U.S. patent application number 09/760916 was filed with the patent office on 2001-12-20 for method of preparing coated low fat and fat free snack food.
Invention is credited to Anderson, Barbara Ann, Heisey, Jacqueline Conrad, Hsieh, Yen-Ping Chin, Lanner, David Arthur, McDonald, Gerald C., Villagran, Maria Dolores Martinez-Serna, Weber, Michael, Wehner, Pamela Susan, Williams, Kenneth Bryan.
Application Number | 20010053401 09/760916 |
Document ID | / |
Family ID | 22242594 |
Filed Date | 2001-12-20 |
United States Patent
Application |
20010053401 |
Kind Code |
A1 |
Lanner, David Arthur ; et
al. |
December 20, 2001 |
METHOD OF PREPARING COATED LOW FAT AND FAT FREE SNACK FOOD
Abstract
Disclosed are low-fat and fat-free snacks having a glossy
coating and a process for making the same. Disclosed in a preferred
embodiment are coated low-fat and fat-free pretzels having a
surface area to inner volume ratio of from about 22 inches.sup.-1
(8.66 cm.sup.-1) to about 40 inches.sup.-1 (15.75 cm.sup.-1), a pH
of about 8 or less, a digestible fat content of less than 3 g per
28 g serving, and a moisture content of from about 1% to about 4%.
The large surface area to inner volume ratio permits the use of
reduced concentrations of caustic solution and facilitates drying.
Coated pretzels are prepared by: (1) applying a warm coating
comprising a carbohydrate selected from modified starch, corn syrup
solids, maltodextrins, dextrins, and mixtures thereof; water; and
preferably flavoring to ready-to-eat pretzels while tumbling; (2)
adding sugar and optionally salt to the tumbling pretzels; (3)
removing the pretzels from the tumbling device; and (4) drying the
pretzels with the products stationary. The pretzels have
substantially improved texture, taste and flavor display.
Additionally, the color and shiny surface which is characteristic
of pretzels is maintained.
Inventors: |
Lanner, David Arthur;
(Cincinnati, OH) ; McDonald, Gerald C.;
(Fairfield, OH) ; Hsieh, Yen-Ping Chin;
(Cincinnati, OH) ; Weber, Michael; (Fairfield,
OH) ; Wehner, Pamela Susan; (Harrison, OH) ;
Anderson, Barbara Ann; (Cincinnati, OH) ; Villagran,
Maria Dolores Martinez-Serna; (Mason, OH) ; Williams,
Kenneth Bryan; (Jackson, TN) ; Heisey, Jacqueline
Conrad; (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: |
22242594 |
Appl. No.: |
09/760916 |
Filed: |
January 16, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09760916 |
Jan 16, 2001 |
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09357000 |
Jul 20, 1999 |
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6217921 |
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60094056 |
Jul 24, 1998 |
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Current U.S.
Class: |
426/94 ; 426/302;
426/499; 426/549 |
Current CPC
Class: |
A21D 13/24 20170101;
A21D 10/00 20130101; A21D 13/068 20130101; A21D 2/16 20130101; A23L
7/117 20160801; A23L 7/122 20160801 |
Class at
Publication: |
426/94 ; 426/549;
426/499; 426/302 |
International
Class: |
A21C 003/08 |
Claims
What is claimed is:
1. A dough composition for producing low-fat and fat-free snacks
comprising: (a) from about 55% to about 75% flour; (b) from about
0.05% to about 2% leavening; (c) from about 0% to about 4% added
gluten; (d) from about 0% to about 5% corn syrup; (e) from about
25% to about 35% added water; and (f) from about 0.01% to about 7%
added fat.
2. The dough composition of claim 1 comprising from about 65% to
about 70% flour, from about 0.08% to about 0.5% leavening, from
about 0% to about 4% added gluten, from about 1% to about 2% corn
syrup, from about 28.5% to about 29.5% added water, and from about
0.1% to about 4% added fat, wherein the added fat comprises an
emulsifier system comprising DATEM and shortening.
3. The dough composition of claim 2 comprising from about 0.2% to
about 0.4% of said emulsifier system, wherein said emulsifier
system has a ratio of DATEM:shortening of from about 10:1 to about
1:10.
4. A pretzel prepared from the dough composition of claim 1,
wherein said pretzel has less than 3 grams of digestible fat/28
gram serving, a pH of about 8 or less, and from about 1% to about
4% moisture.
5. The pretzel of claim 4 wherein said pretzel has a surface area
to inner volume ratio of from about 22 inches.sup.-1 (8.66
cm.sup.-1) to about 40 inches.sup.-1 (15.75 cm.sup.-1).
6. The pretzel of claim 5 wherein said pretzel has a pH of from
about 6 to about 7.5, a surface area to volume ratio of from about
27 inches.sup.-1 (10.63 cm.sup.-1) to about 29 inches.sup.-1 (11.42
cm.sup.-1), and from about 2% to about 2.7% moisture.
7. The pretzel of claim 6 wherein said pretzel is in the shape of
an eagle.
8. The pretzel of claim 6 further comprising a coating.
9. The pretzel of claim 8 wherein said coating comprises a flavor
selected from the group consisting of yogurt, honey-mustard, sour
cream and onion, bacon, caramel, toffee and malt.
