U.S. patent application number 11/341314 was filed with the patent office on 2006-07-27 for aerated polymeric composition.
This patent application is currently assigned to Sergeant's Pet Care Products, Inc.. Invention is credited to Mark Levin, Li Nie.
Application Number | 20060165854 11/341314 |
Document ID | / |
Family ID | 36697079 |
Filed Date | 2006-07-27 |
United States Patent
Application |
20060165854 |
Kind Code |
A1 |
Levin; Mark ; et
al. |
July 27, 2006 |
Aerated polymeric composition
Abstract
The present invention relates to an aerated polymeric
composition. The composition includes a protein polymer and an
agent or method for causing porosity in the finished aerated
polymeric composition, such as a leavening agent. Additionally, the
present invention relates to methods for forming the aerated
polymeric composition, in particular, methods for forming aerated
pet treats or chews.
Inventors: |
Levin; Mark; (Papillion,
NE) ; Nie; Li; (Parkville, MO) |
Correspondence
Address: |
Polsinelli Shalton Welte Suelthaus PC;Suite1100
100 S. Fourth Street
St. Louis
MO
63102
US
|
Assignee: |
Sergeant's Pet Care Products,
Inc.
|
Family ID: |
36697079 |
Appl. No.: |
11/341314 |
Filed: |
January 27, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60647499 |
Jan 27, 2005 |
|
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|
Current U.S.
Class: |
426/132 ;
426/2 |
Current CPC
Class: |
A23K 40/20 20160501;
A23K 50/70 20160501; A23K 40/30 20160501; A23K 20/20 20160501; A23K
50/50 20160501; A23K 50/40 20160501; A23K 40/25 20160501; A23K
20/147 20160501; A23K 40/00 20160501 |
Class at
Publication: |
426/132 ;
426/002 |
International
Class: |
B65D 85/78 20060101
B65D085/78 |
Claims
1. An aerated pet chew, the pet chew comprising: (a) a body, the
body including a substantially sealed, non-porous outer skin; and,
(b) an inner portion integral with the skin, with the inner portion
having a porous construction and, at least, substantially
surrounded by the skin, the inner portion including a plurality of
cavities or air pockets to provide the body with elastic
deformability and flexibility; (c) a plant protein polymer in an
amount ranging between about 20% and about 70%; and, (d) a reducing
agent, whereby the disulfide bonds have been cleaved within the pet
chew in a range between about 2.0% and about 75%.
2. The pet chew of claim 1, wherein the chew has a pliability equal
to being bent in half, without breaking.
3. The pet chew of claim 1, wherein the chew has cavities ranging
in size between 0.0005 inches and 0.040 inches.
4. A method for forming an aerated pet chew, the method comprising:
(a) forming a dry blend composition containing a protein polymer
that is biodegradable, digestible, flowable, and can be formed into
a selected shape; (b) adding a slurry mixture to the dry blend; (c)
adding an amount of a leavening agent to the dry blend, whereby the
dry blend, slurry mixture, and leavening agent combine to form a
polymeric composition; (d) heating the polymeric composition to
achieve a homogeneous and flowable composition and activate the
leavening agent to form an aerated polymeric composition; (e)
forming the aerated polymeric composition pet chew; and, (f) curing
the pet chew with heat to form a thermal set pet chew.
5. The method of claim 4, wherein the method further includes
coating the pet chew after the forming step and prior to the curing
step to eliminate sticking.
6. The method of claim 4, wherein the temperatures for heating the
polymeric composition range between about 25.degree. C. and about
75.degree. C.
7. The method of claim 4, wherein the leavening agent is a compound
that produces a gas in the presence of heat.
8. The method of claim 7, wherein the compound is selected from the
group consisting of sodium bicarbonate, baking powder, sodium acid
pyrophosphate, monocalcium phosphate, sodium aluminum phosphate,
and combinations thereof.
9. The method of claim 4, wherein the leavening agent is a
compressed gas.
10. The method of claim 9, wherein the compressed gas is selected
from the group consisting of CO.sub.2, nitrogen, compressed air,
helium, and combinations thereof.
11. The method of claim 4, wherein the protein polymer is a plant
protein.
12. The method of claim 11, wherein the plant protein is wheat
gluten.
13. The method of claim 4, wherein the curing step comprises
denaturing the aerated polymeric composition pet chew by heating
the pet chew at a temperature ranging between about 80.degree. C.
and about 145.degree. C. to form a thermal set pet chew.
14. The method of claim 4, wherein the dry blend comprises plant
protein equal to between about 20% and about 70% by weight of the
dry blend, starch equal to between about 5% and about 50% by weight
of the dry blend, and a reducing agent for cleaving disulfide bonds
equal to between about 0.01% and about 0.5% by weight of the dry
blend.
15. The method of claim 4, wherein the dry blend further comprises
processing aids, cellulose, flavors, starch, and colors.
