dawn, Seiden, Paul, Villagran, Maria Dolores Martinez-Serna, Zimmerman, Stephen Paul.
Application Number | 20010024674 09/776809 |
Document ID | / |
Family ID | 22043604 |
Filed Date | 2001-09-27 |
United States Patent
Application |
20010024674 |
Kind Code |
A1 |
Villagran, Maria Dolores
Martinez-Serna ; et al. |
September 27, 2001 |
Low-fat snacks having improved eating qualities and dough
compositions used to prepare low-fat fabricated snacks
Abstract
Low-fat fried snacks which have reduced waxiness, improved
crispness and increased mouthmelt. The low-fat snacks are made from
dough compositions comprising starch-based materials, water and a
unique emulsifier-lipid composition. Use of the emulsifier-lipid
composition system in the dough provides textural and flavor
advantages in the finished snack, and improved theological
properties in the dough used to make the fabricated snacks. The
emulsifier composition comprises a specific blend of a
mono-diglyceride component or distilled monoglyceride, a
polyglycerol ester component and a fat component. The low-fat fried
fabricated snacks of the present invention can be formulated to
comprise from about 0.84 grams digestible fat/1 oz. serving to less
than about 0.5 grams digestible fat/1 oz. serving and are
texturally distinguishable from fabricated snacks typically fried
in a non-digestible fat.
Inventors: |
Villagran, Maria Dolores
Martinez-Serna; (West Chester, OH) ; Zimmerman,
Stephen Paul; (Wyoming, OH) ; Reed, Jada Dawn;
(Cincinnati, OH) ; Seiden, Paul; (Cincinnati,
OH) ; Brower, S. Michelle; (Cincinnati, OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY
PATENT DIVISION
IVORYDALE TECHNICAL CENTER - BOX 474
5299 SPRING GROVE AVENUE
CINCINNATI
OH
45217
US
|
Family ID: |
22043604 |
Appl. No.: |
09/776809 |
Filed: |
February 5, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09776809 |
Feb 5, 2001 |
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09174990 |
Oct 19, 1998 |
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6228414 |
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60062607 |
Oct 20, 1997 |
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Current U.S.
Class: |
426/550 ;
426/637; 426/808 |
Current CPC
Class: |
A23L 19/19 20160801;
A23D 9/013 20130101; A23L 7/117 20160801; Y10S 426/808 20130101;
A23L 7/13 20160801 |
Class at
Publication: |
426/550 ;
426/808; 426/637 |
International
Class: |
A23L 001/216 |
Claims
1. A fabricated snack made from a dough composition comprising: a)
from about 50% to about 70% starch-based material; b) from about
20% to about 50% added water; and c) from about 0.5% to about 8.0%
of an emulsifier-lipid component comprising; (i) from about 2.0% to
about 40% of a mono-diglyceride component comprising from about 30%
to about 98% monoglyceride and less than 50% free glycerine; (ii)
from about 0.5% to about 40% of a polyglycerol ester component
comprising less than 50% free glycerine and having from about 2 to
about 10 glycerol units per polyglycerol moiety and from about 5%
to about 60% monoester; and (iii) from about 60.0% to about 97.5%
fat, wherein the snack comprises less than 9% surface fat having a
viscosity of 10 cp.sup.3.
2. The fabricated snack of claim 1 further comprising from about
0.5% to about 6% moisture and from about 20% to about 38% fat.
3. A fabricated snack of prepared from the dough of claim 8 wherein
the dough has a G' from about 5.0 kPa to about 30 kPa.
4. The fabricated snack of claim 2 wherein the snack has an
internal structure comprising a multiplicity of internal voids and
a total internal void area of at least 21%.
5. The fabricated snack of claim 4 wherein the internal voids have
a void size from about 0.1 to about 1.5.
6. The fabricated snack of claim 4 wherein at least 25% of the fat
is distributed across the internal void area.
7. The fabricated snack of claim 4 wherein the fabricated snack is
a chip.
8. A fabricated chip according to claim 16 wherein the fat is a
non-digestible fat or triglyceride.
9. A dough composition comprising: a) from about 50% to about 70%
starch-based material; b) from about 20% to about 50% added water;
and c) from about 0.5% to about 8.0% of an emulsifier-lipid
component comprising; (i) from about 2.0% to about 40% of a
mono-glyceride component comprising from about 30% to about 98%
monoglyceride and less than 2.0% free glycerine; (ii) from about
0.5% to about 40% of a polyglycerol ester component comprising less
than 50% free glycerine and having from about 2 to about 10
glycerol units per polyglycerol moiety and from about 5% to about
60% monoester; and (iii) from about 60.0% to about 97.5% fat.
10. The dough of claim 9 wherein the fat is a non-digestible
fat.
11. The dough composition of claim 9 wherein the monoglyceride is a
mono-diglyceride, distilled.
12. The dough composition of claim 9 wherein the monoglyceride
component is a mono-diglyceride.
13. The dough composition of claim 12 wherein the distilled
monoglyceride comprises from about 80% to about 95% monoglyceride
and wherein the polyglycerol ester comprises less than 25% free
glycerine.
14. The dough composition of claim 13 wherein the starch-based
materials are selected from the group consisting of potato flakes,
potato granules, rice flour, potato flour, modified starch,
pregelatinized starch, wheat starch, waxy corn starch, waxy rice
starch and mixtures thereof.
15. The dough composition of claim 14 further comprising at least
about 3% hydrolyzed starch having a DE of from about 5.0 to about
30.
16. The dough composition of claim 15 wherein the potato flakes
comprise from about 16% to about 27% amylose and a water absorption
index of from about 6.7 to about 9.5 grams of water per gram of
flake and wherein the potato granules comprise from about 9% to
about 13% amylose and have a water absorption index of from about
4.0 to about 7 grams of water per gram of granule.
17. The dough composition of claim 11 wherein the dough is
sheetable and wherein the dough has a sheet strength of from about
140 gf to about 250 gf.
18. The dough composition of claim 12 wherein the dough is
sheetable and wherein the dough has a sheet strength of from about
140 gf to about 250 gf.
19. The dough composition of claim 15 wherein the dough is
sheetable and wherein the dough has a sheet strength of from about
140 gf to about 250 gf.
Description
[0001] This Application claims priority to Provisional Application
Ser. No. 60/062,607 filed on Oct. 20, 1997.
BACKGROUND
[0002] The problems of waxiness, slower mouthmelt and reduced
crispness that are characteristic of snacks fried in non-digestible
fats are well known. These problems are believed to be caused by
solids crystallizing in the non-digestible fat that are absorbed by
the snack during frying. The non-digestible fat is absorbed by the
snack during frying in a liquefied state. As the snack cools,
crystallization of the intermediate-melting and low-melting fats
occur, and the solids formed as a result of crystallization alter
the organoleptical properties of the snack, for example, crispness,
waxiness impression and mouthmelt.
[0003] Several methods of reducing the waxiness problem associated
with snacks fried in non-digestible fats have been recognized and
disclosed in the art (see European Patent Application 236,288 to
Bernhardt, published Sept. 9, 1986). Representative of these
methods include modifying the non-digestible fat composition (see
U.S. Pat. No. 5,085,884 to Young, issued Feb. 4, 1992), combining
the non-digestible fat with increasing levels of triglyceride fat
(see European Patent Application 233,856 to Bernhardt, published
Aug. 26, 1987), altering the composition of the dough (see U.S.
Pat. No. 5,464,642 to Villagran et al, issued Nov. 7, 1995), and
removing excess fat from the snack by stripping with supercritical
steam (see U.S. Pat. No. 5,171,600 to Young et al. issued Dec. 15,
1992).
[0004] Prior attempts by food formulators to produce low-fat snacks
having a crisp texture and reduced waxiness have generally not been
successful, insofar as avoiding undesirable textural changes that
occur during frying. Additionally, food formulators have had
limited success with reducing the waxiness impression of the snack
without the use of stripping techniques. Because the non-digestible
fat compositions generally have a viscosity higher than that of
triglycerides and comprise intermediate-melting and low-melting
fats, the products depending on the dough composition tend to
expand and collapse uncontrollably during frying. Further, the
viscous fat tends to remain on the surface of the snack and tends
to be poorly distributed within the internal structure of the
snack. Another problem discovered is that the internal structure of
snacks made from many dough compositions tend to form either large
internal voids which result in snacks having a dense, hard and
glassy texture or small voids which results in snacks having foamy
(Styrofoam-like) texture.
[0005] Products with large voids correspondingly have larger,
uninterrupted regions of solid matter creating a denser, harder
mass. A cross section of these products can be visually
characterized by tunnel like voids surrounded by thick regions of
dense mass where the cross-sectional area of a single void can have
a size that is about 2.0% to about 4.0% of the total cross
sectional area of the product.