10. A process for preparing coated pretzels comprising the steps
of: (a) preparing the dough composition of claim 1; (b) preparing
dough pieces from the dough composition; (c) extruding the dough
pieces; (d) proofing the dough pieces; (e) applying a caustic
solution to the dough pieces; (f) baking the dough pieces using a
two step baking process wherein said baking process comprises
baking the dough pieces a first time in an oven at a temperature of
from about 375.degree. F. (190.6.degree. C.) to about 550.degree.
F. (287.8.degree. C.) for about 3 to about 5 minutes, then baking
the dough pieces a second time in an oven at temperature of from
about 220.degree. F. (104.4.degree. C.) to about 250.degree. F.
(121.1.degree. C.) for a time sufficient to produce pretzels having
a moisture content of less than about 4%; and (g) coating the
pretzels of step (f) with an edible solution comprising water,
sugar and a carbohydrate selected from the group consisting of
modified starch, corn syrup, corn syrup solids, maltodextrins,
dextrins and mixtures thereof.
11. The process of claim 9 wherein the caustic solution has a
concentration of from about 0.6% to about 0.8% and wherein the
caustic solution is at a temperature of from about 190.degree. F.
(87.8.degree. C.) to about 200.degree. F. (93.3.degree. C.).
12. The process of claim 10 wherein the caustic solution is applied
to the pretzel using a bath or waterfall.
13. The process of claim 10 wherein step (g) comprises: (1)
applying the edible solution to the pretzels while tumbling; (2)
adding sugar and optionally salt to the tumbling pretzels; (3)
spreading the pretzels into a mono-layer arrangement; and (4)
drying the pretzels in an oven at a temperature of from about
220.degree. F. (104.4.degree. C.) to about 300.degree. F.
(148.9.degree. C.) for a time sufficient to produce coated pretzels
having a moisture content of from about 1% to about 4%.
14. The process of claim 10 wherein said edible solution comprises:
(a) from about 40% to about 60% water; (b) from about 11% to about
15% carbohydrates selected from the group consisting of modified
starch, corn syrup, corn syrup solids, maltodextrins, dextrins and
mixtures thereof; and (c) from about 10% to about 25% sugar.
15. The process of claim 14 wherein said carbohydrate is corn syrup
solids.
16. The process of claim 14 wherein said edible solution further
comprises a flavoring selected from the group consisting of yogurt,
honey-mustard, sour cream and onion, bacon, caramel, toffee, malt,
and sourdough.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/094,056 filed Jul. 24, 1998.
TECHNICAL FIELD
[0002] The present invention relates generally to low-fat and
fat-free snacks having a glossy coating, a process for making the
same, and the application of coatings to the snacks.
BACKGROUND OF THE INVENTION
[0003] In today's health conscious environment, there is a need for
low-fat and fat-free snack products. The United States Food &
Drug Administration regulations require snack products, in
particular pretzels, to contain less than 3 grams digestible fat/28
gram serving size to be classified as low-fat and less than 0.5
grams digestible fat/28 gram serving size to be classified as
fat-free. Therefore, substantial reformulation is necessary in
order to produce snacks that will fall within the regulations and
contain consumer-acceptable taste and texture qualities.
[0004] One problem to overcome in order to produce low-fat and
fat-free snack products is the reduction of fat-contributing
ingredients (e.g., emulsifiers, shortening, oil, flavoring, etc.)
while maintaining an acceptable taste and texture. Fats play an
important role in the way a dough behaves during processing and
greatly affect the quality, flavor and texture of the ready-to-eat
product. As the fat content in snack products is reduced or
replaced with other ingredients (e.g., non-digestible fat, protein,
fiber, gums), adverse organoleptical effects (e.g., mouthcoating,
drying, lack of crispness and lack of flavor) are increased. The
adverse organoleptic effects result in products having reduced
palatability.
[0005] Another problem to overcome is the lack of flavor display
and lubriciousness often exhibited by conventional low-fat and
fat-free pretzels. Typically, low-fat and fat-free pretzels are
hard, have decreased flavor display, and are not as lubricious as
high-fat snacks such as potato chips, cheese curls, corn chips and
the like.
[0006] One approach for improving the palatability, lubriciousness,
and flavor display of low-fat and fat-free snacks has been to add
flavors. The flavors are traditionally applied to the snack as
topical coatings in the form of dry powders (with or without a
binder) and/or as liquids (e.g., oil-based, water-based). Although
snacks having topical coatings comprising flavors are appetizing to
consumers, there are several problems associated with snack
products having these topical coatings. Several problems include:
(1) the products tend to be greasy and/or messy; (2) the coatings
have a tendency to leave a residue on the hands of the consumers;
(3) the appearance of the product can vary from batch to batch; (4)
increased drying times are needed to reduce the moisture of the
product; (5) the products have poor appearance (e.g., dull,
powdery); and (6) the products are mouth-drying. In addition,
especially in the case of pretzels, the desirable surface sheen and
color is also lost.
