U.S. patent application number 11/048654 was filed with the patent office on 2005-07-28 for aerated compositions, process and apparatus for achieving such aerated compositions.
This patent application is currently assigned to Good Humor - Breyers Ice Cream, division of Conopco, Inc.. Invention is credited to Spindler, Suzanne Mary, Wix, Loyd.
Application Number | 20050163905 11/048654 |
Document ID | / |
Family ID | 8173430 |
Filed Date | 2005-07-28 |
United States Patent
Application |
20050163905 |
Kind Code |
A1 |
Spindler, Suzanne Mary ; et
al. |
July 28, 2005 |
Aerated compositions, process and apparatus for achieving such
aerated compositions
Abstract
The present invention provides a cold extruded composition with
at least 90% overrun, wherein said composition comprises a fat
phase which has a high ratio of liquid fat to solid fat at the
processing temperature. The present invention also relates to a
process for the production of such compositions wherein a mix is
aerated in an internal volume of a freezer barrel with a aerating
means which has a low displacement of said internal volume, prior
to cold extrusion.
Inventors: |
Spindler, Suzanne Mary;
(Bedford, GB) ; Wix, Loyd; (Bedford, GB) |
Correspondence
Address: |
UNILEVER INTELLECTUAL PROPERTY GROUP
700 SYLVAN AVENUE,
BLDG C2 SOUTH
ENGLEWOOD CLIFFS
NJ
07632-3100
US
|
Assignee: |
Good Humor - Breyers Ice Cream,
division of Conopco, Inc.
|
Family ID: |
8173430 |
Appl. No.: |
11/048654 |
Filed: |
January 28, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11048654 |
Jan 28, 2005 |
|
|
|
10005677 |
Dec 5, 2001 |
|
|
|
6852351 |
|
|
|
|
Current U.S.
Class: |
426/565 |
Current CPC
Class: |
A23G 9/327 20130101 |
Class at
Publication: |
426/565 |
International
Class: |
A23G 009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 6, 2000 |
EP |
00310835.4 |
Claims
1-5. (canceled)
6. Apparatus comprising a freezer barrel enclosing an internal
volume comprising an aerating means, said freezer barrel further
comprising an outflow means allowing flow of aerated material into
a cold extruder, characterised in that said aerating means
displaces less than 40% of the internal volume of said freezer
barrel.
7. Use of an apparatus according to claim 6 in the preparation of a
cold extruded ice cream comprising a fat phase and having overrun
of at least 90% wherein at least 45% w/w of the fat phase is liquid
at -5.degree. C.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] The invention relates to aerated food compositions. More
particularly the invention relates to aerated ice cream
compositions which comprise a fat component having a low melting
point and thereby retaining liquid properties at processing
temperatures. The invention further relates to a process for
preparing such compositions by cold extrusion. Finally the
invention relates to apparatus and the use thereof for preparing
the compositions novel concerned.
BACKGROUND TO THE INVENTION
[0002] It is known to aerate a mix for the preparation of an ice
cream through the use of an aerating means comprising a rotating
element that fits into the barrel of a continuous ice cream
freezer. This aerating means is commonly referred to as a dasher.
On rotation the dasher imparts mechanical energy into the mix in
order to achieve aeration and generate a fat network by aggregating
some of the fat droplets. This aggregation is necessary for product
stability.
[0003] For many industrial continuous freezers there are a variety
of dasher types available. These can be differentiated from each
other by the volume displaced within the freezer barrel which can
be assessed by simply filling the freezer barrel with a liquid,
such as water, and measuring the volume of liquid displaced when
the dasher is fitted therein. A dasher described as a series 80
indicates that this rotating element occupies 80% of the available
internal volume of the freezer barrel so that only 20% of the space
is available to be occupied by the mix to be aerated. By contrast a
series 15 dasher, also known in the art, demonstrates a
displacement volume of only 15% of the internal barrel volume, the
remaining 85% being available to be occupied by a mix to be
aerated.