[0006] Snack products with an internal structure consisting
primarily of small voids where the cross-sectional area of single
void has a size less than 0.1% of the total cross-sectional area of
the product will display a foamy texture due to the elastic
resistance provided by the thinner, less rigid mass arranged in a
uniform sequence. The cross-sectional appearance of this product is
characterized by numerous small voids surrounded by small regions
of mass with thicknesses on the same order of magnitude as the void
sizes. The foamy internal structure promotes over-hydration of the
starch leading to a gummy texture. It has been found that these
structures are particularly prevalent when the doughs used to
produce the snacks have the improper viscoelastic properties and
when insufficient amylose is bound, insufficient water is
distributed/available in the dough during frying, and/or when
insufficient fat is distributed in the dough. Ideally, the internal
structure of a snack will have a homologous mixture of small to
large voids randomly dispersed to provide sufficient strength for
crispness, but with lower localized solid mass density.
[0007] Accordingly, it is an object of this invention to provide
low-calorie fabricated snacks having a unique structure.
[0008] Another object of object of the invention is to provide
reduced-calorie and low-calorie farinaceous snacks having improved
organoleptical properties (e.g., increased mouthmelt, substantially
reduced waxiness impressions and substantially improved
crispness).
[0009] Still another object of the invention is to provide dough
compositions used to prepare low-fat snacks.
[0010] These and other objects of the invention will become
apparent hereafter.
SUMMARY OF THE INVENTION
[0011] The present invention relates to fried low-fat fabricated
snacks and dough compositions used to prepare low-fat snacks. The
snacks have a novel structure distinct from that of other low-fat
fabricated snacks fried in compositions comprising non-digestible
fat. The snacks are prepared from a farinaceous dough.
[0012] The low-fat snack has improved crispness, reduced waxiness
and increased mouthmelt. The improved texture (e.g. crispness) and
mouthmelt is achieved by controlling the internal structure of the
fried snack. The expanded structure serves as a means for
distributing fat throughout the internal structure and limits the
amount of fat remaining on the surface of the snack.
[0013] The snacks of the of the present invention comprise
non-digestible fat, less than 40% digestible fat, and less than
9.0% of fat having a viscosity of greater than 103 cp remain on the
surface of the fabricated snack.
[0014] Snacks of the present are low-fat fried snack and comprise a
multiplicity of individual internal voids. The low-fat snacks have
a thickness of from about 0.02 to about 0.20 in. The low-fat fried
snacks comprise:
[0015] A) from about 0.5% to about 6% moisture
[0016] B) from about 20% to about 38% non-digestible fat;
[0017] The most preferred dough compositions for delivering the
structural, textural and organoleptical benefits of the present
invention comprise:
[0018] A) from about 50% to about 70% of a starch-based material
comprising,
[0019] i) at least about 0.2% modified starch wherein any dried
modified starches present have a water absorption index of from
about 0.4 to about 8.0 grams of water per gram of modified
starch;
[0020] ii) at least about 3.0% hydrolyzed starches having a D.E.
value of from about 5 to about 30;
[0021] iii) up to about 96.8% potato flakes having a water
absorption of from about 6.7 to about 9.5 grams of water per gram
of starch;
[0022] provided that if any other starch-containing ingredient is
present in the starch-based material other than potato flakes, the
other starch-containing ingredient has a water absorption index
below that of the potato flakes;
[0023] B) from about 30% to about 50% added water; and
[0024] C) from about 0.5% to about 8% of an emulsifier-lipid
composition comprising:
[0025] i) from about 2.0% to about 40% of monoglycerides component
comprising,
[0026] (a) from about 60% to about 98% monoglycerides;
[0027] (b) less than 2% free glycerine;
[0028] (c) the balance being diglycerides with small amounts of
triglycerides;
[0029] ii) from about 0.5% to about 40% of a polyglycerol ester
component comprising,
[0030] (a) less than 50% free polyol glycerine;
[0031] (b) from about 2 to about 10 glycerol units per polyglycerol
moiety wherein less than 40% of their hydroxyl groups are
esterified with mytistic acid, palmitic acid, stearic acid, or
mixtures thereof; and
[0032] iii) from about 60% to about 97.5% fat.
[0033] The snack products, if fried in fat consisting essentially
of non-digestible fat, have a digestible fat content of less than
0.05 gm/30 gram serving. According to another aspect of the
invention, the fabricated snack has fat distributed across at least
25% of the internal structure.
[0034] The snacks can be prepared using conventional processing
equipment in a continuous process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 (a-f), is a cross section elevation view showing the
internal structure typical of a starch based snack containing an
emulsifier (mono-diglyceride) fried in digestible fat.
[0036] FIG. 2 (a-f), is a cross section elevation view showing the
internal structure typical of a starch based snack containing an
emulsifier-lipid composition (mono-diglyceride/non-digestible fat).
The snack has been fried in non-digestible fat.
[0037] FIG. 3 (a-f), is a cross section elevation view showing the
internal structure typical of a starch based snack containing an
emulsifier-lipid composition (polyglycerol ester/non-digestible
fat). The snack has been fried in non-digestible fat.
[0038] FIG. 4 (a-f), is a cross section elevation view showing the
internal structure of the starch based snack of the present
invention containing an emulsifier-lipid composition
(mono-diglyceride/polyglycerol ester/non-digestible fat). The snack
has been fried in non-digestible fat.
DETAILED DESCRIPTION
[0039] Definitions
[0040] As used herein "sheetable dough" is a dough capable of being
placed on a smooth surface and rolled to the desired final
thickness without tearing or forming holes.
[0041] As used herein "starch-based materials" refer to naturally
occurring, high polymeric carbohydrates composed of glucopyranose
units, in either natural, dehydrated (e.g., flakes, granules, meal)
or flour form. The starch-based materials include, but are not
limited to, potato flour, potato granules, corn flour, masa corn
flour, corn grits, corn meal, rice flour, wheat flour, buckwheat
flour, oat flour, bean flour, barley flour, tapioca, as well as
modified starches, native starches, and pea starches, starch
derived from tubers, legumes and grain, for example cornstarch,
wheat starch, rice starch, waxy corn starch, oat starch, cavassa
starch, waxy barley, waxy rice starch, glutinous rice starch, sweet
rice starch, amioca, potato starch, tapioca starch, and mixtures
thereof.
[0042] As used herein "kPa" is kilapascals, a viscosity measurement
unit.
[0043] As used herein "Brabender Units (BU)" is an arbitrary unit
of viscosity measurement roughly corresponding to centipoise.
[0044] As used herein, "modified starch" refers to starch that has
been physically or chemically altered to improve its functional
characteristics. Suitable modified starches include, but are not
limited to, pregelatinized starches, low viscosity starches (e.g.,
dextrins, acid-modified starches, oxidized starches, enzyme
modified starches), stabilized starches (e.g., starch esters,
starch ethers), cross-linked starches, starch sugars (e.g. glucose
syrup, dextrose, isoglucose) and starches that have received a
combination of treatments (e.g., cross-linking and gelatinization)
and mixtures thereof.
[0045] As used herein, the term "added water" refers to water which
has been added to the dry dough ingredients. Water which is
inherently present in the dry dough ingredients. such as in the
case of the sources of flour and starches, is not included in the
added water.
[0046] All percentages are by weight unless otherwise
specified.
[0047] The low-fat snacks of the present invention have a novel
structure characterized generally by a multiplicity of internal
voids having a random distribution of sizes and crisp, low-density
solid mass regions. The structure is obtained by adjusting the
dough composition so that expansion is controlled when the dough is
fried in fat compositions comprising non-digestible fat. The
expansion is controlled such that the snack remains crisp and the
fat is better distributed across the internal structure of the
snack. The expanded structure of the snack also helps reduce the
perceived waxiness impression associated with snacks fried in
non-digestible fat.
[0048] The internal void area is an important aspect of the present
invention from the standpoint of increased crispness, reduced
waxiness and increased mouth-melt. It is believed that the
multi-layers of void spaces in the internal structure of the snack
of the present invention create fracture planes during mastication.
It is also believed that series of discrete planes offer resistance
(i.e. crispness) without hardness. It is further believed that the
internal void areas allow rapid breakdown of the snack during
mastication without excessive capillary hydration. The reduced
waxiness is believed to be the result of fat being more uniformly
distributed within the internal structure of the snack in
combination with the rapid breakdown of the snack during
mastication. This combination provides a thinner film of fat
dispersed in the mouth during mastication that can be carried away
by small fractured particulate matter in the mouth.
[0049] The internal structure comprises a multiplicity of internal
voids and spherical nodules. The fat is also distributed across the
internal structure of the fried snack. The internal void area and
level of solid nodule structure can be determined by microscopic
techniques described herein.
[0050] The low-fat fabricated snacks of the present invention
comprise a total void area of at least 21%, preferably from about
22% to about 40%, more preferably from about 24% to about 36%, and
most preferably from about 26% to about 32%.
