U.S. patent application number 10/682672 was filed with the patent office on 2004-05-20 for coating compositions for dough-based goods including doughnuts and other products.
Invention is credited to Goodsell, Gary R., Roskam, Robert O., Stevens, Cheree L.B., Stevens, John F..
Application Number | 20040096548 10/682672 |
Document ID | / |
Family ID | 32073446 |
Filed Date | 2004-05-20 |
United States Patent
Application |
20040096548 |
Kind Code |
A1 |
Stevens, Cheree L.B. ; et
al. |
May 20, 2004 |
Coating compositions for dough-based goods including doughnuts and
other products
Abstract
A food product including an edible substrate at least partially
derived from dough or batter is provided. Such a food product
includes a first water-soluble coating. The first coating includes
a starch, a starch derivative, or a mixture thereof. The first
coating at least partially covers the surface of the edible
substrate prior to the application of a second coating. The
substrate and the second coating have different water activities.
The first coating provides at least a partial moisture barrier
between the substrate and the second coating.
Inventors: |
Stevens, Cheree L.B.; (Idaho
Falls, ID) ; Stevens, John F.; (Idaho Falls, ID)
; Roskam, Robert O.; (Grand Rapids, MI) ;
Goodsell, Gary R.; (Dallas, TX) |
Correspondence
Address: |
PRICE HENEVELD COOPER DEWITT & LITTON, LLP
695 KENMOOR, S.E.
P O BOX 2567
GRAND RAPIDS
MI
49501
US
|
Family ID: |
32073446 |
Appl. No.: |
10/682672 |
Filed: |
October 9, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60417295 |
Oct 9, 2002 |
|
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|
Current U.S.
Class: |
426/94 |
Current CPC
Class: |
A23G 2200/08 20130101;
A23G 2210/00 20130101; A23G 3/48 20130101; A23G 2200/00 20130101;
A23G 3/343 20130101; A23G 3/343 20130101; A23G 3/343 20130101; A21D
13/26 20170101; A23G 3/343 20130101; A23G 3/343 20130101; A23G
3/0063 20130101; A23G 3/54 20130101; A23G 2200/06 20130101; A23G
2210/00 20130101; A23G 2200/08 20130101; A23G 2200/00 20130101;
A23G 2200/06 20130101 |
Class at
Publication: |
426/094 |
International
Class: |
A23G 003/00 |
Claims
The invention claimed is:
1. A food product comprising: an edible substrate at least
partially derived from dough or batter; and a first water-soluble
coating comprising a starch, a starch derivative, or a mixture
thereof at least partially covering the surface of the substrate
prior to application of a second coating, wherein the substrate and
the second coating have different water activities and the first
coating provides at least a partial moisture barrier between the
substrate and the second coating.
2. The food product of claim 1, wherein dough or batter is at least
partially derived from wheat.
3. The food product of claim 2, wherein the edible substrate
comprises a doughnut.
4. The food product of claim 1, wherein the first coating comprises
a wet slurry comprising at least one component other than
water.
5. The food product of claim 4, wherein the second coating
comprises a glaze.
6. The food product of claim 4, wherein the wet slurry is applied
to the edible substrate when the substrate comprises a raw dough,
raw batter, or a fried doughnut.
7. The food product of claim 6, wherein the wet slurry comprises at
least one modified starch wherein the starch has been modified by
acetylation, oxidation, substitution, crosslinking,
pregelatinization, or a mixture of these modifications.
8. The food product of claim 7, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
rice starch, a corn starch, a tapioca starch and a wheat
starch.
9. The food product of claim 6, wherein the wet slurry comprises a
high-solubility dextrin.
10. The pastry product of claim 9, wherein the high-solubility
dextrin comprises about 50% solids content of the wet slurry.
11. The food product of claim 4, wherein the substrate further
comprises a raw dough after proofing.
12. The food product of claim 6, wherein the components of the wet
slurry comprise from about 20% to about 90% of at least one starch
component; from about 0% to about 6% of a leavening system; from
about 2% to about 50% dextrin; from about 0% to about 30%
sweetener; from about 0% to about 3% stabilizer; from about 0% to
about 10% emulsifier; and from about 5% to about 50% rice
flour.
13. The food product of claim 12, wherein the starch component
comprises a wheat starch.
14. The food product of claim 12, wherein the components of the wet
slurry comprises at least one modified starch chosen from the group
consisting of an acetylated starch, an oxidized starch, a
substituted starch and a crosslinked starch.
15. The food product of claim 12, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
rice starch, a corn starch, a tapioca starch and a wheat
starch.
16. The food product of claim 12, wherein the leavening system
comprises: from about 0% to about 4% sodium acid pyrophosphate; and
from about 0% to about 2% sodium bicarbonate.
17. The food product of claim 12, wherein the dextrin comprises a
low-solubility dextrin.
18. The food product of claim 12, wherein the sweetener comprises
sucrose.
19. The food product of claim 4, wherein the substrate comprises a
raw dough substrate and the wet slurry is applied to the substrate
before or after proofing.
20. The food product of claim 4, wherein the wet slurry is applied
to a fried, then cooled, and subsequently reheated edible
substrate.
21. The food product of claim 20, wherein the edible substrate
comprises a doughnut at least partially derived from wheat.
23. The food product of claim 1, wherein the first coating
comprises at least one modified starch chosen from the group
consisting of an acetylated starch, an oxidated starch, a
substituted starch, a crosslinked starch, and a pregelatinized
starch.
24. The food product of claim 23, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
rice starch, a corn starch, a tapioca starch and a wheat
starch.
25. The food product of claim 14, wherein the components of the wet
slurry comprise a modified wheat starch.
26. The food product of claim 25, wherein the components of the wet
slurry comprise a starch and a starch derivative comprising a
low-solubility dextrin.
27. The food product of claim 14, wherein the components of the wet
slurry comprise a low-solubility dextrin.
28. The food product of claim 26, wherein the wet slurry components
comprise: from about 50% to about 100% modified wheat starch; and
from about 50% to about 100% of a dextrin.
29. The food product of claim 1, wherein the first coating
comprises a dry coating composition.
30. The food product of claim 29, wherein the dry coating
composition comprises at least one starch derivative.
31. The food product of claim 30, wherein the starch derivative
comprises a dextrin component.
32. The food product of claim 31, wherein the dry coating
composition comprises from about 20% to about 100% low-solubility
dextrin.
33. The food product of claim 29, wherein the dry coating
composition is applied to the substrate before proofing and frying
when the substrate comprises a raw dough or batter substrate.
34. The food product of claim 33, wherein the raw dough substrate
comprises a doughnut.
35. The food product of claim 33, wherein the dry coating
composition comprises a low-solubility dextrin.
36. The food product of claim 35, wherein the dry coating
composition comprises from about 20% to about 100% low-solubility
dextrin.
37. The food product of claim 29, wherein the dry coating
composition is applied to the edible substrate when the substrate
comprises a fried substrate.
38. The food product of claim 37, wherein the fried substrate
comprises a doughnut.
39. The food product of claim 38, wherein the dry coating
composition comprises at least one modified starch, wherein the
starch has been modified by acetylation, oxidation, substitution,
crosslinking, pregelatinization, or a mixture of these
modifications.
40. The food product of claim 39, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
rice starch, a corn starch, a tapioca starch and a wheat
starch.
41. The food product of claim 40, wherein the modified starch
comprises from about 20% to about 100% pregelatinized, crosslinked
corn starch.
42. The food product of claim 29, wherein the dry coating
composition is applied to a fried, then cooled and subsequently
reheated edible substrate.
44. The food product of claim 43, wherein the dry coating
composition comprising at least one modified starch wherein the
starch has been modified by acetylation, oxidation, substitution,
crosslinking, pregelatinization, or a mixture of these
modifications.
45. The food product of claim 44, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
rice starch, a corn starch, a tapioca starch and a wheat
starch.
46. The food product of claim 45, wherein the modified starch
comprises from about 20% to about 100% modified corn starch.
47. A bakery product comprising: a substantially uncooked doughnut
substrate at least partially derived from dough or batter, wherein
the dough is at least partially derived from wheat; and a wet
slurry coating composition comprising components of the wet slurry
other than water, wherein the components comprise: from about 20%
to about 90% of at least one starch component; from about 0% to
about 6% of a leavening system; from about 2% to about 50% dextrin;
from about 0% to about 30% sweetener; from about 0% to about 3%
stabilizer; from about 0% to about 10% lecithin; and from about 5%
to about 50% rice flour; wherein the wet slurry composition at
least partially covers the surface of the substrate prior to
application of a second coating, wherein the substrate and the
second coating have different water activities and the first wet
slurry coating composition provides a moisture barrier between the
substrate and the second coating.