16. The method of claim 4, wherein the slurry mixture comprises a
humectant and water.
17. The method of claim 16, wherein the humectant is selected from
the group consisting of propylene glycol, glycerin, sucrose,
glucose, fructose, dextrose, maltose, maltitol, sorbitol, salt,
monosaccharide, disaccharide, metal salt, sodium chloride, and
combinations thereof.
18. The method of claim 4, wherein the leavening agent is added in
an amount ranging between about 0.05% and about 5.0% by weight of
the polymeric composition.
19. The method of claim 4, wherein the method for shaping is an
extrusion process that utilizes an extruder selected from the group
consisting of a twin screw extruder and a single screw
extruder.
20. The method of claim 16, wherein the slurry mixture comprises an
amount of water ranging between about 5% and about 25% by weight of
the slurry mixture.
21. The method of claim 4, which comprises a method of shaping
selected from the group consisting of extrusion, injection molding,
and compression molding.
22. The method of claim 16, wherein the slurry mixture comprises a
humectant in an amount equal to between about 5% and about 85% by
weight of the slurry mixture.
23. The method of claim 5, wherein the coating step includes adding
an agent selected from the group consisting of fine milled grain
flour, cornstarch, petrolatum, wheat starch, mineral oil, petroleum
jellies, and combinations thereof.
24. A composition for forming an aerated polymeric composition, the
composition comprising: (a) a dry blend; (b) a slurry mixture; (c)
a leavening agent; and, (d) a reducing agent.
25. The composition of claim 24, wherein the dry blend comprises a
compound selected from the group consisting of a plant protein
polymer, processing aids, cellulose, flavors, and colors.
26. The composition of claim 24, wherein the slurry comprises a
humectant and water.
27. The composition of claim 26, wherein the humectant is selected
from the group consisting of propylene glycol, glycerin, sucrose,
glucose, fructose, dextrose, maltose, maltitol, sorbitol, salt,
monosaccharide, disaccharide, metal salt, sodium chloride, and
combinations thereof.
28. The composition of claim 24, wherein the leavening agent is
added in an amount ranging between about 0.05% and about 5.0% by
weight of the composition.
29. The composition of claim 26, wherein the amount of water in the
composition ranges between about 5.0% and about 25.0% by weight of
the composition.
30. The composition of claim 24, wherein the dry blend comprises a
plant protein polymer in an amount equal to between about 20% and
about 70% by weight, a starch equal to between about 5% and about
50% by weight, and a reducing agent equal to between about 0.01%
and about 0.5% by weight of the dry blend.
31. The composition of claim 24, further comprising a coating,
wherein the coating is selected from the group consisting of fine
milled grain flour, cornstarch, petrolatum, wheat starch, mineral
oil, petroleum jellies, and combinations thereof.
32. The composition of claim 24, wherein the leavening agent is a
compound that produces a gas in the presence of heat.
33. The composition of claim 32, wherein the compound is selected
from the group consisting of sodium bicarbonate, baking powder,
sodium acid pyrophosphate, monocalcium phosphate, sodium aluminum
phosphate, and combinations thereof.
34. The composition of claim 24, wherein the leavening agent is a
compressed gas.
35. The composition of claim 34, wherein the compressed gas is
selected from the group consisting of CO.sub.2, nitrogen,
compressed air, helium, and combinations thereof.
36. The composition of claim 24, wherein the dry blend comprises a
compound selected from the group consisting of a plant protein
polymer, processing aids, a compound that discourages infestation,
and a compound that discourages consumption by animals.
37. A method for forming an aerated pet chew, the method
comprising: (a) mixing a dry blend, with a slurry mixture, an
amount of a leavening agent and a reducing agent to form a
polymeric composition; (b) heating the polymeric composition to
cause aeration in the composition and formation of an aerated
polymeric composition; and, (c) curing the aerated pet chew with
heat.
38. The method of claim 37, wherein the method further includes
coating the pet chew after the formation of the aerated polymeric
composition and prior to the curing step to eliminate sticking.
39. The method of claim 37, wherein the leavening agent is a
compound that produces a gas in the presence of heat.
40. The method of claim 39, wherein the compound is selected from
the group consisting of sodium bicarbonate, baking powder, sodium
acid pyrophosphate, monocalcium phosphate, sodium aluminum
phosphate, and combinations thereof.
41. The method of claim 37, wherein the leavening agent is a
compressed gas.
42. The method of claim 41, wherein the compressed gas is selected
from the group consisting of CO.sub.2, nitrogen, compressed air,
helium, and combinations thereof.
43. The method of claim 37, wherein the dry blend further comprises
a plant protein polymer.
44. The method of claim 37, wherein the curing step comprises
denaturing the polymeric composition pet chew by heating the chew
at a temperature ranging between about 80.degree. C. and about
145.degree. C. to form a thermal set pet chew.