[0051] Less than 12%, preferably from about 4.0% to about 10%, more
preferably 6.0% to about 9.0%, and most preferably from about 7.0%
to about 8.0% of the voids that are distributed in the void area
have a size less than 0.1 units (where a unit represents the % of
total product cross sectional area occupied by the void space cross
sectional area); less than from about 8.0% to about 70%, preferably
from about 10% to about 60%, more preferably from about 20% to
about 40%. and most preferably from about 25% to about 35% of the
voids that are distributed in the void area have a size from about
0.1 to about 0.3; from about 5.0% to about 30%, preferably from
about 10% to about 25%, more preferably from about 13% to about 25%
of the voids that are distributed in the void area have a size of
from about 0.3 to about 0.8; from about 5.0% to about 50%,
preferably from about 9.0% to about 45%; more preferably from about
15% to about 40% of the voids that are distributed in the void area
have a size of from about 0.8 to about 1.5; less than about 30%,
preferably less than about 20%, more preferably less than 10%. and
most preferably less than about 5.0% of the voids that are
distributed in the void area have a size of less than 1.5.
[0052] The percentage of solid structure present in the internal
structure of the snack having a nodule morphological form comprises
from about 0% to about 30%, preferably from about 1.0% to about
25%, and more preferably from about 2.0% to about 20% of the
internal structure of the snack.
[0053] The novel structural aspects of the snacks of the present
invention are characteristic features of the present invention.
[0054] The low-fat snacks of the present invention have a unique
structure. The volume hydration ratio (described herein) is a
measurement relating to the volume of internal voids in the
finished product. A higher volume hydration ratio indicates a snack
is less dense.
[0055] The low-fat snacks of the present invention have a volume
hydration ratio of at least about 0.05 gm water/gm chips,
preferably at least about 0.15 gm water/ gm chips, more preferably
at least about 0.19 gm water/gm chips, and most preferably at least
about 0.20 gm water/gm chips.
[0056] The thin section microscopy technique (described herein) was
used in quantification of the fat distribution within the product.
The emulsifier lipid composition delivered an increased level of
fat dispersion.
[0057] The low-fat fabricated snacks of the present invention
preferably comprise 15 to 40% fat, more preferably 22 to 38% fat,
most preferably 24 to 34% fat wherein at least 25%, preferably at
least 30%, more preferably 40% and most preferably 45% is
distributed across the internal structure of the snack and less
than 9.0%, preferably less than 7.0%, more preferably less than
6.0% and most preferably less than 5.0% by weight of snack of the
surface fat have a viscosity of greater than 103 cp at 92.degree.
F. (33.3.degree. C.).
[0058] The novel structure of the present invention will be
understood best by comparing it with the structure of a
corresponding snack fried in digestible and typically
non-digestible fat and by referring to the accompanying drawings
which are described in detail below.
[0059] The internal chip structure was characterized directly by
cross sectional and thin sectional microscopy techniques. The cross
sectional measure was used to define the types of void areas
present and their relative distribution. Four classes of structure
were identified; solid structure, small voids, large voids, and
nodules. Voids were differentiated from solid structures based on
the contrast of light reflected from the structure with voids
giving a darker shading due to more light absorption.
[0060] FIG. 1. Is a cross section elevation view showing the
internal structure of a starch based snack containing an emulsifier
(mono-diglyceride) fried in a digestible fat. The structure is a
random dispersion of voids covering a homologous range of sizes. A
multitude of voids are in the <0.1 to 0.1 to 0.3 unit size range
both grouped in clusters and intermittently around larger voids.
The solid mass region is characterized by thin, platelet regions
with some having a honeycomb appearance.
[0061] FIG. 2. Is a cross section elevated view showing the
internal structure of a starch based snack containing an
emulsifier-lipid composition (distilled
monoglyceride/non-digestible fat) fried in non-digestible fat. The
predominant feature of the internal structure is large cavernous
voids with entire void distribution shifted towards larger sizes.
The solid mass has thicker denser regions with less void
interruption, particularly at the edge of the snack.
[0062] FIG. 3. Is a cross section elevated view showing the
internal structure of a starch based snack containing an
emulsifier-lipid composition (polyglycerol ester/non-digestible
fat) fried in non-digestible fat. The void size distribution of
this structure is shifted to smaller sizes with a low percentage of
large voids. The solid mass is characterized by dense regions with
low void interruption.
[0063] FIG. 4. Is a cross section elevated view showing the
internal structure of a starch based snack containing an
emulsifier-lipid composition (distilled monoglyceride/polyglycerol
ester/non-digestible fat) fried in non-digestible fat. The void
size distribution is about uniformly weighted across all size
ranges within the <0.1, 0.1-0.3, 0.3-0.8, and 0.8-1.5 unit size
ranges with no one size predominating. The width of the solid mass
regions is homologously dispersed with thicker regions interrupted
by a multitude of small voids. The presence of nodule structures is
a predominant feature of the solid mass. Nodules resemble a rounded
or elliptical bubble that consists of a void region surrounded
intimately by solid mass. The nodules can be observed in single
quantities within the center interior structure or in multilayered
clusters towards the edge of the structure.
DOUGH COMPOSITIONS
[0064] The low-fat fabricated products of the present invention are
prepared from a dough comprising starch-based materials, an
emulsifier-lipid component, and water. The dough is cut into pieces
and fried in a fat composition comprising non-digestible fat.
[0065] In accordance with the present invention, novel low-fat
fried snacks having unique structure are produced from a variety of
dough compositions. The novel structures of the low-fat fried
snacks of the present invention can be prepared from conventional
starch-based materials or ingredients containing starch. Generally,
the snacks are prepared by mixing together starch-based materials,
an emulsifier-lipid component and water to form a dough. The dough
is sheeted and formed into pieces which are then fried in fat. The
dough at the time of frying comprises:
[0066] a) from about 50% to about 70% of a starch-based
materials;
[0067] b) from about 30% to about 50% added water; and
[0068] c) from about 0.5% to about 8% of an emulsifier-lipid
composition.
[0069] An important component in the dough compositions of the
present invention are the starch-based materials. The doughs of the
present invention can comprise from about 50% to about 70%.
preferably from about 55% to about 65%, and more preferably about
60% of a starch-based material. The starch-based material can
comprise from about 25 to 100% potato flakes with the balance
(i.e., from 0 to about 75%) being other starch-containing
ingredients such as potato flour, potato granules, corn flour, masa
corn flour, corn grits, corn meal, rice flour, tapioca, buckwheat
flour, oat flour, bean flour, barley flour, wheat flour, as well as
modified starches, native starches, and pea starch, starches
derived from tubers, legumes and grain, for example cornstarch,
wheat starch, rice starch, waxy corn starch, oat starch, cavassa
starch, waxy barley, waxy rice starch, glutinous rice starch, sweet
rice starch, amioca, potato starch, tapioca starch, and mixtures
thereof. The starch-based material preferably comprises from about
40% to about 90%, more preferably from about 50% to about 80%, and
even more preferably about 60% to about 70%, potato flakes and from
about 10% to about 60%, preferably from about 20% to about 50%, and
more preferably from about 30% to about 40%, of these other
starch-containing ingredients.
[0070] Particularly preferred starch-based materials of the present
invention are made from dehydrated potato flakes and potato
granules wherein the potato flakes comprise from about 25% to about
95%, preferably from about 35% to about 90%, and more preferably
from about 45% to about 80% of the starch-based material, and the
potato granules comprise from about 5% to about 75%, preferably
from about 10% to about 65%, and more preferably from about 20% to
about 55%, of the starch-based material.
[0071] Another preferred embodiment can be made using a mixture of
potato flakes and potato granules, combined with other
starch-containing ingredients that are not potato flakes or
granules. Typically, the combined flakes and granules comprise from
about 40% to about 90%, preferably from about 50% to about 80%, and
more preferably from about 60% to about 70% of the starch-based
material, while the other non-potato flake/granule
starch-containing ingredients comprise from about 10% to about 70%,
preferably from about 20% to about 50%, and more preferably from
about 30% to about 40%, of the starch-based materials.
[0072] Particularly preferred potato flakes comprise from about 40%
to about 60% broken cells, from about 16% to about 27% amylose,
from about 5% to about 10% moisture, and at least about 0.1%
emulsifier. Additionally, the dehydrated flakes of the present
invention have a water absorption index of from about 6.7 to about
9.5 grams of water per gram of flakes, a hot paste viscosity of
from about 100 Brabender Units (BU) to about 320 BU and a cold
paste viscosity of from about 100 BU to about 200 BU. From about
40% to about 60% of the dehydrated potato flakes remain on a #40 U
S. screen.
[0073] Particularly preferred potato granules have a water
absorption index of from about 4.0% grams of water per gram of
granules to about 7.0% grams of water per gram of granules,
preferably from about 4.8% grams of water per gram of granules to
about 5.5 grams of water per gram of granules, more preferably from
about 5.2 to about 6.0 grams of water per gram of granules and from
about 9.0% to about 13% amylose, and preferably from about 10%
amylose to about 12% amylose, and more preferably about 11%.