[0004] In conventional ice cream processing it is generally
accepted that higher displacement dashers such as the series 80
give rise to high quality ice cream being highly churned (Ice Cream
5.sup.th Edition, W. S. Arbuckle et al., page 183) thus showing
optimal levels of fat de-stabilisation, while at the same time
product dryness, good meltdown resistance and product hardness.
These displacement dashers are therefore the standard form of
aerating means used in ice cream manufacture.
[0005] Cold extrusion of aerated compositions is also known in the
art. U.S. Pat. No. 5,345,781 describes the extrusion of a
pre-aerated foam through a freezing device. Pre-aeration has
conventionally been undertaken through the use of an aerating means
in the form of a high displacement dasher (Ice Cream 5.sup.th
Edition, W. S. Arbuckle et al., page 184). The foam once aerated is
then transferred to cold extrusion apparatus. FIG. 3 of U.S. Pat.
No. 4,345,781 illustrates this approach.
[0006] Cold extrusion allows a convenient and preferred means of
preparing ice cream, however this freezing route has been found by
the applicants to present additional processing problems with
particular formulations that contain a high ratio of liquid to
solid fat at the processing temperature. The applicants when
applying the conventionally combination of an aeration means with
80% displacement and cold extrusion apparatus, have observed an
inability to achieve desired levels of overrun (>90%). This loss
of overrun can be so severe as to give rise to phase separation and
the loss of control of the process to the extent that extrusion
apparatus may become blocked.
[0007] The ice cream formulations prepared by conventional aeration
and cold extrusion systems comprise a fat phase with a relatively
high melting point. This means that little if any liquid fat is
present at the processing temperature.
[0008] The applicants have identified a need to extend the range of
fats that can be applied to ice cream manufacture. In particular
there is a need for the development of novel ice cream compositions
which have formulations that can comprise a fat component having a
lower melting point, thus imparting a higher level of liquid fat in
the fat phase at the processing temperature. At the same time
formulations must maintain the high degree of stable aeration and
low levels of destabilised fat and overrun loss characteristic of
conventional ice creams. The ability to use increasingly varied
fats would also allow the manufacture of ice cream at a reduced
cost.
[0009] The technical problem to be solved by the present invention
therefore relates to the production of novel ice cream
formulations, wherein said formulations comprise fat types that
have not been conventionally applied to commercial ice cream
manufacture due to high levels of liquid fat that they impart in
the fat phase of a mix at the processing temperature. More
particularly the problem has been found to particularly relate to
enabling the cold extrusion of these so mentioned novel ice cream
formulations.
[0010] It has been surprisingly been found that a solution to this
problem resides in the use of equipment which has never been used
for this type of formulation before. There is no suggestion in the
prior art that this type of equipment has any positive influence on
the destabilisation of fat, phase separation or overrun loss during
the processing of a composition.
[0011] The present invention seeks to provide a stable composition
with at least 90% overrun, wherein said composition comprises a fat
phase which has a high ratio of liquid fat to solid fat at the
processing temperature. More particularly the present invention
provides aerated novel compositions of this type which are also
suitable for cold extrusion.
[0012] Tests and Definitions
[0013] Levels of liquid fat can be determined by .sup.13C-NMR
spectroscopy wherein the liquid fat level of an emulsion of an ice
cream mix of the invention is determined.
[0014] Measurements carried out at -5& +50.degree. C. for 100%
fully liquid state. .sup.13C-NMR is carried out on a Bruker AMX-400
high resolution NMR spectrometer, with 10 mm sample tubes. Data is
acquired with inverse gated proton de-coupling and suitable
interscan delay to ensure quantitative results. Volume of samples
for 100% liquid measurement was reduced to keep total sample within
probe coils and hence negate any complications due to premix
separation. Measurements at -5.degree. C. is carried out after
external equilibration for at least 2 hrs. 100% liquid measurements
is carried out after at least 30 min equilibration, at +50.degree.
C., in spectrometer probe. All temperatures verified using external
thermocouple meter. Liquid fat content is determined by integration
of fat signals (15-40 ppm), relative to integral of sugar signals
(60-85 ppm). At -5.degree. C. and above the integral of sugar
signals will remain constant and hence can be used as an internal
standard. The proportion of liquid fat at the chosen temperature is
calculated by comparison of integrals with those from fat signals
from the 100% "melted" sample.