48. The bakery product of claim 47, wherein the solids content of
the wet slurry comprises: from about 40% to about 70% of a potato
starch; from about 0.8% to about 3.5% of a leavening system; from
about 5% to about 30% dextrin; from about 3% to about 15%
sweetener; from about 0.05% to about 1.0% stabilizer; from about
0.5% to about 5% lecithin; and from about 10% to about 35% rice
flour.
49. A bakery product comprising: a thermally processed doughnut
substrate at least partially derived from dough, wherein the dough
is at least partially derived from wheat; and a wet slurry coating
composition comprising components of the wet slurry other than
water, wherein the components comprise: from about 20% to about 90%
of at least one starch component; from about 0% to about 6% of a
leavening system; from about 2% to about 50% dextrin; from about 0%
to about 30% sweetener; from about 0% to about 3% stabilizer; from
about 0% to about 10% lecithin; and from about 5% to about 50% rice
flour; wherein the wet slurry coating composition at least
partially covers the surface of the substrate prior to application
of a second coating, wherein the substrate and the second coating
have different water activities and the first wet slurry coating
composition provides a moisture.
50. The bakery product of claim 49, wherein the thermally processed
doughnut comprises a fried doughnut.
51. The bakery product of claim 50, wherein the solids of the wet
slurry comprise: from about 40% to about 70% of a potato starch;
from about 0.8% to about 3.5% of a leavening system; from about 5%
to about 30% dextrin; from about 3% to about 15% sweetener; from
about 0.05% to about 1.0% stabilizer; from about 0.5% to about 5%
lecithin; and from about 10% to about 35% rice flour.
52. A bakery product comprising: a thermally processed,
subsequently cooled and thereafter reheated doughnut substrate at
least partially derived from dough or batter, wherein the dough or
batter is at least partially derived from wheat; and a wet slurry
coating composition comprising components of the wet slurry other
than water, wherein the components comprise from about 50% to about
100% high solubility dextrin; wherein the wet slurry composition at
least partially covers the surface of the substrate prior to
application of a second coating, wherein the substrate and the
second coating have different water activities and the wet slurry
coating composition provides a moisture barrier between the
substrate and the second coating.
53. A bakery product comprising: a thermally processed,
subsequently cooled and thereafter reheated doughnut substrate at
least partially derived from dough or batter, wherein the dough or
batter is at least partially derived from wheat; and a wet slurry
coating composition comprising components of the wet slurry other
than water, wherein the components comprise from about 50% to about
100% wheat starch; wherein the wet slurry composition at least
partially covers the surface of the substrate prior to application
of a second coating, wherein the substrate and the second coating
have different water activities and the wet slurry coating
composition provides a moisture barrier between the substrate and
the second coating.
54. The bakery product of claim 53, wherein the wheat starch
comprises an oxidized and substituted wheat starch.
55. A bakery product comprising: a substantially uncooked doughnut
substrate at least partially derived from dough or batter, wherein
the dough or batter is at least partially derived from wheat; and a
dry coating composition comprising: from about 50% to about 100%
potato dextrin; wherein the dry coating composition at least
partially covers the surface of the dough prior to application of a
second coating and the dough and the second coating have different
water activities and the dry coating composition provides a
moisture barrier between the doughnut dough and the second
coating.
56. A bakery product comprising: a thermally processed,
subsequently cooled and thereafter reheated doughnut substrate at
least partially derived from dough or batter, wherein the dough or
batter is at least partially derived from wheat; and a dry coating
composition comprising: from about 20% to about 100% pregelatinized
modified corn starch, wherein the dry coating composition is
applied to at least the surface of the substrate prior to
application of a second coating, the substrate and the second
coating have different water activities and the dry coating
composition provides at least a partial moisture barrier between
the substrate and the second coating.
57. A bakery product comprising: a thermally processed doughnut
substrate at least partially derived from dough or batter, wherein
the dough or batter is at least partially derived from wheat; and a
dry coating composition comprising: from about 20% to about 100%
pregelatinized crosslinked corn starch at least partially covering
the surface of the substrate prior to application of a second
coating, wherein the substrate and the second coating have
different water activities and the first dry coating composition
provides a moisture barrier between the substrate and the second
coating.
58. A method of making a food product comprising: providing an
edible substrate partially derived from dough or batter, wherein
the dough or batter is at least partially derived from wheat; a
first pastry coating comprising starch, a starch derivative or
mixtures thereof; and a second coating; applying the first coating
to at least partially cover the surface of the edible pastry
substrate; thermally processing the edible substrate either before
or after application of the first coating; and applying the second
coating after application of the first coating, wherein the edible
pastry substrate and the second coating have different water
activities and the first coating provides at least a partial
moisture barrier between the edible pastry substrate and the second
coating.
59. The method of claim 58, wherein the edible substrate comprises
a doughnut substrate.
60. The method of claim 59, wherein the first coating comprises a
wet slurry comprising at least one component other than water.
61. The method of claim 60, wherein the wet slurry is applied to
the edible substrate when the substrate comprises a raw dough
substrate before or after proofing.
62. The method of claim 61, wherein the wet slurry comprises at
least one starch, wherein the starch has been modified by
acetylation, oxidation, substitution, crosslinking,
pregelatinization, or a mixture of these modifications.
63. The method of claim 62, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
wheat starch, a corn starch, a tapioca starch and a rice
starch.
64. The method of claim 61, wherein the starch derivative comprises
a low-solubility dextrin.
65. The method of claim 61, wherein the second coating comprises a
glaze comprising a sweetener.
66. The method of claim 61, wherein the wet slurry comprises a
solids content of from about 35% to about 50%.
67. The method of claim 60, wherein the wet slurry components
comprise: from about 20% to about 90% of at least one starch
component; from about 0% to about 6% of a leavening system; from
about 2% to about 50% dextrin; from about 0% to about 30%
sweetener; from about 0% to about 30% stabilizer; from about 0% to
about 10% lecithin; and from about 5% to about 50% rice flour.
68. The method of claim 67, wherein the starch component comprises
wheat starch.
69. The method of claim 68, wherein the wet slurry comprises at
least one modified starch, wherein the starch has been modified by
acetylation, oxidation, substitution, crosslinking,
pregelatinization, or a mixture of these modifications.
70. The method of claim 69, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
rice starch, a corn starch, a tapioca starch and a wheat
starch.
71. The method of claim 67, wherein the leavening system comprises:
from about 0% to about 4% sodium acid pyrophosphate; and from about
0% to about 2% sodium bicarbonate.
72. The method of claim 61, wherein the thermally processing
comprises frying.
73. The method of claim 72, wherein the edible substrate comprises
a doughnut fried on both sides for about 80 to about 90 seconds at
a temperature from about 3650F to about 375.degree. F.
74. The method of claim 60, wherein the wet slurry is applied to
the edible substrate after the substrate has been thermally
processed by frying.
75. The method of claim 74, wherein the wet slurry components
comprise: from about 20% to about 90% of at least one starch
component; from about 0% to about 6% of a leavening system; from
about 2% to about 50% dextrin; from about 0% to about 30%
sweetener; from about 0% to about 3% stabilizer; from about 0% to
about 10% lecithin; and from about 5% to about 50% rice flour.
76. The method of claim 74, wherein the starch component comprises
a wheat starch.
77. The method of claim 76, wherein the wet slurry comprises at
least one modified starch, wherein the starch has been modified by
acetylation, oxidation, substitution, crosslinking,
pregelatinization, or a mixture of these modifications.
78. The method of claim 77, wherein the at least one modified
starch is chosen from the group consisting of a potato starch, a
rice starch, a corn starch, a tapioca starch and a wheat
starch.
79. The method of claim 76, wherein the leavening system comprises:
from about 0% to about 4% sodium acid pyrophosphate; and from about
0% to about 2% sodium bicarbonate.
80. The method of claim 72, wherein the edible substrate comprises
a doughnut fried on both sides for about 20 to about 50 seconds at
a temperature of from about 365.degree. F. to about 375.degree.
F.
81. The method of claim 60, wherein the wet slurry is applied to a
fried, subsequently cooled and thereafter reheated doughnut
substrate.
82. The method of claim 81, wherein the wet slurry comprises from
about 20% to about 100% pregelatinized modified corn starch.
83. The method of claim 81, wherein the doughnut is fried on both
sides for about 80 to about 90 seconds at a temperature of from
about 365.degree. F. to about 375.degree. F.