[0074] In order to obtain the desired organoleptical properties in
the snack product (i.e., crispness, decreased waxiness impression
and increased mouthmelt), it is important that the starch-based
material comprise at least about 0.2% of a modified starch and at
least about 3% hydrolyzed starches having a DE of from about 5 to
about 30, and wherein any dried modified starches present have a
water absorption index of from about 0.4 to about 8 grams of water
per gram of modified starch. It is also important that any potato
flakes in the starch-based materials have a water absorption index
of from about 6.7 to about 9.5 grams, preferably from about 7.0 to
about 9.0, and more preferably from about 7.7 to about 8.3, grams
of water per gram of starch and that any other starch-containing
ingredients have a water absorption index lower than the potato
flakes.
[0075] The starch-based materials also preferably comprise a high
amylopectin flour or starch (.about.at least about 40% amylopectin)
selected from the group consisting of waxy corn, waxy barley, waxy
rice, glutinous rice, sweet rice, and mixtures thereof. When a high
amylopectin flour or starch is used it is preferably present at a
level of from about 1% to about 15%, preferably from about 2% to
about 10%, and more preferably from about 3% to about 6%, by weight
of the starch-based materials.
[0076] In order to obtain the desired organoleptical properties of
the snack and sheetability of the doughs of the present invention,
it is important that the high amylopectin flour have a water
absorption index lower than the flakes or granules used to make the
dough composition. Preferred high amylopectin flours are selected
from the group consisting of sweet rice flour, waxy rice flour and
waxy corn flour. Particularly preferred high amylopectin starches
are available from National Starch and Chemical Corporation,
Bridgewater, N.J. and is sold under the trades name of Cereal
Crisp.TM., Amioca.TM. and Hylon V.TM. (50% amylose ) and Hylon
VII.TM. (70% amylose).
[0077] Preferably modified starch is used as an ingredient in the
dough compositions of the present invention is modified starch.
(When calculating the level of modified starch according to the
present invention, modified starch (e.g., gelatinized starch) that
is inherent in potato flakes or granules and flours is not
included.)
[0078] At least about 0.2% modified starch selected from the group
consisting of pregelatinized starches, cross-linked starches, acid
modified starches, and mixtures thereof are used in the dough
compositions of the present invention. Preferably, a level of from
about 0.2% to about 10%, more preferably from about 1% to about 7%,
and even more preferably from about 3% to about 5%, modified starch
is used. Particularly preferred modified starches are available
from National Starch and Chemical Corporation, Bridgewater, N.J.
and are sold under the trade names of N-Lite.upsilon.
(pregelatinized-crosslinked starch,
Ultrasperse-A.TM.(pregelatinized, waxy corn), N-Creamer.TM. 46 and
Corn PCPF400.TM.. This material is a partially pre-cooked corn
meal.
[0079] Hydrolyzed starch is also preferably included in the dough
compositions of the present invention. Hydrolyzed starch is
important to the processability of the doughs of the present
invention which have relatively low water levels. In the absence of
hydrolyzed starches, low moisture levels in the dough can prevent
formation of a continuous, smooth extensible dough sheet.
[0080] Hydrolyzed starches are typically included in the dough
compositions in an amount of at least about 3%, with a usual range
of from about 3% to about 15%. Preferably, hydrolyzed starches are
included in an amount of from about 5% to about 12%. Suitable
hydrolyzed starches for inclusion in the dough include
maltodextrins and corn syrup solids. The hydrolyzed starches for
inclusion in the dough have Dextrose Equivalent (D.E.) values of
from about 5 to about 30, preferably from about 10 to about 20.
Maltrin.TM. M050, M100, M150, M180, M200, and M250 (available from
Grain Processing Corporation, Iowa) are preferred maltodextrins.
The D.E. value is a measure of the reducing equivalence of the
hydrolyzed starch referenced to dextrose and is expressed as a
percentage (on a dry basis). The higher the D.E. value, the higher
the dextrose equivalence of the starch.
[0081] The level of emulsifier added to the dough depends on the
amount of work input that the dough will receive in subsequent
processing (e.g., extrusion, sheeting) steps. As used herein, the
term "added emulsifier" refers to an emulsifier which has been
added to the dry dough ingredients. Emulsifiers which are
inherently present in the dry dough ingredients, such as in the
case of the potato flakes, are not included in the term added
emulsifier.
[0082] A particularly preferred emulsifier composition for
obtaining the snack of the present invention comprises three
functional components: a monoglyceride component, a polyglycerol
ester component, and a fat component.
[0083] The monoglyceride component of the emulsifier system is
comprised of mono-diglycerides, distilled monoglycerides, or
mixtures thereof. The mono-diglyceride can be made in accordance to
well known procedures. One conventional procedure is direct
esterification of one or more fatty acids with glycerol followed
preferably by distillation to obtain a high purity product
containing one or more mono ester. Other procedures for preparation
of distilled monoglyceride products are disclosed in U.S. Pat. Nos.
2,634,234; 2,634,278; and 2,634,279; all to Kuhrt.
[0084] The monoglyceride component is comprised of
mono-diglycerides, distilled monoglycerides, or mixtures thereof
and may be a mixture of saturated and unsaturated glycerol esters
of fatty acids typically derived from hydrogenated to
non-hydrogenated vegetable oils such as soybean oil, corn oil,
olive oil, sunflower oil, cottonseed oil, palm oil and like
vegetable oils, and animal fats such as tallow and lard. The
monoglyceride component comprises at least 30% monoglycerides.
Preferably, more concentrated mono-diglycerides or distilled
monoglycerides are used. The more concentrated mono-diglycerides or
distilled monoglycerides comprises at least about 60%, preferably
from at least about 70% to at least about 98%, more preferably from
at least about 80% to at least about 95%. and most preferably about
90% monoglyceride, with the balance being diglycerides with small
amounts of triglyceride and free glycerine. Preferably the amount
of free glycerine present in the monoglyceride component is less
than about 2.0%. The amount of monoglyceride present in the
mono-diglyceride or distilled monoglyceride can be determined using
AOCS Cd 11-b-91 (95).
[0085] The monoglyceride component useful in the present invention
have an iodine value in the range of from about 2 to about 120,
preferably from about 20 to about 100, more preferably from about
40 to about 80, and most preferably from about 50 to about 75. The
iodine value can be determined using AOCS method Cd 1-25 (93).
[0086] Preferably the mono-diglycerides or distilled monoglyceride
have a linolenic fatty acid level of less than 3.5%.
[0087] Specific mono-diglycerides or distilled monoglycerides
within the scope of the present invention are commercially
available. Monoglycerides suitable for use in the present invention
are sold under the trade names of Dimodan.RTM. available from
Danisco, New Century, Kansas and DMG 70. available from Archer
Daniels Midland Company, Decatur, Ill.
[0088] The monoglyceride component comprises from about 2.0% to
about 50%. preferably from about 5.0% to about 40%, more preferably
from about 10% to about 30%, and most preferably from about 12% to
about 25% of the total emulsifier-lipid composition.
[0089] The second component of the emulsifier-lipid composition is
a polyglycerol ester. Examples of polyglycerol ester include
decaglycerol decaoleate, triglycerol monostearate, octaglycerol
monostearate, and octaglycerol mono-palmitate. These materials are
normally not obtained in pure form, but are generally the reaction
products of an esterification between a preselected cut of
polyglycerols and desired saturated fatty acids. The result is a
distribution of polyglycerol mono-ester and higher-esters
determined by reactants ratios and reaction conditions.
[0090] The polyglycerol esters of the present invention are
specifically tailored by controlling the hydrophilic-lipophilic
balance (HLB) of the polyglycerol esters. This is done by
controlling the balance of esterified to unesterified hydroxyl
groups during the process of esterfication. With an increasing
number of hydroxyl groups esterified, the polyglycerol ester
becomes progressively more lipophilic. This hydrophilic-lipophilic
balance of the polyglycerol ester is important in preparing
polyglycerol ester for use in sheeted doughs.
[0091] Unesterified polyglycerols, long chain polyglycerol
monoesters, and diesters and tri-esters of diglycerols and
triglycerols should be limited in the polyglycerol ester component
of the present invention. Unreacted polyglycerol (i.e. unesterfied)
retained in the finished esters have little or no emulsifier
functionality, but because of their more polar nature are less
soluble in non-digestible lipids leading to phase separation and a
non-homogenous emulsifier-lipid composition.