[0015] For the purpose of the invention overrun can be determined
as described in Ice Cream 4.sup.th Edition, Arbuckle et al., page
181.
[0016] Cold extrusion (coldex) is used to denote a cooling system
wherein a material enters extrusion apparatus a temperature which
is somewhat higher than that at the point of extrusion. Typically
in the cold extrusion of ice cream material enters the extrusion
apparatus at about -13.degree. C. and subsequently about
-18.degree. C. at the point of extrusion.
BRIEF DESCRIPTION OF THE INVENTION
[0017] It is a first object of the present invention to provide a
cold extruded composition comprising a fat phase and having an
overrun of at least 90%, characterised in that at least 45% weight
by weight of the fat phase is liquid at -5.degree. C.
[0018] In a preferred embodiment the cold extruded composition of
the invention is an ice cream.
[0019] In the light of conventional teachings that an aerating
means that displaces 80% of freezer barrel volume is most suited to
giving the best quality ice cream in terms of optimal fat
de-emulsification, product dryness, good meltdown resistance and
product hardness; it is unexpected to find that the novel
compositions of the invention cannot be processed to an ice cream
of acceptable quality by this route.
[0020] It has been found that the use of cold extrusion apparatus
leads to an increase in destabilised fat levels in the high liquid
fat compositions of the invention. This is due to the temperature
of extrusion and the increased shear stress imposed on the ice
cream. Similarly a high displacement aerating means will also lead
to unacceptable high levels of destabilised fat in those
formulations of the invention due to the reduced residence time of
the mix in the freezer barrel. The combined effect of this
phenomenon occurring at both stages of processing has been found to
make it impossible to prepare ice cream compositions with liquid
fat levels in excess of 45% w/w of the fat phase by using the
combination of a high displacement aerating means and cold
extrusion apparatus.
[0021] The presently proposed solution to this newly identified
problem is to provide for the aeration of a composition as
described above with a aerating means which displaces less than 40%
of a freezer barrel internal volume prior to entry of said mix into
cold extrusion apparatus.
[0022] It is a second object of the present invention to provide a
process for the preparation of a cold extruded composition, wherein
said process comprises;
[0023] (i) aerating a mix comprising a fat phase in a freezer
barrel enclosing an internal volume, said internal volume
comprising an aeration means;
[0024] (ii) extruding the mix through a cold extruding means;
[0025] characterised in that, said aeration means displaces less
than 40% of said internal volume and at least 45% weight by weight
of the fat phase is liquid at -5.degree. C.
[0026] By way of the present invention a process has been devised
as described above wherein a selected displacement range for the
aerating means of less than 40% of the internal freezer barrel
volume, has been found to yield a stable aerated ice cream
demonstrating good properties. These properties include low fat
de-emulsification, product dryness, good meltdown resistance and
product hardness for the novel compositions provided herein.
[0027] Through the use of an aerating means that displaces less
than 40% of internal freezer barrel volume it has been possible to
achieve aeration levels in excess of 90% overrun for a mix having
at least 45% w/w of its fat phase in a liquid state at -5.degree.
C. In a preferred embodiment, the invention therefore comprises a
process for the preparation of a cold extruded composition as
disclosed above wherein said mix is aerated to an overrun of at
least 90%.
[0028] It is preferred that the aerating means used for the purpose
of the invention displaces at least 10% of the internal barrel
volume, more preferably at least 15%, most preferably the aerating
means displaces from 15 to 30% of the internal freezer barrel
volume. Suitable aeration means are commercially available from the
manufacturer WCB.
[0029] It is recognised that as the proportion of liquid fat in the
fat phase increases it becomes more preferable to choose a aerating
means towards the lower end of the displacement range specified
above. This increases the residence time of the mix in the freezer
barrel and thereby allows a longer and more effective aeration
period without destabilisation of the fat.