84. The method of claim 83, wherein doughnuts are cooled and
thereafter reheated to a surface temperature of greater than
160.degree. F.
85. The method of claim 58, wherein the first coating comprises a
dry coating composition.
86. The method of claim 85, wherein the edible substrate comprises
a doughnut substrate.
87. The method of claim 86, wherein the dry coating composition is
applied to the edible substrate when the substrate comprises a raw
dough substrate before or after proofing.
88. The method of claim 86, wherein the dry coating composition
comprises from about 20% to about 100% potato dextrin.
89. The method of claim 88, wherein the doughnut substrate is
thermally processed by frying the substrate on both sides for from
about 80 to about 90 seconds at a temperature of from about
365.degree. F. to about 375.degree. F.
90. The method of claim 85 further comprising cooling the thermally
processed edible pastry substrate, subsequently reheating the
edible substrate and wherein the dry composition is applied after
the edible substrate has been reheated.
91. The method of claim 90, wherein the dry composition comprises
from about 20% to about 100% pregelatinized modified corn
starch.
92. The method of claim 90, wherein the doughnuts are thermally
processed on both sides for from about 80 to about 90 seconds at a
temperature of from about 365.degree. F. to about 375.degree.
F.
93. The method of claim 90, wherein the edible pastry substrate
comprises a doughnut substrate and the doughnut substrate is cooled
to a temperature of less than 100.degree. F. prior to
reheating.
94. The method of claim 93, wherein the doughnut substrate is
reheated to a surface temperature of greater than about 160.degree.
F. prior to application of the dry coating composition.
95. The method of claim 85, wherein the edible pastry substrate
comprises a doughnut substrate, the doughnut substrate is thermally
processed by frying the doughnut substrate, and the dry coating
composition is applied to the doughnut substrate after frying.
96. The method of claim 95, wherein the dry coating composition
comprises from about 20% to about 100% pregelatinized crosslinked
corn starch.
97. The method of claim 96, wherein the doughnut substrate is fried
on both sides for about 80 to about 90 at a temperature of from
about 365.degree. F. to about 375.degree. F.
98. The method of claim 86, wherein the second coating comprises a
glaze.
99. A product comprising: a doughnut substrate comprising raw dough
or batter at least partially derived from wheat; and a wet slurry
coating comprising water and components other than water
comprising: from about 40% to about 70% starch; from about 0.8% to
about 3.5% leavening system; from about 5% to about 30%
low-solubility dextrin; from about 3% to about 15% granular sugar;
from about 0.05% to about 1.0% xanthan gum; from about 0.5% to
about 5% lecithin; and from about 10% to about 35% rice flour;
wherein the wet slurry coating substantially covers the surface of
the doughnut substrate prior to thermal processing of the doughnut
substrate and prior to application of a second coating, the
doughnut substrate and the second coating have different water
activities and the wet slurry coating provides a substantially
complete moisture barrier between the doughnut substrate and the
second coating.
100. A product comprising: a fried doughnut substrate at least
partially derived from dough or batter, wherein the dough or batter
is at least partially derived from wheat; and a wet slurry coating
comprising water and components other than water comprising: from
about 40% to about 70% starch; from about 0.8% to about 3.5%
leavening system; from about 5% to about 30% low-solubility
dextrin; from about 3% to about 15% granular sugar; from about
0.05% to about 1.0% xanthan gum; from about 0.5% to about 5%
lecithin; and from about 10% to about 30% rice flour; wherein the
wet slurry coating substantially covers the doughnut before
application of a second coating, wherein the doughnut and the
second coating have different water activities and the wet slurry
coating provides a substantially complete moisture barrier between
the doughnut and the second coating.
101. A product comprising: a fried, then cooled, reheated doughnut
substrate at least partially derived from dough or batter, wherein
the dough or batter is at least partially derived from wheat; and a
wet slurry coating comprising water and components other than water
comprising: from about 50% to about 100% wheat starch or from about
50% to about 100% dextrin; wherein the wet slurry coating
substantially covers the surface of the doughnut substrate prior to
the application of a second coating, wherein the doughnut substrate
and the second coating have different water activities and the wet
slurry coating provides a substantially complete moisture barrier
between the doughnut substrate and the second coating.
102. A product comprising: a doughnut substrate comprising raw
dough or batter, wherein the dough or batter is at least partially
derived from wheat; and a dry coating composition comprising a
dextrin substantially covering the surface of the doughnut
substrate prior to application of a second coating, wherein the
doughnut substrate and the second coating have different water
activities and the dry coating composition provides a substantially
complete moisture barrier between the substrate and the second
coating.
103. The product of claim 102, wherein the dry coating composition
is applied to the doughnut substrate and thereafter the doughnut
substrate and the coating thereon are thermally processed.
104. A product comprising: a fried doughnut substrate at least
partially derived from dough or batter, wherein the dough or batter
is at least partially derived from wheat; and a dry coating
composition comprising a starch substantially covering the surface
of the fried doughnut substrate prior to application of a second
coating, wherein the fried doughnut substrate and the second
coating have different water activities and the dry coating
composition provides a substantially complete moisture barrier
between the fried doughnut and the second coating.
105. A product comprising: a fried, then cooled, then reheated
doughnut substrate at least partially derived from dough or batter,
wherein the dough or batter is at least partially derived from
wheat; and a dry coating composition comprising starch
substantially covering the surface of the doughnut substrate prior
to application of a second coating, wherein the doughnut substrate
and the second coating have different water activities and the dry
coating composition provides a substantially complete moisture
barrier between the doughnut substrate and the second coating.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 60/417,295, filed Oct. 9, 2002, the
disclosure of which is hereby incorporated by reference in its
entirety.
BACKGROUND OF THE INVENTION
[0002] This invention generally relates to a coating compositions
applied to the external surface of dough-based goods (at least
partially derived from dough) including doughnuts and other
products, typically wheat-based doughnuts.
[0003] Numerous different types of edible food coatings are known.
These include relatively heavy and thick coatings of various
materials (e.g., bread crumbs, potato batter, tempura, etc.) as
well as various flour or starch-based coatings that are usually
applied as a relatively thin batter thereby forming a much thinner
coating, which can be substantially transparent after application
to the food substrate. The thinner coatings are then cooked,
further cooked if parfried, or otherwise thermally processed. This
latter type of coating is extensively used on commercially prepared
french fry potatoes, where they are often referred to as "clear
coats" due to their unobtrusive and, in some cases, virtually
unnoticeable visual characteristic. Traditionally, clear coats
formulated for french fry products do not adhere effectively to
wheat based substrates, such as pastries or dough.
[0004] It is also known to use clear glazes on dough-based baked
goods such as doughnuts and the like. The glazes may be applied
either before or after baking. While generally sugar-based glazes
are applied to impart shine and eye appeal, they tend to become wet
and sticky. Still other glazes have been used to impart softness to
the surface of a baked or fried good, such as doughnuts.
[0005] Doughnuts have been known since at least about the
mid-19.sup.th century. A doughnut is typically a small, usually
ring-shaped dough fried in fat. Yeast raised and cake doughnuts are
typically fried dough products traditionally having a sugar glaze
applied to the surface. The dough portion of the finished product
typically has a water activity of from about 0.8 to about 9.5
whereas the glazed portion of the finished product typically has a
water activity of less than about 0.7. Water activity is a measure
of how much water is bound within a product matrix that is unable
to migrate and take part in reactions or be available for
microorganisms. The water activity of pure water is 1.0. In food
systems or products where two or more distinct components that have
different water activities are combined, as in glazed doughnuts,
there will be a migration of moisture from the area of higher water
activity to the area of lower water activity until equilibrium is
reached. When this happens in traditional glazed doughnuts, the
moisture from the dough portion migrates to the glazed portion and
causes the sugar ingredients in the glazed portion to dissolve,
become wet and liquefy. The time it takes for the glaze to liquefy
as a result of this migration is typically the determining factor
for identifying the shelf-life of the finished doughnut product.
Generally, doughnuts available in the retail market generally have
a shelf-life of from about 6 hours to about 2 days depending upon
the relative humidity in the given marketplace, more typically such
doughnuts have a shelf-life of from about 8 hours to about one
day.
[0006] Food coating moisture barriers are typically either
water-soluble or solvent-soluble. The more water-soluble a film or
barrier, usually the film or barrier becomes more permeable to
water vapor. The solvent-soluble barriers are typically the best
moisture barriers (e.g. shellac) because water vapor does not pass
through them as readily. Shellac is a resinous secretion called
lac, of the insect Liaccifen lacca. Shellac is not water-soluble
and is generally considered a glaze and a surface finishing agent.