[0092] The short chain monoesters are very functional components of
the polyglycerol esters in the polyglycerol ester component of the
emulsifier-lipid composition and thus their concentration should be
relatively high compared to other ester moieties. The di- and
triesters of di- and triglycerols are too lipophilic and may also
have a deleterious effect on the finished snack product. Saturated
diglycerides (e.g. dipalmitin, distearin) and the cylic diglycerol
esters are deleterious emulsifier components and therefore their
concentrations should be minimized in the polyglycerol esters.
Preferably, the polyglycerol esters of the present invention
comprise less than 5% cylic diglycerol esters and less than 5%
diglycerides.
[0093] Polyglycerol esters can be purified through fractionation,
molecular distillation or solvent crystallization. The fractionated
polyglycerol esters are more functional and can be used at lower
concentration.
[0094] The composition of the polyglycerol ester can be determined
by Supercritical Fluid Chromatography described herein.
[0095] The polyglycerol esters suitable for use in the present
invention comprise less than 50%, preferably from about 2.0% to
about 40%, and more preferably from about 5.0% to about 25% free
glycerine; from about 5.0% to about 60%, preferably from about 15%
to about 50%, more preferably from about 10% to about 45% and most
preferably from about 25% to about 40% monoester. The polyglycerol
ester of the present invention additionally have from about 2 to
about 10 glycerol units per polyglycerol moiety wherein the
glycerol units have less than 40%, preferably from about 20% to
about 33%, more preferably from about 18% to about 30% of their
hydroxyl groups esterified with myristic acid, palmitic acid,
stearic acid or mixtures thereof.
[0096] The polyglycerol ester component comprises from about 0.5%
to about 40%, preferably from about 1.0% to about 35%, more
preferably from about 1.5% to about 30% and most preferably 2.0% to
about 25% of the total emulsifier-lipid composition.
[0097] Polyglycerol esters suitable for use in the present
invention are sold under the trade name Lonza Polyaldo.RTM..
[0098] The third component of the emulsifier-lipid composition of
the present invention is a fat. The terms "fat" and "oil" are used
interchangeably herein, unless otherwise specified. The terms "fat"
or "oil" refer to edible fatty substances in a general sense,
including natural or synthetic fats and oils consisting essentially
of triglycerides, such as, for example soybean oil, corn oil,
cottonseed oil, sunflower oil, palm oil, coconut oil, canola oil,
fish oil, lard and tallow, which may have been partially or
completely hydrogenated or modified otherwise, as well as non-toxic
fatty materials having properties similar to triglycerides, herein
referred to as non-digestible fats, which materials may be
partially or fully indigestible. Reduced calorie fats and edible
non-digestible fats, oils or fat substitutes are also included in
the term. A particularly preferred non-digestible fat suitable for
use as the third component of the emulsifer-lipid of the present
invention is Olean. available from The Procter & Gamble
Company, Cincinnati, Ohio.
[0099] The fat comprises from about 60% to about 97.5% of the total
emulsifier lipid composition.
[0100] The emulsifier is present in the dough compositions of the
present invention in an amount of from about 0.5% to about 8%.
preferably from about 2% to about 6%. more preferably from about 3%
to about 5% of an emulsifier.
[0101] The dough compositions of the present invention comprise
from about 20% to about 50% added water, preferably from about 22%
to about 40%, and more preferably from about 24% to about 35%,
added water. The level of water in flours and starches is usually
from about 3% to about 8%. However, if the maltodextrin or corn
syrup solids are added as a solution or syrup, the water in this
syrup or solution is included as "added water". The amount of added
water includes any water used to dissolve or disperse ingredients
and includes water present in corn syrups, etc.
DOUGH PROPERTIES
[0102] An important factor in obtaining the structure of the
fabricated snacks of the present invention is the viscoelastic
properties of the dough. Since the doughs are relatively
non-flowable an oscillatory test method is used (described herein).
The viscoelastic properties can be measured using a Control Stress
Rheometer. The viscoelastic property G' (elastic modulus) relates
to the elasticity of the dough while G" (viscous modulus) relates
to the fluidity of the dough. When a dough sheet has high rigidity
or elastic modulus the internal structure of the snack is highly
expanded. This expanded structure results in a fried snack that has
a foamy (Styrofoam-like) texture and a slow mouth-melt. The G'
measurement is an indication of how well the doughs will tolerate
stress and also the type of internal structure that will be present
in the snack after frying.
[0103] When a dough sheet has low rigidity or elastic modulus, the
internal structure of the snack is dense. This dense structure
results in a fried snack that has a hard, glassy texture. One way
of controlling the viscoelastic properties of the dough is by
incorporating an emulsifier or blend of emulsifiers in the dough
composition. However, it is important that the
emulsifier/emulsifier blend not only complexes free amylose, but
also coats the starch, and controls fat distribution, while still
providing a dough that is extensible, cohesive and sheetable. An
emulsifier blend comprising a polyglycerol ester and a
non-digestible fat has been found suitable for obtaining the
desired structure.
[0104] Doughs used to obtain the desired structure comprise a G' of
from about 20 kPa to about 70 kPa; preferably from about 30 kPa to
about 60 kPa; more preferably from about 35 kPa to about 55 kPa;
and most preferably from about 38 kPa to about 50 kPa.
[0105] Doughs used to obtain the desired structure comprise a G" of
from about 3.0 kPa to about 30 kPa, preferably from about 5.0 kPa
to about 25 kPa, more preferably from about 6.0 kPa to about 20
kPa, and most preferably from about 7.0 kPa to about 18 kPa.
[0106] The low-fat snacks of the present invention are preferably
prepared from doughs that are sheetable and extensible. The sheet
strength and extensibility measurement characterize the rheological
properties of the doughs used to prepare the snacks of the present
invention.
[0107] The sheet strength is a measurement of the force needed to
break a piece of dough. The sheet strength measurement correlates
with cohesiveness of the dough and the ability of the dough to
resist developing holes and/or tearing during subsequent processing
steps. The sheet strength and extensibility can be determined by
techniques described herein.
[0108] The doughs used to make the snack of the present invention
mixed in a conventional low work input mixer, for example, a
Hobart.RTM. or Cuisinart.RTM., will typically have a sheet strength
between about 140 to about 375 depending on whether the doughs have
received low work input or higher work input.
[0109] Dough composition receiving relatively low work input
typically have a sheet strength measurement of from about 170 gf to
about 250 gf, preferably from about 180 gf to about 240 gf, and
more preferably from about 190 gf to about 220 gf.
[0110] Doughs produced on a commercial scale where higher work
input mixers (for example, if a Turboilizer.RTM. or extruder is
used) the sheet strength is generally from about 1.5 times to about
2.5 times the sheet strength of the doughs produced from the low
work input mixer.
[0111] The extensibility is a measurement of the maximum elongation
distance achieved prior to structural failure of the dough, after
the steady application of a constant force. The doughs used to
prepare the snacks of the present invention preferably have an
extensibility of from about 5cm to about 15 cm, preferably from
about 7 cm to about 12 cm, and more preferably from about 9 cm to
about 11 cm.
[0112] When doughs having the preferred dough composition,
viscoelastic properties, sheet strength and extensibility are fried
in a non-digestible fat, the resulting snack has a slightly
expanded structure and crisp texture.
DOUGH PREPARATION
[0113] The dough of the present invention can be prepared by any
suitable method for forming sheetable doughs. The dough
compositions of the present invention can be prepared by thoroughly
mixing together the flakes, granules, modified starches and added
emulsifier. Typically, a water pre-blend of flavoring (optional),
modified starches, sucrose and/or salt, and lower water absorption
index starch-based materials are mixed separately. The water
pre-blend is then added to the potato flour and/or granules mixture
and added emulsifier blend and mixed to form a loose, dry dough.
Preferred devices for mixing together the dough ingredients are
conventional mixers. Hobart(D mixers are used for batch operations
and Turbolizer.RTM. mixers can be used for continuous mixing
operations. However, extruders can also be used to mix the dough
and to form the sheets or shaped pieces.
[0114] Once prepared, the dough is then formed into a relatively
flat, thin sheet. Any method suitable for forming such sheets from
starch-based doughs can be used. For example, the sheet can be
rolled out between two counter rotating cylindrical rollers to
obtain a uniform, relatively thin sheet of dough material. Any
conventional sheeting, milling and gauging equipment can be used.
The mill rolls should be heated to about 90.degree. F. (32.degree.
C.) to about 135.degree. F. (57.degree. C.). In a preferred
embodiment, the mill rolls are kept at two different temperatures,
with the front roller being cooler than the back roller.