[0030] A composition of the invention may comprise one or more fat
components derived from any fat source having a low melting point,
wherein the addition of said component(s) results in a proportion
of at least 45% w/w liquid fat in the fat phase of the product at
-5.degree. C. Preferably the fat phase comprises one or more fats
selected from the group comprising soy bean oil, palm oil, walnut
oil, pistachio oil, hazelnut oil, hydrogenated or partially
hydrogenated sunflower oil.
[0031] For a cold extruded ice cream according to the invention it
is preferable that the proportion of the fat phase being liquid at
-5.degree. C. is less than 55% w/w of the phase. A mix comprising a
fat phase with a liquid fat in the range 45 to 55% w/w can
therefore be suitably processed by the invention, most preferably
47 to 53% w/w of the fat phase is liquid at -5.degree. C.
[0032] The total fat content may range from 3% w/w to 15% w/w of
the composition, preferably 5 to 10% w/w. Most preferred fat
content of a composition according to the invention is about 8% w/w
of the composition.
[0033] Preferably compositions of the invention have an overrun of
at least 100%, more preferably the level of overrun is at least
110%.
[0034] It is a third object of the invention to provide an
apparatus comprising a freezer barrel enclosing an internal volume
comprising an aerating means, said freezer barrel further
comprising an outflow means allowing passage of aerated material to
a cold extruder, characterised in that said aerating means
displaces less than 40% of the internal volume of said freezer
barrel. Preferably the outflow means is continuous with the cold
extruder.
[0035] The cold extrusion apparatus used in the process of the
invention may comprise either a single or twin screw extruder.
Preferably the extruder is the single screw type.
[0036] A fourth object of the invention provides for the use of the
apparatus as described above in the preparation of a cold extruded
ice cream, wherein preferably said ice cream has a formulation in
accordance with the invention.
DETAILED DESCRIPTION
EXAMPLE
[0037] 500 kg of an ice cream mix A was prepared with the
composition indicated in table 1. The mix was made in a large scale
mix plant at a temperature of approximately 65-70.degree. C.,
wherein the order of ingredients into the tank was water, skimmed
milk powder, sugars and stabilisers/emulsifier compounds (suitably
Cremodan.TM. SE 019 available from Danisco.TM. ingredients) and
fats/oils. MD40 is a refined and spray dried glucose syrup in
powder form having 40% dextrose equivalent and is sold as
Cerestar.TM. or Morsweet.TM.. The mix was homogenised at
1.379.times.10.sup.7 Nm.sup.-2-138 Bar (2000 psi) and then
pasteurised at 83.degree. C. for 15 seconds. Following
pasteurisation the mixture was immediately chilled to approximately
4.degree. C. and aged in a ageing tank for at least 2 hours.
[0038] According to the methodology described above the level of
liquid fat at the processing temperature of -5.degree. C. was 53%
w/w of the fat phase in the product.
1TABLE 1 Mix A Ingredient Parts by weight Sucrose 13.61 Walnut oil
2.86 Skimmed milk powder 10.08 MD40 4.05 Butter fat 5.14 Cremodan
SE 019 0.45 Water 63.81
[0039] Mixes prepared as described and according to the above
formulation were separately processed through freezer barrels
comprising an aerating means of 15, 30 and 80% displacement of the
internal volume of the barrel.
[0040] The aerated material from the freezer barrel was then passed
through a conventional single screw extruder (SSE). Inlet pressure
to the SSE was maintained constant at 7.times.10.sup.5 Nm.sup.-2 (7
bar) and the aerated composition in the SSE remained at a
temperature between -12 and -15.degree. C.
[0041] The effect of varying the displacement of the aerating means
on the extruded product was assessed, wherein it was observed that
an aerating means of 15 or 30% displacement it was possible to
achieve a cold extruded product having an overrun of at least 90%
wherein said product demonstrated good organoleptic properties
showing a creamy texture with little or no ice and no phase
separation or unacceptable level of fat destabilisation.
[0042] In contrast where an aerating means having a displacement of
80% was used with this formulation the extruded product showed
destabilisation of fat, phase separation and overrun loss. This
product was highly inferior to that obtained with an aerating means
of 15 or 30% displacement.
* * * * *