However, solvent-soluble barriers possess a major disadvantage,
namely, they are solvents. Food manufacturers have to ensure that
the solvent exhausted from their facilities is regulated since it
contributes to the total volatile organic compounds (VOCs). The
United States Environmental Protection Agency tightly regulates
VOCs, especially in more populated urban areas.
[0007] Another known type of coating utilizes a food grade wax
dispersed in vegetable oil. This type of coating is most often used
on pizza crusts and meat pies to prevent moisture in the sauce or
filling, respectfully, from leaching into the crust or shell. This
coating is not water soluble, requires hot water detergents for
cleaning, and significantly increases the fat content of the
finished product.
[0008] Accordingly, there is a need for water-soluble, moisture
barrier compositions that (1) can be applied to the surface of
doughnuts or other pastry products before glaze or other coating
application and (2) form at least a partial barrier to moisture
transfer that otherwise occurs between the dough portion and the
glazed or other coated portion of the finished product when water
activity gradients are present.
SUMMARY OF THE INVENTION
[0009] The present invention goes well beyond prior art technology
in both the nature and use of thin, edible food coatings by
providing coating formulations and application procedures that
enable the coatings to be applied either in a slurry state or a dry
solid state and either before or after thermal processing of the
dough-based good(s) such as a doughnut. The present invention
includes a coating that includes starch where the coating is in dry
or slurry form that can be applied to the surface of a doughnut or
other dough-based product either before or after the doughnut is
processed, typically by frying, prior to a glaze or other coating
application. The starch mixture provides at least a partial
moisture barrier that at least partially prevents moisture transfer
that would otherwise occur between the dough portion and the glaze
portion due to the different water activities of the dough portion
and the glaze portion. The coating provides significantly extended
shelf-life to doughnuts over typical doughnuts without such a
moisture barrier. The present invention also relates to dough-based
products, typically doughnuts and the like, produced utilizing the
coating compositions of the present invention and methods of
producing the dough-based, coated products.
[0010] These and other features, advantages, and objects of the
present invention will be further understood and appreciated by
those skilled in the art by reference to the following
specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a flow chart depicting an embodiment of the
process of applying the water-soluble moisture barrier wet slurry
composition to raw dough before or after proofing according to the
present invention;
[0012] FIG. 2 is a flow chart depicting an embodiment of the
process of applying the water-soluble moisture barrier wet slurry
composition to a fried doughnut according to the present
invention;
[0013] FIG. 3 is a flow chart depicting an embodiment of the
process of applying the water-soluble moisture barrier wet slurry
composition to a fried, cooled, and then reheated doughnut
according to the present invention;
[0014] FIG. 4 is a flow chart depicting an embodiment of the
process of applying the water-soluble moisture barrier composition,
typically by dusting, to raw dough before or after proofing
according to the present invention;
[0015] FIG. 5 is a flow chart depicting an embodiment of the
process of applying the water-soluble moisture barrier composition,
typically by dusting, to a fried doughnut according to the present
invention; and
[0016] FIG. 6 is a flow chart depicting an embodiment of the
process of applying the water-soluble moisture barrier composition,
typically by dusting, to a fried, cooled and then reheated doughnut
according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0017] A doughnut is typically a small usually ring-shaped dough
product most often cooked by frying in fat. Consumers may purchase
a doughnut for immediate consumption, reheat then consume, or thaw
and then consume. Typically, doughnut varieties include, but are
not limited to glazed, filled, iced, cake and/or yeast dough-based,
and/or flavored doughnuts, etc. Any flavor dough or coating may be
employed. Doughnuts also include a variety of shapes, including but
not limited to spherical mass (i.e. doughnut holes), O-shaped
(i.e., a doughnut ring with a missing center), oval shaped, star
shaped, etc. Typically, yeast raised doughnuts have lower moisture
content than chemically raised doughnuts such as cake doughnuts,
but the moisture barrier coating compositions of the present
invention apply to both. However, due to the water activity
difference, the coating is especially beneficial when providing a
moisture barrier for yeast-raised doughnuts. However, the term
"doughnut" is meant to encompass any dough-based or batter-based
product that is fried or otherwise thermally processed prior to
consumption. Accordingly, the term doughnuts includes items such as
elephant ears and funnel cakes.
[0018] The clear coat moisture barrier composition of the present
invention is typically applied to the surface of the doughnut prior
to application of a glaze or other coating. The clear coat
water-soluble moisture barrier composition forms at least a
partial, but more typically a substantially complete or complete
water-soluble moisture barrier that substantially inhibits transfer
of moisture that, absent the moisture barrier coating, otherwise
occurs between the dough portion and the glazed or other coated
portion of the finished product due to the difference in water
activities between the dough portion and the glaze or other coating
portion. "Water soluble" as used herein means the components are
capable of being at least partially dissolved in water or are
capable of being dispersed in water. The clear coat moisture
barrier coating is typically substantially invisible to the
consumer and thus will not detract from the appearance of the
doughnut to which it is applied. Optionally, a colorant could be
added, but this is usually not desired and, therefore, is not
typically included in the formula. However, if one were to use a
colorant, possible colorants include caramel, or any water
dispersible food colorant or combination of food colorants.
[0019] By incorporating a moisture barrier between the dough
portion and the glazed coated portion, the water migration to the
glaze does not occur or is greatly limited. The moisture barrier
offers many benefits including, but not limited to, extending the
shelf-life of the glazed doughnuts. The shelf-life of glazed coated
doughnuts can be extended from about 6 hours to 6 or more days. In
this instance the shelf-life of the product is determined by the
staling (hardening of the starch) within the doughnut and not
wetting out of the glaze. Because of the clear coat moisture
barrier glazed doughnuts have an increased shelf-life and because
they are less affected by changes in humidity, there is no need for
multiple and costly doughnut production facilities strategically
placed throughout their marketplace. Rather, the moisture barrier
coated glazed or other coated doughnuts may be produced in one
location and then shipped to their final destinations without risk
of staling within the time frame of past glazed doughnuts. This is
a result of the significantly increased shelf-life of the goods,
typically doughnuts, from about 8 hours to one day to about six or
more days. Thus, through use of the inventive coating compositions
this new distribution method for doughnuts utilizes fewer
centralized facilities.
[0020] Additionally, an effective clear coat moisture barrier is
achieved without the use of solvent-soluble films which are
generally regarded as the most effective moisture barrier, but have
strict United States Environmental Protection Agency regulations
regarding their exhaust from production facilities. To the
contrary, because the coating compositions of the present invention
include starch and other water-soluble components, they are not
strictly controlled and are not strictly regulated by the United
States Environmental Protection Agency.
[0021] The water-soluble, clear coat moisture barrier composition
of the present invention is typically applied as a wet slurry or as
a dry dusting or a combination of the two on the doughnut or other
dough-based goods. Either the wet slurry or any applications may be
done before or after proofing and frying (FIGS. 1 and 4), on fried
doughnuts (FIGS. 2 and 5) or on fried, cooled, then reheated
doughnuts or other dough-based goods (FIGS. 3 and 6). It is
presently believed that the water-soluble, clear coat composition
of the present invention best forms a moisture barrier upon thermal
processing or by its application to a warm or hot food substrate;
however, heating or a hot surface is not presently believed to be a
requirement for formation of the moisture barrier.
[0022] Additionally, the coating compositions can be applied at the
source of consumer purchase. If the doughnuts are produced on-site
or thawed after freezing, once thermally processed, the coating
composition can be applied prior to coating with a glaze or other
coating. Also, the doughnuts can be produced and coated and
subsequently frozen in a liquid nitrogen freezer system such as
those available from BOC Gases in Murry Hill, N.J. This allows the
doughnuts to be thawed and a glaze applied either later at the same
location, but more often at the end production facility such as a
grocery store or doughnut store.
[0023] Moreover, the doughnut may be coated with the composition of
the present invention, glazed and subsequently frozen. This allows
for total production at one facility, easy distribution over a
larger distance without spoilage, and surprisingly, when the
finished product is thawed, there is no wetting out of the
doughnut. In doughnuts without the coating composition of the
present invention, wetting-out occurs at least 2-4 times as
rapidly. It is presently believed that ice crystals, typically
formed at the surface of the glaze, and condensation from ambient
air humidity as the doughnut thaws are essentially pulled in and
absorbed by the moisture barrier coating composition preventing
wetting-out of the glaze upon thawing.