[0115] Dough compositions of the present invention are usually
formed into a sheet having a thickness of from about 0.015 to about
0.10 inches (from about 0.038 to about 0.25 cm), and preferably to
a thickness of from about 0.02 to about 0.09 inches (from about
0.051 to about 0.229 cm), and most preferably from about 0.025 to
about 0.08 inches (0.062 to 0.203 cm). For rippled (wavy shaped)
chips, the preferred thickness is about 0.75 inches (1.9 mm). The
dough sheet is then formed into snack pieces of a predetermined
size and shape. The snack pieces can be formed using any suitable
stamping or cutting equipment. The snack pieces can be formed into
a variety of shapes. For example, the snack pieces can be in the
shape of ovals, squares, circles, a bowtie, a star wheel, or a pin
wheel. The pieces can be scored to make rippled chips as described
in published PCT application WO 95/07610, Dawes et al., Jan. 25,
1996, which is incorporated by reference.
FAT FRYING
[0116] After the snack pieces are formed, they are cooked until
crisp. The snack pieces can be cooked by frying, partially frying
and then baking or by partially baking then frying. The snack
pieces can be fried in a fat composition that consists essentially
of non-digestible fat, or a blend of non-digestible fat and
triglyceride fat.
[0117] Particularly preferred are non-digestible fats such as those
described in U. S. Pat. Nos. 3,600,186 to Mattson et al., issued
May 12, 1970; 4,005,195 to Jandacek, issued Jan. 25, 1977;
4,005,196 to Jandacek et al., issued Jan. 25, 1977; 4,034,083 to
Mattson, issued Jul. 5, 1977; and 4,241,054 to Volpenhein et al.,
issued Dec. 23, 1980, all of which are incorporated by
reference.
[0118] The terms "fat" and "oil" are used interchangeably herein
unless otherwise specified. The terms "fat" or "oil" refer to
edible fatty substances in a general sense, including natural or
synthetic fats and oils consisting essentially of triglycerides,
such as, for example soybean oil, corn oil. cottonseed oil,
sunflower oil, palm oil, coconut oil, canola oil, fish oil, lard
and tallow, which may have been partially or completely
hydrogenated or modified otherwise, as well as non-toxic fatty
materials having properties similar to triglycerides, herein
referred to as non-digestible fats, which materials may be
partially or fully indigestible. Reduced calorie fats and edible
non-digestible fats, oils or fat substitutes are also included in
the term.
[0119] The term "non-digestible fat" refers to those edible fatty
materials that are partially or totally indigestible. e.g.. polyol
fatty acid polyesters, such as OLEAN.RTM..
[0120] By "polyol" is meant a polyhydric alcohol containing at
least 4, preferably from 4 to 11 hydroxyl groups. Polyols include
sugars (i.e., monosaccharides, disaccharides, and trisaccharides),
sugar alcohols, other sugar derivatives (i.e., alkyl glucosides),
polyglycerols such as diglycerol and triglycerol, pentaerythritol,
sugar ethers such as sorbitan and polyvinyl alcohols. Specific
examples of suitable sugars, sugar alcohols and sugar derivatives
include xylose, arabinose, ribose, xylitol, erythritol, glucose,
methyl glucoside, mannose, galactose, fructose, sorbitol, maltose,
lactose, sucrose, raffinose, and maltotriose.
[0121] By "polyol fatty acid polyester" is meant a polyol having at
least 4 fatty acid ester groups. Polyol fatty acid esters that
contain 3 or less fatty acid ester groups are generally digested
in, and the products of digestion are absorbed from, the intestinal
tract much in the manner of ordinary triglyceride fats or oils,
whereas those polyol fatty acid esters containing 4 or more fatty
acid ester groups are substantially non-digestible and consequently
non-absorbable by the human body. It is not necessary that all of
the hydroxyl groups of the polyol be esterified, but it is
preferable that disaccharide molecules contain no more than 3
unesterified hydroxyl groups for the purpose of being
non-digestible. Typically, substantially all, e.g., at least about
85%, of the hydroxyl groups of the polyol are esterified. In the
case of sucrose polyesters, typically from about 7 to 8 of the
hydroxyl groups of the polyol are esterified.
[0122] The polyol fatty acid esters typically contain fatty acid
radicals typically having at least 4 carbon atoms and up to 26
carbon atoms. These fatty acid radicals can be derived from
naturally occurring or synthetic fatty acids. The fatty acid
radicals can be saturated or unsaturated, including positional or
geometric isomers, e.g., cis- or trans- isomers, and can be the
same for all ester groups, or can be mixtures of different fatty
acids.
[0123] Liquid non-digestible oils can also be used in the practice
of the present invention. Liquid non-digestible oils have a
complete melting point below about 37.degree. C. include liquid
polyol fatty acid polyesters (see Jandacek; U.S. Pat. No.
4,005,195; issued Jan. 25, 1977); liquid esters of tricarballylic
acids (see Hamm; U.S. Pat. No. 4,508,746; issued Apr. 2, 1985);
liquid diesters of dicarboxylic acids such as derivatives of
malonic and succinic acid (see Fulcher; U.S. Pat. No. 4,582,927;
issued Apr. 15, 1986); liquid triglycerides of alpha-branched chain
carboxylic acids (see Whyte; U.S. Pat. No. 3,579,548; issued May
18, 1971); liquid ethers and ether esters containing the neopentyl
moiety (see Minich; U.S. Pat. No. 2,962,419; issued Nov. 29, 1960);
liquid fatty polyethers of polyglycerol (See Hunter et al; U.S.
Pat. No. 3,932,532; issued Jan. 13, 1976); liquid alkyl glycoside
fatty acid polyesters (see Meyer et al; U.S. Pat. No. 4,840,815;
issued Jun. 20, 1989); liquid polyesters of two ether linked
hydroxypolycarboxylic acids (e.g., citric or isocitric acid) (see
Huhn et al; U.S. Pat. No. 4,888,195; issued Dec. 19, 1988); various
liquid esterfied alkoxylated polyols including liquid esters of
epoxide-extended polyols such as liquid esterified propoxylated
glycerins (see White et al; U.S. Pat. No. 4.861.613; issued Aug.
29, 1989; Cooper et al; U.S. Pat. No. 5,399,729: issued Mar. 21,
1995; Mazurek; U.S. Pat. No. 5,589,217: issued Dec. 31, 1996; and
Mazurek; U.S. Pat. No. 5,597,605; issued Jan. 28, 1997); liquid
esterified ethoxylated sugar and sugar alcohol esters (see Ennis et
al; U.S. Pat. No. 5,077,073); liquid esterified ethoxylated alkyl
glycosides (see Ennis et al; U.S. Pat. No. 5,059,443, issued Oct.
22, 1991); liquid esterified alkoxylated polysaccharides (see
Cooper; U.S. Pat. No. 5,273,772; issued Dec. 28, 1993); liquid
linked esterified alkoxylated polyols (see Ferenz; U.S. Pat. No.
5,427,815; issued Jun. 27, 1995 and Ferenz et al; U.S. Pat. No.
5,374,446; issued Dec. 20, 1994); liquid esterfied polyoxyalkylene
block copolymers (see Cooper; U.S. Pat. No. 5,308,634; issued May
3, 1994); liquid esterified polyethers containing ring-opened
oxolane units (see Cooper; U.S. Pat. No. 5,389,392; issued Feb. 14,
1995); liquid alkoxylated polyglycerol polyesters (see Harris; U.S.
Pat. No. 5,399,371; issued Mar. 21, 1995); liquid partially
esterified polysaccharides (see White; U.S. Pat. No. 4,959,466;
issued Sep. 25, 1990); as well as liquid polydimethyl siloxanes
(e.g., Fluid Silicones available from Dow Corning). All of the
foregoing patents relating to the liquid nondigestible oil
component are incorporated herein by reference. Solid
non-digestible fats or other solid materials can be added to the
liquid non-digestible oils to prevent passive oil loss.
Particularly preferred non-digestible fat compositions include
those described in U.S. Pat. No. 5,490,995 issued to Corrigan,
1996, U.S. Pat. No. 5,480,667 issued to Corrigan et al, 1996, U.S.
Pat. No. 5,451,416 issued to Johnston et al, 1995 and U.S. Pat. No.
5,422,131 issued to Elsen et al, 1995. U.S. Pat. No. 5,419,925
issued to Seiden et al, 1995 describes mixtures of reduced calorie
triglycerides and polyol polyesters that can be used herein but
provides more digestible fat than is typically preferred.
[0124] The preferred non-digestible fats are fatty materials having
properties similar to triglycerides such as sucrose polyesters.
OLEAN.RTM., a preferred non-digestible fat, is made by The Procter
and Gamble Company. These preferred non-digestible fat are
described in Young; et al., U.S. Pat. No. 5,085,884, issued Feb. 4,
1992, and U. S. Pat. 5,422,131, issued June 6, 1995 to Elsen et
al.
[0125] It is preferred to fry the snack pieces in a fat composition
comprising a non-digestible fat at temperatures of from about
275.degree. F. (135.degree. C.) to about 400.degree. F (204.degree.
C.), preferably from about 300.degree. F. (148.degree. C.) to about
375.degree. F. (191.degree. C.), and more preferably from about
315.degree. F. (157.degree. C.) to about 350.degree. F.