[0007] Another approach has been to add flavor to the dough;
however, these products have poor flavor display, primarily due to
the interaction between the flavor and starches in the dough
composition. It is believed that the starches bind the flavor
components and the flavor intensity is greatly suppressed. To
complicate matters further, the strong caustic-treated surface of
the pretzels prevents balanced flavor display, whether additional
flavors are added to the dough and/or topically to the pretzel.
[0008] Despite these various approaches which have been taken to
improve consumer appeal and palatability of low-fat and fat-free
pretzels, there is still an apparent need for improved low-fat and
fat-free pretzels having coatings applied thereto with the visual
appeal, flavor, and texture of full-fat pretzels. In addition,
processes of improved efficiency, methods of producing the
pretzels, and methods of coating pretzels are also needed.
[0009] An object of the present invention is to provide dough
compositions suitable for making low-fat and fat-free pretzels.
[0010] Another object of the present invention is to provide coated
low-fat and fat-free pretzels.
[0011] Still another object of the present invention is to
incorporate flavor in a stable glossy coating which can be applied
to snack foods, such as pretzels, corn chips, potato chips, puffed
products, tortilla chips and the like.
[0012] A further object of the present invention is to provide a
process for preparing coated pretzels having a glossy coating.
[0013] Still another object of the present invention is to provide
a coating which is capable of suspending and carrying flavors for
application onto the surface of snacks such as pretzels.
SUMMARY OF THE INVENTION
[0014] In accordance with the present invention, a dough
composition suitable for producing low-fat and fat-free pretzels is
provided. The dough composition comprises: (1) from about 55% to
about 75% flour; (2) from about 0.05% to about 2% leavening; (3)
from about 0% to about 4% added gluten; (4) from about 0% to about
5% corn syrup; (5) from about 25% to about 35% added water; and (6)
from about 0.01% to about 7% added fat. The dough retains its
shape, and additionally results in pretzels which have
substantially improved taste, texture and lubriciousness when
compared to conventional low-fat and fat-free pretzels.
[0015] Further, in accordance with the present invention, a process
for producing coated pretzels is provided. The process comprises
the steps of: (1) preparing the dough pieces; (2) applying caustic
solution to the dough pieces for a time sufficient to produce
ready-to eat pretzels having a pH less than about 8; (3) baking the
dough pieces in an oven at a temperature of from about 200.degree.
F. (93.3.degree. C.) to about 600.degree. F. (315.6.degree. C.);
and (4) coating the ready-to-eat pretzels with an edible
composition comprising sugar, salt, corn syrup solids, water and
optionally flavoring.
[0016] Still further in accordance with the present invention,
coated pretzels having a larger surface area to inner volume ratio
are provided. It has been found that pretzels having a larger ratio
of surface area to inner volume have substantially improved
organoleptical properties (e.g., crunchiness, lubriciousness,
mouthmelt, dryness) and can be produced using relatively short
drying times. Levels of caustic in solutions may also be reduced
which results in pretzels with less caustic taste.
[0017] In a preferred embodiment, a pretzel is prepared from a
low-fat or fat-free dough. The dough pieces are conveyed through a
bath of caustic solution, baked a first time at a temperature in
the range of from about 375.degree. F. (190.6.degree. C.) to about
550.degree. F. (287.8.degree. C.) for about 3 to about 5 minutes,
and baked a second time at a temperature in the range of from about
220.degree. F. (104.4.degree. C.) to about 250.degree. F.
(121.1.degree. C.) for a time sufficient to produce pretzels having
a moisture content of about 1% to about 4%.
[0018] The preferred pretzels have a ratio of surface area to inner
volume of about 22 inches.sup.-1 (8.66 cm.sup.-1) to about 40
inches.sup.-1 (15.75 cm-.sup.1), a pH of about 8 or less, a
digestible fat content of less than 3 g/28 g serving, and a
moisture content of from about 1% to about 4%.
[0019] In the production of shaped products having a small
cross-sectional area, such as pretzels in the shape of a bird or
other animal, the combination of gluten, diacetyl tartaric acid
esters of monoglycerides (DATEM) and small amounts of shortening is
preferably included in the dough composition to retain the shape of
the dough during machining and baking. Also, in the production of
pretzels comprising non-digestible fat, it has been found that it
is important to use the combination of gluten, DATEM and shortening
to: (a) improve gas retention/product expansion during baking; (b)
increase the mouthmelt of the pretzel; and (c) reduce the density,
hardness and dryness which may result when non-digestible fats are
used in the production of snacks.
[0020] Still further in accordance with the present invention, a
process for coating pretzels is provided, comprising the steps of:
(1) applying a coating (comprising a carbohydrate selected from the
group consisting of modified starch, corn syrup, corn syrup solids,
maltodextrins, dextrins and mixtures thereof), water, and
preferably, water-soluble flavoring, to ready-to-eat pretzels while
tumbling; (2) adding sugar and optionally salt to the tumbling
pretzels; (3) removing the pretzels from the tumbling device; and
(4) drying the pretzels while in a stationary position for a time
sufficient to produce pretzels having a moisture content of from
about 1% to about 4%.
DETAILED DESCRIPTION OF THE INVENTION
[0021] DEFINITIONS
[0022] As used herein, the term "coating" refers to a thin
film.