[0024] The doughnut substrate may also be coated with a coating
composition of the present invention, frozen, thawed, and coated
again prior to application of the glaze or other coating. A larger
amount of the coating composition could also be applied prior to
freezing to thereby provide a more complete moisture barrier to the
food substrate upon thawing and application of the glaze.
WET SLURRY
[0025] Typical Moisture Barrier Composition for Fried or Raw Dough
Doughnuts
[0026] When the moisture barrier coating of the present invention
is applied as a wet slurry on a fried doughnut, parfried, or to raw
dough before or after proofing, the clear coat water-soluble
moisture barrier composition may include the following ingredients:
a modified potato starch; sodium acid pyrophosphate 28 (leavening
agent); sodium bicarbonate (leavening agent); dextrin; sucrose
(sweetening agent); gums (stabilizer); an emulsifier (granular
lecithin); and flour, typically rice flour.
[0027] The modified (chemically or physically) potato starch is
typically present in the moisture barrier slurry composition
applied to raw dough before or after proofing or to a fried
doughnut in an amount of from about 20% to about 90% by weight of
the coating composition, more typically from about 40% to about
70%, and most typically at about 56.65%. The modified potato starch
primarily provides film formation properties. Typically, the potato
starch has been modified by any industrially acceptable
modification means, including, but not limited to, crosslinking or
substitution. Any suitable potato starch may be used whether
modified or unmodified. In fact, it is presently believed that any
starch may be utilized in the slurry composition of the present
invention including corn starch, potato starch, tapioca starch,
wheat starch or mixture thereof.
[0028] The moisture barrier wet slurry composition applied to a
fried doughnut, a parfried doughnut, or to raw dough before or
after proofing also may contain a leavening system, usually a
two-component, acid/base leavening system. When utilized in the
moisture barrier coating, the leavening system typically utilizes
an acid in combination with a bicarbonate salt. When a leavening
system is used, the sodium acid pyrophosphate (SAPP) or other acid
is typically present in the range of from about 0% to about 4% by
weight of the coating composition, more typically from about 0.5%
to about 2.5%, and most typically about 1.0%. The bicarbonate salt
typically includes sodium bicarbonate within the range of from
about 0% to about 2% by weight of the coating composition, more
typically from about 0.3% to about 1.5%, and most typically at
about 0.7%. Any sodium bicarbonate or SAPP may be used in the
present invention. The sodium acid pyrophosphate, in combination
with sodium bicarbonate, provides chemical leavening that results
in a lighter tender texture of the exterior of the doughnut. While
a leavening system is typically employed in a slurry application of
the coating of the present invention, use of a leavening system is
optional.
[0029] The moisture barrier slurry compositions applied to raw
dough before or after proofing or to a fried doughnut also
typically includes a dextrin. The dextrin utilized may include corn
dextrin, tapioca dextrin, potato dextrin, or any other commercially
acceptable dextrin; however, corn dextrin is most typically used.
The dextrin is believed to provide superior film forming
functionality to the coating compositions when used to coat
dough-based products over other dextrins. All dextrins are soluble
to some degree; however, a low solubility dextrin is typically used
in the moisture barrier composition for fried or raw dough
doughnuts. The term "low solubility dextrin" typically means less
than 32% of the dextrin is soluble when placed in cold water
(approximately 77.degree. F.). Further, to one of ordinary skill in
this art, the term "low solubility dextrin" also generally refers
to the solubility of a dextrin when compared to other dextrins. For
example, a medium solubility dextrin typically exhibits from about
32% to about 90% solubility when placed in cold water
(approximately 77.degree. F.) and a high solubility dextrin
typically exhibits about 90% or more solubility when placed in cold
water (approximately 77.degree. F.).
[0030] The typical moisture barrier slurry composition used in the
coatings of the present invention contains corn dextrin in an
amount of from about 2% to about 50% by weight of the coating
composition, more typically from about 5% to about 30%, and most
typically about 10% dextrin.
[0031] The moisture barrier slurry compositions applied to raw
dough before or after proofing or to a fried doughnut of the
present invention optionally also includes sucrose or other
sweetening agents. When sucrose is utilized, the sucrose is
typically added as a solute to control starch hydration in film
formation. In appropriate amounts, sucrose imparts a sweet flavor,
if desired. The sucrose is typically granular sucrose. When
incorporated into the coating compositions of the present
invention, the sucrose is typically present in an amount of from
about 0% to about 30% by weight of the coating composition, more
typically from about 3% to about 15%, and most typically at about
5%.
[0032] Additionally, the moisture barrier slurry compositions
applied to raw dough before or after proofing or to a fried
doughnut optionally include a natural or synthetic stabilizer such
as a gum or a similar stabilizer, including, but not limited to,
xanthan gum, guar gum, or CMC (carboxymethylcellulose). Mixtures of
such stabilizers may also be used. When a stabilizer is utilized,
the water-soluble moisture barrier slurry compositions typically
utilize a xanthan gum such as KELTROL F.TM. available from Kelco
Co. of Wilmington, Del. The xanthan gum or other stabilizer may be
present in the amount of from about 0% to about 3% by weight of the
coating composition, more typically from about 0.05% to about 1.0%,
and most typically at about 0.15%.
[0033] The moisture barrier slurry compositions of the present
invention applied to raw dough before or after proofing or to a
fried doughnut optionally also include an emulsifier, such as
lecithin, phospholipids, mono and di-glycerides, casienates.
Typically lecithin is used. The lecithin is typically present in
the amount of from about 0% to about 10% by weight of the coating
composition, more typically from about 0.5% to about 5%, and most
typically at about 1.5%.
[0034] Additionally, the moisture barrier slurry composition
applied to raw dough before or after proofing or to a fried
doughnut typically includes flour. The flour utilized may include
wheat flour, rice flour, corn flour, potato flour, or any other
commercially acceptable flour; however, rice flour is most
typically used. The flour is believed to provide film forming
functionality to the slurry composition. The flour of the slurry
composition is typically present in the amount of from about 5% to
about 50% by weight of the coating composition, more typically from
about 10% to about 35%, and most typically at about 25%.
[0035] The wet slurry typically has a wet slurry solids content of
from about 35% to about 50%, and more typically at about 45%. The
wet slurry solids parameter is an indication of the percentage of
the slurry in solid physical form.
[0036] Dextrin Moisture Barrier Composition for Fried or Raw Dough
Doughnuts
[0037] Alternately, the moisture barrier coating may only include a
dextrin with water in a slurry form and may be applied to a wet
slurry on proofed raw doughnut dough or on a fried doughnut. The
preferred dextrin in this moisture barrier coating is a
high-solubility dextrin (i.e., 90% or more solubility when placed
in cold water (approximately 77.degree. F.)). The dextrin has a
solids content of approximately 50% solids at room temperature.
[0038] Application Process for Both the Typical and Dextrin
Moisture Barrier Compositions Raw Dough
[0039] When the moisture barrier slurry composition is utilized on
raw (substantially uncooked) dough 10, it may be applied to by any
industrially acceptable method, including, but not limited to,
spray coating or a dunk/drip bath. However, the typical application
method is a spray coating application that typically coats the
entire doughnut dough. The wet slurry may also be applied to the
raw dough substrate before or after proofing. One application
process for moisture barrier compositions when applied to raw dough
and fried doughnuts is shown in FIG. 1.
[0040] At whatever stage the moisture barrier is applied, the
process typically begins by extruding doughnut dough and cutting
the doughnut dough into individual doughnuts or alternatively by
forming the dough substrate by any means 12. Each individually cut
doughnut typically has a dough weight of from about 27 grams to
about 34 grams. In one embodiment, the wet slurry is then sprayed
onto the individually cut raw dough doughnuts 14. Optionally, the
raw dough doughnuts may be transferred to a proofer prior to
coating. In this instance, the moisture barrier composition is
subsequently applied to the proofed raw dough. The wet slurry
coated dough or, as yet uncoated, doughnuts are typically placed on
sheets or trays prior to placement in the proofer. The proofer is
an enclosed machine wherein temperature and humidity are modified
to activate yeast. In this particular processing step, yeast is
activated to make gas and therefore the dough rises or proofs.
Typically, higher temperatures and greater humidity results in the
dough rising more and gives larger doughnuts. Conversely, lower
temperatures and less humidity results in the dough rising less
yielding smaller doughnuts. If not previously coated, the raw dough
doughnuts may be coated at this stage 16. Conceivably, coating
after proofing could be a second coating, but coating at this stage
is not typically a subsequent coating.