(177.degree. C.) for a time sufficient to form a product having
from about 0.5% to about 6.0%, preferably from about 1.0% to about
5.0%, and more preferably from about 2.0% to about 4.0%, moisture.
The exact frying time is controlled by the temperature of the
frying fat and the starting water content of the dough which can be
easily determined by one skilled in the art.
[0126] Preferably, the snack pieces are fried in oil using a
continuous frying method and are constrained during frying. This
constrained frying method and apparatus is described in U.S. Pat.
No. 3,626,466 (Liepa, 1971). The shaped, constrained pieces are
passed through the frying medium until they are fried to a crisp
state with a final moisture content of from about 0.5% to about
4.0% water, preferably 1.0% to 2.0%.
[0127] Continuous frying or batch frying of the snack pieces in a
non-constrained mode is also acceptable. In this method the pieces
are immersed in the frying fat on a moving belt or basket.
ANALYTICAL METHODS
OSCILLATORY TEST METHOD
[0128] Rheolotical Properties (G' & G")
[0129] Oscillatory testing involves applying a small,
non-destructive sinudoidal stress on the sample and measuring the
strain output. The elastic modulus is a measurement of how
elasticity or fluidity of the dough is derived from the dough's
response to the applied stress. G' was examined because the dough
visco-elastic properties change with work input and emulsifier
level in the dough. G' measures the ability to store energy in the
dough. The viscous modulus G" applies to fluidity. G" is defined as
the viscous modulus (or loss modulus) of viscoelastic materials. G'
and G" are used as a measurement of dough's response to work input
during processing. A high G' number indicates a more rigid,
solid-like material. A lower G' means the material flows more
readily and may be easily deformed.
[0130] The theological properties of the dough are measured by
preparing a dough comprising:
[0131] a) 200 g starch-based material;
[0132] b) 90 g of water; and
[0133] c) 0.5 of emulsifier.
[0134] The dough is made in a small Cuisinart.RTM. mixer at low
speed for 10-20 seconds. After mixing the dough is sheeted using a
convention milling machine to a thickness of from about 0.021 to
about 0.025 inches. The mill rolls are about 1.2 meters in
length.times.0.75 meter in diameter.
[0135] A Control Stress Rheomether CSL2 100) (TA Instruments Inc.,
New Castle DE is used to measure G' and G". The dynamic testing was
done with a 4 cm cross-hatch parallel plate at 32.2 deg. C. This is
an average temperature at which the dough is sheeted out between
the rollers.
[0136] 1) A sample is placed on the bottom plate, and zeroed the
gap by lowering the top plate to 80% compression of the original
thickness of the dough piece (.about.0.1 mm). The sample is trimmed
to the same size as the upper plate. The exposed edge of the sample
is coated with a thin layer of mineral oil to minimize moisture
loss during the test.
[0137] 2) All samples are rested or allowed to equilibrate for 2
min. before the measurement to relax any stresses introduced during
the sample mounting.
[0138] 3) Stress sweep was performed at low and high frequencies in
order to find the linear viscoelastic region for the dough, where
the sample structure is unperturbed.
[0139] 4) A frequency sweep is performed at one stress in the
linear viscoelastic region to determine the sample's structure
changes with increasing frequency of oscillation. This gives a
representative view of how the elastic and viscous components
behave in the sample.
[0140] 5) The elastic modulus (G'), and loss modulus (G") are
recorded at both 1 and 100 rad/sec. In general, the data recorded
at 1 rad/sec is used to compare different compositions and process
conditions.
[0141] Sheet Strength Test
[0142] The sheet strength is determined as follows: Sheet strength
is the measurement of the force needed to break a dough sheet of
0.635 mm. The sheet strength is read as the maximum peak force (gf)
of a graph obtained from force against distance. The test is
designed to measure potato dough sheet strength. All products are
tested at room temperature. Sheet strength is an average of ten
repetitions of each test. The sheet strength is measured by
preparing a dough comprising:
[0143] a) 200 g of solids;
[0144] b) 90 g of water; and
[0145] c) 0.5 g of emulsifier.
[0146] The dough is made in a small Cuisinart.RTM. mixer at low
speed for 10-20 seconds. After mixing, the dough is sheeted using a
conventional milling machine to a thickness of 0.635 mm (22 mils).
The mill rolls are usually 1.2 meter length.times.0.75 diameter
meter.
[0147] This test is conducted using a Texture Analyzer (TA-XT2)
from Texture Technologies Corp. This equipment uses a software
called XTRAD. This test utilizes a {fraction (7/16)}" diameter
acrylic cylinder probe (TA-108), which has a smooth edge to
minimize any cutting of the dough sheet. The dough sheet is held
between two aluminum plates (10.times.10 cm). The aluminum plates
have a 7 cm diameter opening in the center. Through this opening
the probe makes contact with the sheet and pushes it downwards
until it breaks. These plates have an opening in each corner to
hold the sheet dough in place. Each dough sheet is pre-punched with
holes to fit over the alignment pins at the corners of the plate
and cut to the size (10.times.10 cm) of the plate. This provides
uniform tension as the probe moves down and through the sheet. The
probe travels at 2.0 mm/second until the dough sheet surface is
detected at 20 grams of force. The probe then travels at 1.0
mm/second for up to 50 mm, a distance chosen to stretch the dough
sheet until it thoroughly ruptures. The probe withdraws at 10.0
mm/second. The probe is run in a "Force vs Compression" mode, which
means the probe will move downward measuring the force.
[0148] Extensibility Method
[0149] The extensibility of the sheet strip is measured using an
Instron Universal Testing Machine Model 1123 set with a crosshead
speed of 5 inches/minute, a full scale load of 10%, and a chart
recorder speed of 10 inches/minute.
[0150] 1) A dough formulation is milled using a conventional
milling machine to form a sheet with a thickness of 0.0020-0.0022
inches.
[0151] 2) The sheet is cut into a rectangular strip 1" in width by
6' in length.
[0152] 3) The top of the sheet strip (about 1/4 inch) is placed
within a spring clamp that is attached to the movable crosshead of
the Instron. The clamp is slightly wider than the strip and the
pressure is high enough to hold the strip, but low enough so as not
to make an indelible mark in the strip that would result in a
fracture point or tear in the strip. The top clamp is attached to
the crosshead via a swivel connector to allow flexible movement of
the strip prior to load application.
[0153] 4) The bottom part of the sheet strip (about 1/4") is
attached to a similar clamp that is attached to the Instron load
cell.
[0154] 5) The linear distance between the lowest part of the
crosshead clamp and the uppermost part of the load cell lower clamp
is initially less than 4 inches to allow loading of the dough in
the clamps. Prior to the start of the measurement, the crosshead is
moved upward to make the dough slightly taught between the clamps,
about 5.5 inches of distance between the upper and lower clamp.
[0155] 6) The dough is loaded within the clamps within 1 minute of
sheeting or it is discarded.
[0156] 7) Once the dough is taught between the clamps, the
measurement is begun by moving the crosshead upward at a preset
fixed rate (5 inches/minute). A strip chart records the force
measured by the load cell during the normal upward strain placed on
the dough.
[0157] 8) Once the dough strip breaks as indicated visually and by
an absence of force recorded by the load cell, the measurement is
stopped. The extensibility is measured as the distance measured on
the strip chart recorder paper between the start of strain to the
absence of strain provided by the load cell.
INTERNAL FAT DISTRIBUTION
[0158] This procedure shows the fat within cross sections of
chips.
[0159] Snack products are freeze sectioned (.about.16-18 m thick)
placed on pre- cleaned slides. Sections are separately stained in
Osmium Tetroxide vapors. The sections are imaged using a black and
white (B/W) Dage video camera. The Osmium Tetroxide section shows
the fat location in the chip structures.
1 Equipment Minotome, Microtome Cryostat Model 3398, Damon/IEC
Division Specimen Holder Plate and disc Damon/IEC Division
Microscope Universal, Zeiss, capable of magnifications up to 800X;
5X eyepiece. Video camera Dage Vidicon. B/W Glass Slides &
covers Standard microscopic variety Desiccators Solid cover, Pyrex,
large I.D. 250 mm; small I.D. Masking tape 2" width
[0160]
2 Reagents Mounting Medium Tissue Tek Osmic Acid 1/2 gram ampoule
Methanol (Anhydrous) Permount (medium used to reduce fading for
Iodine vapors stained sections) Water De-ionized distilled Mineral
Oil Food Grade
[0161] Sample Preparation
[0162] 1) Samples were broken into pieces .about.1/2" by 1/4"
[0163] 2) Samples were then place in Tissue Tek medium inside the
Minotome Cryostat and quickly frozen for five minutes; after five
minutes the samples were mounted on specimen holder disc and
allowed to set for .about.20-30 minutes before sectioning.