[0023] As used herein, the term "low-fat" means that the amount of
digestible fat, as regulated by the United States Food & Drug
Administration for pretzels, is 3 grams or less for a 28 gram
serving. The amount of digestible fat present in a product to be
labeled low-fat is referenced in terms of a reference serving size.
For pretzels the reference serving size is 28 grams.
[0024] As used herein, the term "fat-free" means that the amount of
digestible fat, as regulated by the United States Food & Drug
Administration for pretzels, is less than 0.5 gram for a 28 gram
serving. The amount of digestible fat present in a product to be
labeled fat-free is referenced in terms of a reference serving
size. For pretzels the reference serving size is 28 grams.
[0025] As used herein, the term "fat" is used interchangeably with
the terms "shortening" and "oil" unless otherwise specified. The
terms "fat", "shortening" 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 edible fatty materials having properties similar to
triglycerides; non-digestible fats, oils or fat substitutes;
reduced calorie fats; emulsifiers; and mixtures thereof are also
included in the term.
[0026] As used herein, 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.TM..
[0027] As used herein, "added fat" refers to fat, both digestible
and non-digestible, which is added to the dough over and above that
amount inherently present in the flour.
[0028] As used herein, "added gluten" refers to gluten which is
added to the dough over and above that amount inherently present in
the flour.
[0029] All percentages herein are by weight unless stated
otherwise.
[0030] SNACK FOOD PRODUCT
[0031] The snacks of the present invention can be prepared in a
variety of shapes and sizes. The invention described herein is
primarily in terms of a coated pretzel, however the coating and the
method for coating the pretzel can be applied to a variety of
shaped snacks suitable for topical flavor applications, such as
twists, balls, circles, and nuggets and the like.
[0032] Dough Composition
[0033] The dough compositions of the present invention comprise
predominantly wheat flour. However, small amounts other flours, for
example, barley flour, rye flour, oat flour, corn flour and
mixtures thereof, may be used in combination with wheat flour.
Preferably, at least about 60% of the flour is wheat flour.
[0034] Flour is present in the dough compositions at a level of
from about 55% to about 75%, preferably from about 60% to about
72%, and more preferably from about 66% to about 70%.
[0035] A leavening agent is included in the dough compositions of
the present invention. The preferred leavening agent is yeast.
Other leavening agents, however, may be used. Examples of other
leavening agents suitable for use in the present invention include
sodium aluminum phosphate, alkali metal carbonates, hydrogen
carbonates (e.g. sodium bicarbonate, sodium or potassium carbonate,
calcium carbonate), and mixture thereof. When chemical leavening is
used, it has been found that sodium bicarbonate or ammonium
bicarbonate used in conjunction with the emulsifier DATEM provides
improved leavening compared to the leavening provided when DATEM is
not used as the emulsifier. It has also been found that dough
expansion is suppressed when non-digestible fats are used in dough
compositions comprising yeast. Surprisingly, DATEM helps to
alleviate this problem.
[0036] The dough compositions of the present invention comprise
from about 0.05% to about 2%, preferably from about 0.07% to about
1%, and more preferably from about 0.08% to about 0.5%, leavening.
When yeast is used as the leavening, the level of leavening in the
dough is typically in the range of from about 0.05% to about 2%,
preferably from about 0.07% to about 1%, and more preferably from
about 0.08% to about 0.5%.
[0037] Wheat gluten is also included in the dough compositions of
the present invention to increase the strength of the dough and
crunchiness of the pretzel. The dough compositions of the present
invention comprise about 4% to about 11%, preferably about 5% to
about 10%, and more preferably about 6% to about 8%, gluten. The
dough compositions of the present invention comprise from about 0%
to about 4% added gluten.
[0038] Corn syrup is typically present in the dough compositions of
the present invention at a level of from about 0% to about 5%,
preferably from about 0.1% to about 3%, and more preferably from
about 1% to about 2%. As used herein, "corn syrup" refers to a
hydrolyzed carbohydrate. Typically corn syrups are classified on
the basis of dextrose equivalent (DE) value, which is a measurement
of the percentage of reducing sugars in the corn syrup, calculated
as dextrose, on a dry weight basis. Corn syrup typically has a DE
greater than about 20. Corn syrup is available with DE values
ranging from about 20 to about 65.
[0039] The dough compositions of the present invention comprise
from about 0.01% to about 7%, more preferably from about 0.1% to
about 4%, and most preferably about 0.2%, added fat. Suitable fats
include fats 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-digestible fats, reduced calorie fats; fat substitutes;
emulsifiers; and mixtures thereof.
[0040] 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.. 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.
[0041] As used herein, the term "polyol" is intended to include any
aliphatic or aromatic compound containing at least 2 free 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 are mannose, galactose, arabinose, xylose, ribose, apiose,
rhamnose, psicose, fructose, sorbose, tagatose, ribulose, xylulose,
and erthrulose. Oligosaccharides suitable for use herein include,
for example, maltose, kojibiose, nigerose, cellobiose, lactose,
melibiose, gentiobiose, turanose, rutinose, trehalose, sucrose and
raffmose. Polysaccharides suitable for use herein include, for
example, amylose, glycogen, cellulose, chitin, inulin, agarose,
zylans, mannan and galactans. Although sugar alcohols are not
carbohydrates in a strict sense, the naturally occurring sugar
alcohols are so closely related to the carbohydrates that they are
also preferred for use herein. Natural sugar alcohols which are
suitable for use herein are sorbitol, mannitol, and galactitol.