[0041] Once coated, either prior to or after proofing, the
doughnuts are then fried 18. Any industrial acceptable fryer will
work. The doughnuts are fried on both sides for from about 80
seconds to about 90 seconds at a typical temperature of from about
365.degree. F. to about 375.degree. F. More typically, the
doughnuts are fried for about 86 seconds at a temperature of about
370.degree. F. If not previously coated or if a subsequent coating
is desired, which is not typically the case, the slurry should be
applied to the doughnut after the raw dough is fried, but prior to
glazing.
[0042] Typically, a hot or cold glaze or other coating may then be
applied to the wet slurry coated doughnuts 20. The amount of glaze
pickup or other coating pickup is typically measured in all
application methods. The temperature of the glaze affects glaze
pickup with cooler glazes resulting in more glaze pickup by the
doughnut. The glaze pickup measures the amount of glaze, which does
not fall off or drip from the doughnut after application. The glaze
pickup percentage is determined via the following calculation: the
glaze-coated weight of the glazed-coated doughnut minus the
unglazed weight of the unglazed doughnut divided by the unglazed
weight times 100. The glaze pickup of the glaze-coated doughnuts
employing the moisture barrier of the present invention is
typically from about 30% to about 47%.
[0043] The glazed or otherwise coated doughnuts are then cooled 22
even if a cool or cold glaze is used because the doughnut itself is
still warm or hot. This is typically done by using cooled forced
air. The cooled doughnuts are then packed into paperboard carton,
or other packing material and prepared to be shipped to their final
destination 24.
[0044] Fried Doughnuts
[0045] The moisture barrier wet slurry may be applied to fried
doughnuts 25 by any industrial acceptable method, including, but
not limited to, spray coating or a dunk/drip bath. The typical
method of application is a spray method of application which
typically coats the entire doughnut. One application process for
the moisture barrier composition when applied to a fried doughnut
is shown in FIG. 2. This method of application typically begins by
extruding doughnut dough and cutting the dough into individual
doughnuts as discussed above 26. The individual extruded doughnuts
are transferred to the proofer and proofed 28. The proofed
doughnuts are then typically parfried on both sides 30 for about 20
seconds to about 50 seconds at a temperature of from about
365.degree. F. to about 375.degree. F. More typically, the proofed
doughnuts are parfried on both sides for about 40 seconds at a
temperature of about 370.degree. F. The wet slurry is then sprayed
onto the parfried doughnuts 32. As discussed above, the wet slurry
typically has a wet slurry solids content of from about 35% to
about 50%. More typically, the wet slurry solids content is about
45%. The coated doughnuts are then finish fried 34 from about 20
seconds to about 50 seconds at a temperature of from about
365.degree. F. to about 375.degree. F. More typically, the
doughnuts are finish fried for about 48 seconds at a temperature of
about 375.degree. F.
[0046] As discussed above, typically the next step is application
of a glaze or other coating to the doughnut surface 36. The amount
of glaze pickup or other coating pickup is typically measured in
all application methods and is measured via the same method and
calculation as discussed above. The glaze pickup for coated fried
doughnuts is typically substantially similar to the glaze pickup
discussed above, about 30% to about 47%. After glazing, the
doughnuts may be cooled, using forced air 38. The cooled doughnuts
may be packed into paperboard cartons or other industrial
acceptable packing materials and prepared to be shipped to their
final destination 40.
[0047] Typical Moisture Barrier Compositions for Fried, Cooled,
Reheated Doughnuts
[0048] The moisture barrier in wet slurry form may also be applied
to fried, cooled, and then reheated doughnuts. Typically, the clear
coat moisture barrier in wet slurry form applied to fried, cooled,
and reheated doughnuts includes a starch component, typically
MIDSOL 35.TM. (an oxidized and acetylated wheat starch component)
and/or a dextrin component, typically a potato dextrin
component.
[0049] The modified wheat starch may be present in the moisture
barrier in an amount of from about 50% to about 100% and most
typically at about 100%. As previously mentioned, it is presently
believed that other modified and/or unmodified starches such as
corn starch, potato starch, and tapioca starch also form an at
least partial moisture barrier, but modified wheat starch either
alone or in combination with a potato dextrin is presently
preferred when the moisture barrier coating composition is to be
applied to a fried or parfried that typically is subsequently
cooled prior to finish frying or reheating.
[0050] The modified wheat starch is typically used to provide
viscosity, crispness and film formation. Such a wheat starch may be
a modified wheat starch such as an oxidized and/or substituted
wheat starch. Typically, the wheat starch used in the clear coat
moisture barrier wet slurry for doughnuts is modified. The
modification is typically an oxidized and substituted wheat starch
that has a substitution level that typically ranges from about
0.01% to about 1%; however, the more typical substitution level is
about 0.1%. One modified wheat starch that may be used in the clear
coat moisture barrier wet slurry of the present invention is MIDSOL
35.TM., which can be purchased from Midwest Grain Products of
Atchison, Ks.
[0051] The moisture barrier wet slurry may also, or alternatively,
contain a dextrin. The dextrin utilized may include corn dextrin,
tapioca dextrin, and potato dextrin; however, potato dextrin is
most typically used. The dextrin is believed to provide superior
film forming functionality to the coating composition. All dextrins
are soluble to some degree; however, a low solubility dextrin is
typically used in the present invention. The typical clear coat
moisture barrier wet slurry used to coat doughnuts contains from
about 50% to about 100% potato dextrin, and more typically about
100% potato dextrin. One source of potato dextrin is EMDEX.TM.
potato dextrin available from Emsland Staerke, Gmbh of Germany.
[0052] Application Processes for the Moisture Barrier Compositions
When Applied to Fried, Cooled and Reheated Doughnuts
[0053] As in the case of the raw dough and fried dough application
processes discussed above, the typical method of application of the
moisture barrier wet slurry to the fried or parfried, cooled, and
then reheated doughnuts 41 utilizes a spray method that typically
coats the entire doughnut. Conceivably though and as with these
other processes, some advantages and benefits of the present
invention could be achieved by coating only a portion of the
doughnut, i.e. the portion to have the most glaze or other coating
applied to it. One application process for the moisture barrier
composition when applied to a fried, cooled, and reheated doughnut
is shown in FIG. 3.
[0054] The method of applying the slurry to the fried or parfried,
cooled, and reheated doughnuts typically begins by forming the
doughnut or similar substrate as discussed earlier with regard to
other processes 42. Once formed, the extruded doughnuts are then
typically placed on sheets or trays and then placed in a proofer
44. Proofed doughnuts are then fried on both sides 46 from about 80
seconds to about 90 seconds at a temperature of from about
365.degree. F. to about 375.degree. F. More typically, the proofed
doughnuts are fried on both sides for about 86 seconds at a
temperature of about 370.degree. F. The doughnuts are then cooled
48 to a temperature of typically less than 100.degree. F., more
typically to a temperature of about 80.degree. F. At this stage,
the doughnuts may be frozen or otherwise stored if desired or
required. The doughnuts are then reheated or thawed and reheated 50
to a surface temperature of typically greater than 160.degree. F.
and more typically to a temperature of about 210.degree. F.
Thereafter, the clear coat moisture barrier wet slurry may be
sprayed onto the parfried doughnuts 52.
[0055] The wet slurry typically has a wet batter solids content of
from about 20% to about 55%, but more typically the wet batter
solids content is about 50%. The wet slurry coated doughnuts are
then baked 54 at a temperature of typically from about 200.degree.
F. to about 450.degree. F. for about 2 to about 6 minutes, or more
typically baked at a temperature of about 400.degree. F. for about
3 minutes, or until the wet slurry is set. A glaze or other coating
may then be applied to the coated surface of the doughnut 56. The
glaze pickup is typically from about 30% to about 47%. The glazed
doughnuts are then cooled. Typically the glazed doughnuts are
cooled using forced air 58. The cooled clear coated and glazed or
otherwise frosted or coated doughnuts are packed into paperboard
cartons, or other industrial acceptable packing material and
prepared for shipment to their final destination 60.
DRY DUSTING
[0056] Instead of being applied as a slurry, the moisture barrier
composition may also be dry dusted onto doughnuts or other
dough-based goods. Currently, the dry dusting method is generally
preferred primarily due to the significant processing auvaflLages
over using a wet slurry application. Like the slurry composition,
the moisture barrier dry dusting compositions of the present
invention may be applied to dough, fried products, parfried
products and/or fried, cooled, then reheated products as well as
frozen, thawed, and reheated products. Also the dry dusting
compositions are typically clear coat moisture barrier dry dusting
compositions.