[0164] Note: Minotome Cryrostat should be set for 24.degree.
C..+-.3.degree. C. and the knife blade should be placed in the
Minotome at least 2 hours before sectioning samples.
[0165] 3) The frozen samples were sectioned .about.16-18 m thick
and placed on pre-cleaned slides.
[0166] 4) Slides were then stained in desiccators inside of fume
hoods using the above specific stains.
[0167] Staining
[0168] Osmium Tetroxide the 1/2 gram ampoule is mixed with a
solution of methanol/water (24 mil methanol/1 mil water) and the
sections are exposed to the osmium vapors overnight (16 hours).
After the sections are removed from the desiccator, the slides are
allowed to set in the hood for 1 hr. prior to added mineral oil and
cover slip. The samples are then imaged using a 6.3.times.
objective, 1.25 optivar ( specific to Zeiss microscope) and a
5.times. eyepiece.
[0169] Sample Imaging
[0170] The Dage Vidicon camera is attached to Zeiss Microscope for
image capture. The images are captured and the data is processed
using Optimas 4.02 software. The measurement utility used is
Percent Area. This utility allows you to calculate the percentage
of area in an image based on different threshold ranges. The
Percent Area is used to compare the areas with fat staining vs.
total area. The Percent Area measurements for the fat stained
images are obtained using the following thresholds:
3 Threshold Name Thresholds Total area 5 255 Void 3 220 255 Chip
Structure 70 220 Fat 0 70
VOID SIZE MEASUREMENT & STRUCTURE CHARACTERIZATION
[0171] Fabricated snacks are extracted and cut or broken to expose
a cross section view to observe the void structures present in
samples. The samples are rinsed with solvent to remove fat. The
samples are dried under nitrogen and placed in a desiccator.
Samples are then coated with gold palladium and mounted to view the
cross section in the Scanning Electron Microscope (SEM). The SEM
shows a three dimensional view of the structure.
4 Equipment Scanning Electron Microscope JEOL, JSM T-300 Beakers
Pyrex, 100 ml Sputter Coater Edwards 150A Video Camera Dage Vidicon
B/W Imaging Capability Computer equipped with BioScan Optimas 4.02
Software Coping Saw Saddle Mold Sonicator
[0172]
5 Reagents Hexane Distilled in Glass, UV grade
[0173] Sample Preparation
[0174] 1) Samples of Pringles potato crisps were cut into pieces
approximately 1/2" by 1/4" with a coping saw over the Pringles
saddle mold. This was done to give an even surface for SEM
observation of the void structure. Crisps which are not in a molded
form were broken into pieces approximately 1/2" by 1/4".
[0175] 2) These cut or broken samples were placed in 100 ml beakers
and covered with hexane.
[0176] 3) The beakers were then place in a Sonicator for 5 min. and
the solvent was decanted and replaced. The solvent replacement and
sonication was done 4 times.
[0177] 4) Hexane was again added and the samples were placed on the
steam bath and heated until solvent began to boil. The remaining
solvent was decanted, replaced with fresh solvent and heated again.
The remaining solvent was decanted and samples were placed under
nitrogen to remove any remaining solvent.
[0178] 5) After solvent removal the samples were placed in a
desiccator overnight to dry.
[0179] 6) Samples were sputter coated with gold palladium and
placed in a sample holder which exposes the cut or broken edge.
[0180] 7) Samples were placed in the SEM and cross section images
were captured.
6 SEM Conditions 10 kV 10.degree. stage tilt 150X-magnification
[0181] Sample Imaging
[0182] The Dage Vidicon camera was attached to the video out
connector on the JSM T-300 SEM.
[0183] Structural features of the image (voids, nodules, chip mass)
were manually identified and marked then measured for relative
areas vs. the total image area. A grid was overlaid on the
photograph of the entire cross sectional area of the product where
the grid was composed of individual square cell units of 0.2 cm
length by 0.2 cm width with an 0.04 cm2 cross sectional area per
cell unit. The total photographic size including the product cross
section and images of the mounting background was about 7.5 cm in
length by 7.5 cm in width. The scaling ration between the total
photograph area to individual grid cell unit area was about 1406:1
and this ratio should be maintained for any enlargements or
reductions to provide consistent imaging analysis.
[0184] The first step of the imaging analysis was to count the
total number of grid unit cells occupied by the product cross
sectional area to derive a total product area. Total void area was
determined by counting the number of grid cell units displaying a
darker or essentially darker gray to black contrast since these
represent areas of depth with increased light absorption.
Individual void size areas were determined by outlining the void
areas, overlaying the grid on the areas, and counting the number of
individual grid cells occupied.
[0185] Nodules were characterized by circular, semi-circular or
elliptical areas of solid structure surrounded by a cell wall
extending up into the three dimensional plane providing a bubble
like appearance. The nodule structures were outlined, the grid was
overlaid, and the number of individual grid unit cells occupied was
counted.
VOLUME HYDRATION RATIO TEST
[0186] 1) A whole chip is weighed on a balance to +0.01 g.
[0187] 2) The chip is then submersed in a beaker of water at
ambient temperature (70-80.degree. F.) for 10 seconds and
removed.
[0188] 3) The chip is allowed to drain over the beaker for 5
seconds with the excess surface water shaken off.
[0189] 4) The chip is blotted with a clean, dry absorbent paper
tissue (e.g. Kimwipes.RTM.) to again remove any apparent surface
water.
[0190] 5) The hydrated chip is re-weighed to +0.01 g.
[0191] 6) The difference between the hydrated and original chip
weights is divided by the original chip weight and hydration time
to calculate the hydration rate.
[0192] 7) The above procedure is repeated for twenty chips and an
average hydration rate is calculated.
[0193] The following examples illustrate the invention in more
detail but are not meant to be limiting thereof.
EXAMPLE 1
[0194] The following ingredients are combined in the manner
described below to form a low-fat snack of the present
invention.
7 STARCH BASED PRE-BLEND Ingredient Wt. % Potato flakes (8.5) 83.5
Potato granules (4.7) 8.4 Rice flour 6.5 N-Lite LP .TM. (modified
starch) 1.6 Total 100.0
[0195]
8 WATER BASED PRE-BLEND Ingredient Wt. % Maltodextrin DE 18 8 Water
91.2 Salt 0.4 Sugar 0.4 Total 100.0
[0196]
9 EMULSIFIER-LIPID BLEND Ingredient Wt. % Mono-diglyceride 12.75%
Polyglycerolester 2.25 Non-digestible fat 85%
[0197] A mix containing 64.3% of a starch based flour pre-blend,
32.7% of a water pre-blend, and 3.0% of the emulsifier-lipid
composition are blended in a Turbolizer.RTM. to form a loose, dry
dough (.about.15-60 seconds). The dough is sheeted by continuously
feeding it through a pair of sheeting rolls forming an elastic
continuous sheet without pin holes. Sheet thickness is controlled
to 0.02 inches (0.05 cm). The front roll is heated to about
90.degree. F. (32.degree. C.) and the back roll is heated to about
135.degree. F. (57.degree. C.). The dough sheet is then cut into
oval shaped pieces and fried in a constrained frying mold at
385.degree. F. (196.degree. C.) in OLEAN.RTM. (made by The Procter
and Gamble Company) for about 12 seconds. The product is held in
the molds for about 20 seconds to allow the OLEAN.RTM. to drain.
The resulting product has a crisp texture. The non-digestible fat
level is about 30%. The digestible fat level from the emulsifier is
less than 0.3 grams/30 gram serving.
[0198] The rheological properties of the dough are:
10 Property Value Sheet Strength 197 gm-force Extensibility 11 cm
G` kPa 40 G" kPa 12
[0199] The physical properties of the final chip product are:
11 Property Value % Internal Fat Distribution 41 % Total Void Area
31 % Nodular Void Area 15-20 Volume Hydration Ratio gm water/gm
chip 0.198 % Surface Fat 5.5
EXAMPLE 2
[0200] A mix containing 62.1% of a starch-based flour pre-blend,
34.8% of a water pre-blend, and 3.95% of the emulsifier/lipid
composition are combined in the manner described in Example 1 to
form a low-fat snack of the present invention.
12 STARCH BASED PRE-BLEND Ingredient Wt. % Potato flakes (8.5) 85.6
Potato granules (4.0) 9.4 *N-Creamer (pregelatinized, waxy corn)
1.0 *Ultrasperse-A .TM. (modified starch) 4.0 Total 100.0
*Available from National Starch Co.
[0201]
13 WATER BASED PRE-BLEND Ingredient Wt. % Maltodextrin DE 18 8
Water 91.2 Salt 0.4 Sugar 0.4 Total 100.0
[0202]
14 EMULSIFIER-LIPID BLEND Ingredient Wt. % Mono-diglyceride 12.75%
Polyglycerolester 2.25 Non-digestible fat 85%
* * * * *