Particularly preferred classes of materials suitable for use herein
include the monosaccharides, the disaccharides and sugar alcohols.
Preferred unesterified polyols include glucose, fructose, glycerol,
alkoxylated polyglycerols, sugar ethers, and linked alkoxylated
glycerines as described in U.S. Pat. No. 5,516,544 to Sekula et
al., issued Jun. 14, 1996, incorporated by reference. A
particularly preferred polyol is sucrose. Preferred alkoxylated
polyols are described in the following U.S. Patents, incorporated
by reference herein; U.S. Pat. No. 5,273,772 to Cooper, issued Dec.
28, 1993; U.S. Pat. No. 5,288,884 to Cooper, issued Feb. 22, 1994;
U.S. Pat. No. 5,298,637 to Cooper, issued Mar. 29, 1994; U.S. Pat.
No. 5,362,894 to Handwerker et al., issued Nov. 8, 1994; U.S. Pat.
No. 5,374,446 to Ferenz et al., issued Dec. 20, 1994; U.S. Pat. No.
5,387,429 to Cooper, issued Feb. 7, 1995; U.S. Pat. No. 5,427,815
to Ferenz, issued Jun. 27, 1995; U.S. Pat. No. 5,466,843 to Cooper,
issued Nov. 14, 1995; U.S. Pat. No. 5,516,544; U.S. Pat. No.
5,589,217 to Mazurek, issued Dec. 31, 1996; and U.S. Pat. No.
5,597,605 to Mazurek, issued Jan. 28, 1997. More preferred
alkoxylated glycerines are linked alkoxylated glycerines and are
described in the following patents, previously incorporated herein,
U.S. Pat. Nos. 5,374,446; 5,427,815; and 5,516,544. Especially
preferred alkoxylated glycerines are those described in U.S. Pat.
No. 5,516,544, previously incorporated by reference.
[0042] By "polyol fatty acid polyester" is meant a polyol having at
least 2 fatty acid ester groups. 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.
[0043] 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.
[0044] Liquid non-digestible oils can also be used in the present
invention. Liquid non-digestible oils which 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 Hanun; 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 esterified 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 esterified 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.
[0045] 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 fats are
described in Young et al., U.S. Pat. No. 5,085,884, issued Feb. 4,
1992, and U.S. Pat. No. 5,422,131, issued Jun. 6, 1995 to Elsen et
al.
[0046] An emulsifier is also preferably added to the dough
composition of the present invention. The emulsifier may be
selected from the group consisting of polyglycerol monoesters, mono
and diglycerides, diacetyl tartaric acid esters of monoglycerides
(DATEM), mono-di-glycerides, lecithin, and mixtures thereof.
Preferably the emulsifier comprises DATEM and shortening at a ratio
of DATEM:shortening of from about 10:1 to about 1:10, preferably
from about 3:1 to about 1:2, and more preferably at a ratio of
about 2:1. The ratio of DATEM:shortening can vary depending on
whether the product is designed to be a low-fat product or a
fat-free product. The blend of DATEM and shortening is typically
used as an emulsifier system in the dough at a level of from about
0.05% to about 1%, and preferably at a level of from about 0.2% to
about 0.4%.
[0047] It is believed that the emulsifier aids in extrusion by
functioning as a lubricant and thus allowing increased extrusion
rates. It is additionally believed that the emulsifier works in
combination with the gluten by increasing and stabilizing gas
entrapment. It has been found that products comprising DATEM and
gluten exhibit substantially improved texture (e.g., increase
mouthmelt, long lasting crunchiness).
[0048] Water is also added to the dough compositions of the present
invention. Preferably, the dough compositions comprise from about
25% to about 35% added water, more preferably from about 27% to
about 30%, and most preferably from about 28.5% to about 29.5%. The
term "added water" refers to water which has been added to the dry
ingredients. Water which is inherently present in the dry dough
ingredients is not included in the term "added water." Water
present in the corn syrup is not included in the term "added
water."
[0049] Optionally, malt may be added to supplement and/or alter
flavor and texture of the final product. However, the addition of
high levels of malt may affect the rheology of the dough and cause
the loss of definition upon extrusion and cutting. Malt, if used,
is preferably present in the doughs of the present invention at a
level of less than about 1.5%.
[0050] Flavors may also be added to the dough compositions.
Preferred flavors include sourdough, mustard, honey, garlic, and
onion. Flavors are typically added to the dough at a level of less
than about 10%, preferably in the range of from about 0.5% to about
2%. The amount of flavor added will depend upon the concentration
of the flavor, type of flavor added, and the taste desired.