[0057] Moisture Barrier Compositions for Raw Dough Doughnuts
[0058] The moisture barrier composition for dry dusting raw dough
before proofing and frying doughnuts or other pastry products
typically includes a dextrin component such as EMDEX.TM., a potato
dextrin. Typically, when the moisture barrier coating composition
is applied as a dry dusting on raw dough a dextrin component is the
only ingredient of the composition. The dextrin component,
typically potato dextrin, is usually present in the clear coat
moisture barrier dry dusting composition in an amount of from about
20% to about 100% by weight of the coating composition; more
typically from about 50% to about 100%, and most typically at about
100%.
[0059] The dextrin utilized may include corn dextrin, tapioca
dextrin, and/or potato dextrin; however, potato dextrin is most
typically used. Any potato dextrin may be used.
[0060] Application Processes for the Moisture Barrier Compositions
When Applied to Raw Dough
[0061] The moisture barrier dry dusting composition may be applied
to doughnuts by any known industrial acceptable method. However,
typically substantially all of the doughnut or other dough-based
products should be dry dusted. Conceivably, as with wet slurries,
coating only a portion (i.e. the portion of the doughnut or other
pastry product to be coated) of the doughnut would provide at least
some of the benefits of the present invention.
[0062] One application process for the dry dusting moisture barrier
when applied to raw dough before or after proofing 61 is shown in
FIG. 4. When applied at any stage, dry dusting the raw dough,
typically begins by forming the doughnut as discussed earlier 62.
Once the doughnut is formed, the dry dusting mixture is dusted onto
the doughnut dough 64. The dry dusting mixture may be applied to
the doughnut dough as the doughnut dough passes on a horizontal
conveyor under a hopper-like machine. Within the hopper are two
horizontal rotating bars that extend from one end of the hopper to
the other. These bars are scored along the length of the bars so
that one or more valleys exist. As the bars rotate, the valleys
facing upwards, or away from the doughnut dough, fill with a dry
dusting composition of the present invention. The bars rotate along
a horizontal axis. As the bars containing dry dusting composition
filled valleys turn approximately one quarter turn, the valleys
engage a bristled brush. The bristled brush is positioned close
enough to the rotating bars so that when the bars engage the brush,
the bristles bend while the bristle tips remain in the valley. As
the bars rotate further, the brush tilts downward and the bristles
essentially project the coating into the doughnut dough below. Such
a coating machine may be purchased from CHRISTY.RTM. Machine
Company of Fremont, Ohio.
[0063] The amount of dry dusting pickup is typically measured in
all application methods. The dry dusting pickup measures the amount
of the moisture barrier dry dusting composition that does not fall
off the doughnut after application. The dry dusting pickup
percentage is determined via the following calculation: the coated
weight of the coated doughnut minus the uncoated weight of the
uncoated doughnut divided by the uncoated weight times 100. The
moisture barrier dry dusting mixture of the present invention, when
applied to a doughnut, typically attains a percentage pickup of
from about 0.2% to about 5%, but more typically about 2%
pickup.
[0064] The coated doughnuts are then transferred to the proofer 66.
While not preferred, the doughnut can also be coated with dry
dusting coating mixture after the raw dough has been proofed and
prior to frying. The proofed doughnuts are then fried on both sides
68 for typically from about 80 seconds to about 90 seconds at a
temperature of from about 365.degree. F. to about 375.degree. F.,
and more typically at about 86 seconds at a temperature of about
370.degree. F. The glaze or other coating is then applied to the
coated doughnut surface 70. The glaze pickup is from about 30% to
about 47%. The glazed or otherwise coated doughnuts are then
cooled, typically using forced air 72. The cooled doughnuts are
then packed into paperboard cartons, or other industrial acceptable
packing material, and prepared for shipment to their final
destination 74.
[0065] Moisture Barrier Compositions for Fried Doughnuts
[0066] The moisture barrier dry dusting composition may also be
applied to a fried doughnut. Typically, the moisture barrier dry
dusting composition for dry dusting a fried doughnut includes
C*POLARTEX-INSTANT 12640.TM. or HIFORM.TM. (pregelatinized,
stabilized, crosslinked waxy maize starch).
[0067] The pregelatinized, stabilized, crosslinked waxy maize
starch is typically present in the moisture barrier dry dusting
composition from about 20% to about 100% by weight of the coating
composition, more typically from about 50% to about 100%, and most
typically at about 100%.
[0068] Pregelatinized, stabilized, crosslinked waxy maize starch
may be used to provide a continuous, invisible or nearly invisible
film on a fried doughnut. One pregelatinized, stabilized,
crosslinked waxy maize starch used as the water-soluble moisture
barrier dry dusting composition of the present invention for
application to a fried doughnut or other pastry product is
C*HIFORM.TM., which can be purchased from Cargill of Minneapolis,
Minn. Typically, when applied as a dry dust to fried doughnuts, a
starch component is the only ingredient of the composition. The use
of C*HIFORM.TM. starch as the dry dusting composition extended the
shelf-life of the final doughnut at least to about 2 to about 5
days. Another pregelatinized, stabilized, crosslinked waxy maize
starch that may be used as the water-soluble moisture barrier dry
dusting composition of the present invention is C*POLARTEX-INSTANT
12640.TM., which may be purchased from Cargill of Minneapolis,
Minn. When used, the C*POLARTEX-INSTANT 12640.TM. extended the
shelf life of the final doughnut products to at least about 5 to
about 6 days. Of course, mixtures of these starches may also be
used. Moreover, as discussed previously, it is believed other
starches either alone or in combination will exhibit at least some
of the features of the present invention, but in the case of
coating fried doughnuts, pregelatinized, stabilized, crosslinked
waxy maize starch is preferred.
[0069] Application Processes for the Moisture Barrier Compositions
When Applied to a Fried Doughnut
[0070] The clear coat moisture barrier dry dusting composition may
be applied to the doughnut by any industrial acceptable method. One
application process for the dry dusting moisture barrier when
applied to a fried doughnut 75 is shown in FIG. 5. The first step,
as discussed earlier, is to form a doughnut from dough 76. The
doughnuts are then transferred to a proofer 78. The proofed
doughnut dough is then fried on both sides 80 typically for about
80 seconds to about 90 seconds at a temperature of from about
365.degree. F. to about 375.degree. F., and more typically for
about 86 seconds at a temperature of about 370.degree. F. The clear
coat moisture barrier dry dusting composition is dry dusted on the
surface of a hot doughnut 82. The surface temperature of the hot
doughnut is typically greater than 160.degree. F. and more
typically about 210.degree. F. It is believed the hot surface
facilitates film formation, but it is not believed to be a
requirement that the doughnut be hot when dry dusted. When applied
to a fried doughnut, the dry dusting pickup percentage is typically
from about 0.2 to about 5% and more typically from about 0.5% to
about 0.8%. The dry dusted doughnuts are then transferred to a
coating machine, typically a glazer 84. The coated doughnuts are
transferred to the glazer for about 5 seconds to about 120 seconds
and more typically for about 20 to about 50 seconds. It is believed
that this time to the glazer enhances film formation and
facilitates development of the moisture barrier on the coated
doughnuts. A glaze or other coating, which is generally applied at
a temperature of from about 105.degree. F. to about 140.degree. F.
and more typically at about 115.degree. F. to about 120.degree. F.,
is then applied to the dry dusted doughnut surface 86. The glaze
pickup percentage is usually from about 30% to about 47%. The
glazed or otherwise coated doughnuts are then cooled, typically
using forced air 88. The cooled doughnuts are then packed into
paperboard cartons, or other industrial acceptable packing
material, and prepared for shipment to their final destination
90.
[0071] Moisture Barrier Compositions for Parfried or Fried, Cooled,
Reheated Doughnuts
[0072] The moisture barrier dry dusting composition may also be
applied to parfried or fried, cooled, then reheated doughnuts. When
applying the moisture barrier dry dusting composition of the
present invention to parfried or fried, cooled, then reheated
doughnuts, the coating composition typically includes an oxidized,
pregelatinized, modified tapioca starch. Typically, when applied as
a dry dust to parfried or fried, cooled, reheated doughnuts, the
starch component is the only ingredient of the moisture barrier
composition. It is presently believed that other starches such as
corn starch, potato starch, wheat starch and mixtures of these
starches and tapioca starch may also provide some of the benefits
of the present invention in this application method and the method
of dry dusting a fried finished doughnut, as will be discussed
later. However, when coating fried or parfried, cooled, and then
reheated doughnuts, pregelatinized and chemically modified tapioca
starch is presently preferred and, when coating fried doughnuts
pregelatinized corn starch is presently preferred.