[0051] Process for Making Pretzels
[0052] Conventional mixing apparatus may be used to prepare the
pretzels of the present invention. Preferably flour, yeast,
shortening, emulsifier, corn syrup, wheat gluten, water, and
flavors, if desired, are mixed in a conventional mixer and added to
an extruder. The pretzels may be extruded using conventional
pretzel extruders. Extruders suitable for use in this invention
preferably have non-intermeshing screws, and are specifically
designed to operate at a pressure lower than 120 psi, and at lower
work input (i.e., without overworking the dough). A suitable
extruder is a single unit extruder available from Reading Pretzel
Machinery Corporation, Robesonia, Pa. A preferred extruder is an
extruder which has a die that shapes the dough to the desired shape
upon exiting the extruder. However, dough pieces may be formed by
any suitable means such as extrusion, stamping, rolling, cutting or
molding. For pretzels described herein as exemplary of the present
invention, extrusion through a die onto a conveyer is preferred
because it permits the rapid and continuous forming of dough pieces
while allowing good control over the shape, form and surface
characteristics of the pretzel.
[0053] After extrusion, the dough pieces are allowed to sit
stationary on a moving conveyor to "proof." This "proofing" allows
the dough piece to increase in volume while the fermentation
reaction between the yeast and other dough ingredients generate
ethanol gas and carbon dioxide gas. Typically, the proofing time is
about equal to the baking time in the first baking stage.
[0054] After proofing, the dough pieces are treated with a caustic
solution having a temperature of from about 70.degree. F.
(21.1.degree. C.) to about 210.degree. F. (98.9.degree. C.),
preferably from about 170.degree. F. (76.7.degree. C.) to about
205.degree. F. (96.1.degree. C.), and more preferably from about
190.degree. F. (87.8.degree. C.) to about 200.degree. F.
(93.3.degree. C). The caustic solution may be applied to the
pretzels by various methods. Preferably the caustic solution is
applied to the pretzels by dipping the pretzels in a caustic
solution typically comprising from about 0.1% to about 4%,
preferably from about 0.5% to about 1.5%, and most preferably from
about 0.6% to about 0.8% sodium hydroxide for less than about 20
seconds, preferably for about 7 seconds to about 10 seconds. The
concentration of caustic solution used is dependent on several
factors, including: (a) piece size; (b) contact time of the
solution with the pretzel; and (c) procedure used to treat the
pretzel (e.g., waterfall, spray, dip). It has been found that for
preferred embodiments (i.e., pretzels of the present invention
having a high ratio of surface area to inner volume), caustic
concentrations (.about.1%-2%) used in conventional pretzel
processing resulted in products having a strong caustic taste and
very hard texture. One advantage of the process of the present
invention is the ability to use lower levels of caustic solution
which results in products having substantially reduced
caustic-flavor. The pretzels additionally have surfaces which
readily accept topical flavors and which have improved flavor
display.
[0055] Alternatively, the dough pieces may be conveyed through a
waterfall or an atomized spray zone of hot caustic solution having
a plurality of nozzles for uniformly coating the outer surface of
the dough pieces. The atomized spray should be sufficient to
provide enough thermal heat to set proteins, gelatinize surface
starches and activate leavening. If a waterfall is used, a caustic
solution comprising from about 2% to about 7%, preferably from
about 3% to about 6% and more preferably from about 4% to about 5%,
sodium hydroxide is typically used.
[0056] Following the caustic treatment, the dough pieces are
optionally salted and finally conveyed to an oven where they are
baked at a temperature of from about 200.degree. F. (93.3.degree.
C.) to about 600.degree. F. (315.6.degree. C.), and preferably from
about 230.degree. F. (110.degree. C.) to about 450.degree. F.
(232.2.degree. C.). Most preferably, the dough pieces are baked
using a two-step process wherein first the dough pieces are carried
through a high temperature oven having a temperature of from about
375.degree. F. (190.6.degree. C.) to about 550.degree. F.
(287.8.degree. C.) for about 3 to about 5 minutes, and next they
are conveyed through a lower temperature oven having a temperature
of from about 190.degree. F. (87.8.degree. C.) to about 300.degree.
F. (148.9.degree. C.), preferably from about 220.degree. F.
(104.4.degree. C.) to about 250.degree. F. (121.1.degree. C.), for
a time sufficient to obtain a finished pretzel having a moisture
content of less than about 4% .
[0057] Pretzel
[0058] The resulting pretzels have a pH of from about 6 to about 8,
preferably from about 6.3 to about 7.5 and more preferably from
about 6.5 to about 7.2; in comparison, conventional pretzels
typically have a pH greater than about 8. The pretzel also has less
than 3 g digestible fat per 28 gram serving, and has a ratio of
surface area to inner volume of from about 22 inches.sup.-1 (8.66
cm.sup.-1) to about 40 inches.sup.-1 (15.75 cm.sup.-1) preferably
from about 25 inches.sup.-1 (9.84 cm.sup.-1) to about 33
inches.sup.-1 (12.99 cm.sup.-1) and more preferably from about 27
inches.sup.-1 (10.63 cm.sup.-1) to about 29 inches.sup.-1 (11.42
cm.sup.-1), calculated using the following formula: 1 Surface Inner
Volume = 2 .PI. rh .PI. r 2 h = 2 r
[0059] wherein r is the radius of the pretzel piece and h is the
total rope length of a pretzel piece if all intersections are cut
and the segments are joined end-to-end.
[0060] Coating Composition
[0061] The coating composition comprises: (a) a carbohydrate
selected from the group consisting of corn syrup, corn syrup
solids, modified starch and mixtures thereof; (b) water; and (c)
optionally flavoring and salt.
[0062] Preferably the coating comprises from about 47% to about 59%
water and has a total solids content of from about 41% to about
53%. As used herein, the term "water" refers to the total amount of
water. This includes water which is inherently present in the dry
and liquid ingredients added to the coating such as in the case of
the sources of modified starch, sugar, starches, dextrins,
maltodextrins, and corn syrup solids
[0063] Carbohydrates are added to the coating composition.
Preferably the carbohydrate is present in the coating at a level of
from about 11% to about 15%. Carbohydrates suitable for use in the
present invention are selected from the group consisting of corn
syrup, corn syrup solids, modified starch, maltodextrins, dextrins
and mixtures thereof. Suitable carbohydrates produce a glossy
coating when applied to the surface of the product and the product
is processed as described herein. Preferably, water evaporates
relatively quickly from the coating containing the carbohydrate,
the carbohydrate is capable of forming a thin film, and the
carbohydrate imparts no adverse taste to the product.
[0064] "Corn syrup" and "corn syrup solids" refer to hydrolyzed
carbohydrates. Corn syrup solids suitable for use herein have a DE
in the range of from about 20 to about 44. Corn syrups suitable for
used herein have a DE in the range of from about 20 to about
65.
[0065] Modified starches suitable for use herein include any
suitable food which has been modified by at least partial
hydrolysis and/or chemical modifications. Suitable modified
starches can be derived from starches such as corn, potato,
tapioca, and rice by processes including gelatinization,
acetylation, chlorination, acid hydrolysis, enzymatic action,
oxidation, or the introduction of carboxyl, sulfate or sulfonate
groups.
[0066] The sugars suitable for used herein may be selected from
sugars such as sucrose, dextrose, and fructose. Preferably, sucrose
is used because it is non-reducing and has a reduced tendency to
form non-enzymatic browning products and thus imparts less browning
to the finished products. Sugar is typically used at a level of
from about 14% to about 24%.
[0067] Optionally, and preferably, other ingredients such as salt,
flavoring and coloring may be added to the coating composition of
the present invention. Examples of flavorings include seasoning,
condiments, herbs, spices, vegetables, fruit, dairy
components/flavors (e.g., yogurt, cheese), sweetening
components/flavors (e.g., honey, caramel, vanilla, chocolate), malt
and mixtures thereof. The flavors may be added to the coating as a
liquid or may be added in a coarse, medium or finely granulated
form. Fat or oil-based flavorings may also be added but will
increase the overall fat content of the final product.
Additionally, fat or oil based flavoring may reduce the tendency of
the coating to adhere to the base pretzel. Particularly preferred
flavorings include yogurt, honey-mustard, sour cream and onion,
bacon, caramel, toffee, malt, and sourdough. If fat or fat-based
flavors are added to the coating, the level of fat present in the
coating is preferably less than about 5%. Flavorings can be added
to the coating composition up to a level of about 75%. Preferably
flavors are added at a level of from about 17% to about 56%.
[0068] Salt is typically added to the coating compositions at a
level of from about 0% to about 2.5%, preferably from about 0.5% to
about 1.4%.
[0069] Vitamins and minerals may also be added to the coating
compositions of the present invention.
[0070] The coatings of the present invention can be applied to
snack products such as corn chips, potato chips, puffed products,
tortilla chips and preferably pretzels using a process comprising
the steps of: (1) applying a warm coating comprising a
carbohydrate, water, and preferably flavoring, to ready-to-eat
snack products while tumbling; (2) adding sugar and optionally salt
to the tumbling snack products; (3) removing the snack products
from the tumbling device; and (4) drying the snack products while
in a stationary position.
[0071] The snack products are in a ready-to-eat form and are at a
temperature of from about 60.degree. F. (15.6 .degree. C.) to about
150.degree. F. (65.6.degree. C.), preferably from about 70.degree.
F. (21.1.degree. C.) to about 100.degree. F. (37.8.degree. C.) when
the coating is applied. The coating material should be fluid enough
to properly coat the snack products. This typically requires a
coating having a temperature of from about 40.degree. F. (
4.4.degree. C.) to about 200.degree. F. ( 93.3.degree. C.) ,
preferably from about 70.degree. F. (21.1.degree. C.) to about
180.degree. F. (82.2.degree. C.) , and more preferably from about
110.degree. F. (43.3.degree. C.) to about 170.degree. F.
(76.7.degree. C.). The pretzels are placed into a coating
apparatus. A hot solution comprising water, carbohydrate and any
liquid ingredients is applied to the snack product. The solution
may be applied by any conventional means which coats the products,
for example, spray, waterfall, brushing, pouring or dipping. The
pretzels are coated with the solution in a revolving coating pan or
drum. Preferably, the coating is applied to the snack products by
spray nozzles located in a tumbling drum. It is preferred that the
snack products tumble during coating to ensure proper coating.