[0073] The pregelatinized and chemically modified tapioca starch is
typically present in the water-soluble moisture barrier dry dusting
composition from about 20% to about 100% by weight of the coating
composition, more typically from about 50% to about 100%, and most
typically at about 100%.
[0074] The pregelatinized, chemically modified tapioca starch may
be used to provide a continuous, substantially invisible film on a
fried, cooled, then reheated doughnut.
[0075] Application Processes for the Moisture Barrier Composition
When Applied to a Parfried or Fried, Cooled and Reheated
Doughnut
[0076] The moisture barrier dry dusting composition may be applied
to fried or parfried, cooled, then reheated doughnuts using any
industrial acceptable method. One application process for the dry
dusting moisture barrier when applied to a fried, cooled and
reheated doughnut 91 is shown in FIG. 6. As discussed previously
regarding other methods of application, this application method
typically begins by extruding and cutting doughnut dough into
individual doughnuts 92. The doughnut dough may then be transferred
to a proofer 94. The proofed doughnut dough is then fried on both
sides 96 typically for from about 80 seconds to about 90 seconds at
a temperature of about 365.degree. F. to about 375.degree. F., and
more typically for about 86 seconds at a temperature of about
370.degree. F. Typically, the doughnuts are then cooled 98 to a
temperature less than about 100.degree. F., more typically to a
temperature of about 80.degree. F. At this stage, the doughnuts may
be frozen or otherwise stored if desired or required. The doughnuts
are then reheated 100 to a surface temperature of typically greater
than 160.degree. F. and more typically to a temperature of about
210.degree. F. The moisture barrier dry dusting composition is
applied to the surface of a hot doughnut 102. The dry dusting
composition may be applied by any industrially acceptable method or
as described above for example by using a coating machine as
purchased from CHRISTY.RTM. Machine Company of Fremont, Ohio. The
percentage of dry dusting pickup is typically from about 0.2% to
about 5% and more typically from about 0.5 to about 0.8%. The dry
dusted doughnuts are then transferred to a coating machine,
typically a glazer 104. Prior to actual application of a glaze or
other coating, the doughnuts are transferred to the glazer for
typically from about 5 to about 120 seconds and more typically for
about 20 to about 50 seconds. This time to the glazer or other
coating machine is believed to further enhance film formation of
the coating. A hot glaze is then applied to the dry dusted doughnut
surface 106. The hot glaze pickup is typically from about 3 to
about 47%. glazed or otherwise coated doughnuts are then cooled,
typically by forced air 108. The cooled doughnuts are then packed
into paperboard cartons, or other industrial acceptable packing
material, and prepared to be shipped to their final destination
110.
EXAMPLES
[0077] The following examples more precisely and particularly
illustrate the specific details of the present invention.
Equivalent procedures and quantities will occur to those skilled in
the art and, therefore, the following examples are not meant to
define the limits of the present invention, these being defined by
the scope of the appended claims. The object of these examples was
to prepare a moisture barrier coated doughnut in a laboratory
environment, wherein the moisture barrier was not readily visible
on the doughnut, but provided at least a partial barrier to
moisture transfer that otherwise occurs between the dough portion
and the glazed portion of the finished doughnut due to the water
activity gradients present without significantly increasing the fat
content of the doughnut.
Example 1
[0078] The object of this example was to determine an acceptable
wet slurry moisture barrier formula when applied on raw dough
before or after proofing. The ingredients utilized in the wet
slurry moisture barrier coating in this example include:
1 Ingredient % Formula Modified potato starch component 56.65
Sodium acid pyrophosphate (leavening agent) 1.00 Sodium bicarbonate
(leavening agent) 0.70 Xanthan gum (stabilizer) 0.15 Dextrin 10.00
Lecithin (emulsifier) 1.50 Rice flour 25.00 Sucrose 5.00
[0079] Method:
[0080] 1. Dough was extruded and cut into individual doughnuts -
raw doughnut weight is about 27 grains to about 37 grams;
[0081] 2. The clear coat moisture barrier composition was sprayed
onto raw doughnuts using a spray bar;
[0082] 3. Doughnuts are transferred to the proofer either before or
after they were coated with the clear coat moisture barrier
composition. If doughnuts were transferred to the proofer before
they were coated with the clear coat moisture barrier composition,
the doughnuts were then proofed and subsequently coated with the
clear coat moisture barrier before they are fried;
[0083] 4. The proofed doughnuts were fried on both sides;
[0084] 5. The glaze was applied to the doughnut surface that has
been coated with the clear coat moisture barrier composition;
[0085] 6. The glazed doughnuts were then cooled using forced air;
and
[0086] 7. The cooled doughnuts were then packaged into paper board
cartons or other suitable containers.
[0087] In this example the doughnut did not have increased
crispness, however the coating did stabilize the glaze. Ordinarily,
without using a clear coat moisture barrier composition the glaze
will start to liquefy at about 24 hours. By using a clear coat
moisture barrier composition of the present invention the
shelf-life of the coated doughnut is extended to 4 or more
days.
[0088] The Stein (top to first break in stream of slurry material)
viscosity measurement was approximately 14.7 seconds. The slurry
viscosity is typically measured by the industry Stein testing
procedure outlined below:
[0089] 1. Completely fill a clean, dry Stein cup with slurry (using
a fingertip to act as a stopper to prevent the slurry from draining
out the bottom of the cup hole);
[0090] 2. Use other hand to hang onto the wire handle of the Stein
cup and to hold the stopwatch;
[0091] 3. Remove finger covering the bottom cup hole and
simultaneously start stopwatch. Stop the watch when the slurry
stream passing through the bottom cup hole first breaks the
continuous stream;
[0092] 4. Record the time in seconds; and
[0093] 5. Repeat this procedure two additional times. Calculate the
average of the three determinations and record.
[0094] The percentage of slurry solids in Example 1 was
approximately 45%. The moisture barrier wet slurry composition of
Formula 1 stabilized the glaze in the wet slurry coated and glazed
doughnut.
Example 2
[0095] In this example a wet slurry was applied to a fried
doughnut. The ingredients utilized in the wet slurry moisture
barrier in this example include:
2 Ingredient % Formula Modified potato starch component 56.65
Sodium acid pyrophosphate (leavening agent) 1.00 Sodium bicarbonate
(leavening agent) 0.70 Xanthan gum (stabilizer) 0.15 Dextrin 10.00
Lecithin (emulsifier) 1.50 Rice flour 25.00 Sucrose 5.00
[0096] Method:
[0097] 1. The dough was extruded and cut into individual doughnuts
- raw doughnut weight is about 27 grams to about 34 grams;
[0098] 2. The doughnuts were transferred to a proofer;
[0099] 3. The proofed doughnuts were parfried on both sides;
[0100] 4. The clear coat moisture barrier composition was sprayed
onto the parfried doughnuts;
[0101] 5. The doughnuts were finished fried;
[0102] 6. The glaze was applied to the doughnut surface that has
been coated with the clear coat moisture barrier composition;
[0103] 7. The glazed doughnuts were then cooled using forced air;
and
[0104] 8. The cooled doughnuts were then packaged into paper board
cartons or other suitable containers.
[0105] The percentage of slurry solids in Example 2 is
approximately 45%. The Stein (top to first break in stream of
slurry material) viscosity measurements were approximately 14.56,
14.66 and 14.71 seconds with the Stein average being approximately
14.64 seconds.
[0106] Regarding step 4 of the method described immediately above,
the doughnuts were coated with the clear coat moisture barrier
composition by using a spray bottle to spray the composition onto
the doughnuts that had been fried for approximately 10 seconds on
both sides. The clear coat moisture barrier composition coated
doughnuts were then placed back into the fryer to finish frying.
The clear coat moisture barrier had some visibility where the
surface was cracked and peeled back under the glaze (e.g. bumpy).
The cooled coated doughnuts were then set aside to determine their
shelf-life. On days 1 and 2 there was no wetting out. The term
"wetting out" indicates a water activity gradient between the
doughnut portion and the glaze portion where over the course of
time water from the portion having a higher water activity migrates
to the portion having a lower water activity. Typically, the
doughnut portion has a higher water activity than the glaze
portion, therefore, absent a moisture barrier, water migrates from
the doughnut portion to the glaze portion causing at least spots of
wetting out in the glaze.
[0107] In the foregoing description, it will be readily appreciated
by those skilled in the art that modifications may be made to the
invention without departing from the concepts disclosed herein.
Such modifications are to be considered as included in the
following claims, unless these claims by their language expressly
state otherwise.
* * * * *