Preferably, the snack products comprise less than about 25%
coating, more preferably from about 5% to about 20%, and most
preferably from about 10% to about 15% coating. A coating level
greater than about 25% is less desirable because it increases the
drying time.
[0072] After the snack products are coated with a sufficient amount
of the solution, the solids are added to the tumbling snack
products. After the coating is deposited onto the snack products,
the snack products are transferred to an oven and dried at a
temperature of from about 220.degree. F. (104.4.degree. C.) to
about 300.degree. F. (148.9.degree. C.), preferably from about
230.degree. F. (110.0.degree. C.) to about 280.degree. F.
(137.8.degree. C.), and more preferably from about 250.degree. F.
(121.1.degree. C.) to about 275.degree. F. (135.0.degree. C.), for
a time sufficient to produce a snack product having a moisture
content of from about 1% to about 4%, preferably from about 1.5% to
about 3.5%, more preferably from about 2.0% to about 2.7%.
Preferably, the coated snack products are conveyed to an oven such
as a conventional band oven or forced air oven.
[0073] The coating compositions, when applied to snack products and
in particular low-fat and fat-free pretzels, form coated low-fat
and fat-free snacks which are both attractive and palatable to
consumers. A glossy coating which improves the appearance, texture,
flavor, and mouthmelt is very desirable in such products.
EXAMPLES
[0074] The following examples are illustrative of the invention but
are not meant to be limiting thereof.
Example 1
[0075] A fat-free pretzel is prepared from the following dough
composition:
1 Ingredient Wt % Flour 68.00 Water 28.45 Corn Syrup 2.00 Wheat
Gluten 1.00 Shortening 0.15 Emulsifier 0.30 Yeast 0.10 Total
100.00
[0076] All of the ingredients are combined in a dough mixer. The
ingredients are mixed until well blended. The dough is fed into a
single unit extruder equipped with a bandcutter, such as that sold
by Reading Pretzel Machinery Corporation. The dough extrudate is
conveyed on a moving screen and through 0.6% hot sodium hydroxide
solution having a temperature of about 190.degree. F. (87.8.degree.
C.). After being dipped, the partially-cooked pretzels are cooked
in an oven having a temperature of about 425.degree. F.
(218.3.degree. C.) for about 5 minutes and then placed in a kiln
having a temperature of about 220.degree. F. (104.4.degree. C.) for
a time sufficient to reduce the moisture to about 2.5%.
Example 2
[0077] A pretzel comprising non-digestible fat is prepared from the
following dough composition:
2 Ingredient Wt % Flour 65.90 Water 29.00 Corn Syrup 1.60 Wheat
Gluten 1.50 Olean .RTM. 1.50 Emulsifier 0.40 Yeast 0.10 Total
100.00 Olean .RTM. is a non-digestible fat available from The
Procter and Gamble Company, Cincinnati, Ohio.
[0078] Olean.RTM. is a non-digestible fat available from The
Procter and Gamble Company, Cincinnati, Ohio.
[0079] All of the ingredients are combined in a dough mixer. The
ingredients are mixed until well blended. The dough is fed into a
single unit extruder equipped with a bandcutter, such as that sold
by Reading Pretzel Machinery Corporation. The dough extrudate is
conveyed on a moving screen and through 0.8% hot sodium hydroxide
solution having a temperature of about 200.degree. F. (93.3.degree.
C.). After being dipped, the partially-cooked pretzels are cooked
in an oven having a temperature of about 450.degree. F.
(232.2.degree. C.) for about 4 minutes and then placed in a kiln
having a temperature of about 250.degree. F. (121.1.degree. C.) for
a time sufficient to reduce the moisture to about 2.5%.
Example 3
[0080] A flavored pretzel is prepared from the following dough
composition according to the method of Example 1:
3 Ingredient Wt % Flour 65.00 Water 30.00 Corn Syrup solids 2.55
Wheat Gluten 1.00 Shortening 0.15 Emulsifier 0.30 Yeast 0.10 Onion
powder 0.60 Garlic Powder 0.30 Total 100.00
Example 4
[0081] A honey flavored coating composition is prepared from the
following:
4 Ingredient Wt % Water 53.00 Corn Syrup solids 12.50 Sucrose 25.00
Natural and artificial flavoring 8.00 Salt 1.40 Honey Powder 0.10
Total 100.00
[0082] The coating is prepared by combining all ingredients in a
larger mixer and blending on low speed until all ingredients are
mixed and no there are no lumps. The solution is heated to about
160.degree. F. (71.1.degree. C.) to facilitate dissolution. The
coating is applied to the base pretzel of Example 1. The base
pretzels are continuously fed into a rotating drum lined with
flights. The liquid coating is added in as a continuous stream at
the beginning of the drum in order to coat the pretzels as the drum
rotates. The solid flavors are added in a continuous curtain to the
tumbling product stream at the end of the drum, prior to the
discharge of the product. Upon discharge from the tumble drum, the
product is conveyed in such a fashion as to spread the pretzels
into a tightly-packed, mono-layer arrangement; this prevents the
product from forming large agglomerates during the subsequent
drying process. The coated product is then conveyed to a convection
oven and dried at about 275.degree. F. (135.0.degree. C.) until the
product reaches a moisture content of about 2.5%.
* * * * *