45. The method of claim 37, wherein the dry blend comprises a plant
protein polymer in an amount equal to between about 20% and about
70% by weight, a starch in amount equal to between about 5% and
about 50% by weight, and a reducing agent equal to between about
0.01% and about 0.5% by weight of the dry blend.
46. The method of claim 37, wherein the leavening agent is added in
an amount ranging between about 0.05% and about 5.0% by weight of
the polymeric composition.
47. A method of forming an aerated product, whereby a formulation
comprises from about 20% to about 70% by weight of plant protein
polymer, from about 5% to about 50% by weight starch, from about
10% to about 50% by weight humectant and at least about 0.01% by
weight of a reducing agent operable for cleaving disulfide bonds
present in said plant protein polymer; heating the formulation to a
maximum temperature of up to about 25.degree. C. in order to render
the formulation substantially homogeneous and flowable while
avoiding any substantial heat denaturation of said plant protein
polymer, the method comprising: adding an amount of a leavening
agent to the formulation, wherein the leavening agent is added in
an amount equal to between about 0.05% and about 5.0% by weight of
the formulation.
48. A method for forming an aerated pet chew, the method
comprising: (a) adding an amount of a leavening agent to a
polymeric composition containing a reducing agent and slurry
mixture to form a polymeric composition; (b) forming an aerated
polymeric composition; and, (c) thermally setting the aerated
polymeric composition by heating the composition at a temperature
ranging between about 80.degree. C. and about 145.degree. C. to
form a thermal set pet chew.
49. The method of claim 48, wherein the formed aerated polymeric
composition is coated following the shaping step to eliminate
sticking.
50. The method of claim 48, wherein the thermal set aerated pet
chew is polished to remove or cover up the coating used to
eliminate sticking.
51. A composition for forming a pet chew, the composition
comprising: (a) a plant protein polymer composition; (b) a slurry
mixture having an amount of water ranging between about 5% and
about 25% by weight of the composition; (c) a leavening agent added
in an amount ranging between about 0.05% and about 5.0% by weight
of the composition; and, (d) a reducing agent, whereby the
disulfide bonds have been cleaved within the composition in a range
between about 2.0% and about 75%.
52. A method of using a plant protein polymer to form an aerated
polymeric composition, the method comprising: (a) selecting a dry
blend that is biodegradable, digestible, and that can be formed
into a selected shape; (b) adding a slurry mixture to the dry
blend; (c) adding an amount of a leavening agent to the dry blend
and slurry mixture to form a polymeric composition; (d) adding an
amount of reducing agent; (e) heating and extruding the polymeric
composition to form a shaped aerated polymeric composition; and,
(f) thermally setting the formed polymeric composition.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Provisional
Application Ser. No. 60/647,499 filed on Jan. 27, 2005, which is
hereby incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention is directed to an aerated polymeric
composition, with the composition formed from a protein polymer and
an agent or method for causing porosity in the finished aerated
polymeric composition, such as a leavening agent. Additionally, the
present invention relates to methods for forming the aerated
polymeric composition, in particular, methods for forming aerated
pet treats or chews.
BACKGROUND OF INVENTION
[0003] Plant protein polymers have been known for use in a variety
of compositions. In particular, it has been known to use wheat
gluten and related plant protein compositions to form a variety of
chews and treats, as identified in U.S. Pat. No. 5,665,152 and
applied to pet treats. These known chew and treat products tend to
be of a dense nature. It is desired to have a method related to a
protein polymer product formation, which produces an aerated
product that is ductile and compressible. Such an aerated product
is desired because it can be used in any of a variety of
applications.
SUMMARY OF INVENTION
[0004] The present invention relates to an aerated, protein based
polymeric composition, which exhibits unique textural and
functional properties. The resultant aerated polymeric composition
is well suited for use as a unique pet chew for geriatric pets and
those pets less prone to chew, a unique confectionery product, or
biodegradable packing material. As would be guessed, additional
uses for the resultant material are also contemplated. As such, the
aerated polymeric composition can be used as packing foam, with the
benefit of being biodegradable.
[0005] The method for producing the aerated composition starts with
a protein polymer material. Any of a variety of protein sourced
polymers may be used to form the polymer material; however, it is
most preferred to use a plant derived protein polymer. More
particularly, it is desired to use an amount of wheat gluten, or a
similar plant polymer. In particular, the polymer disclosed in U.S.
Pat. No. 5,665,152, is well suited for use. The polymer material
will be formed from a protein polymer and additives.
[0006] A variety of additives or constituents may be mixed with the
plant protein polymer to form the dry blend. Such additives include
processing aids, flavors, starch, and colors. The addition and
amount of such constituents are dependent upon the desired final
product.
[0007] An amount of leavening agent is added to the dry blend. The
leavening agent is added to cause the formation of a polymer having
an aerated construction and a lower density. Generally, a variety
of leavening agents or methods can be used to aerate the polymeric
material, including physical addition of chemical leavening agents,
compressed gasses, or microbiologic fermentation. The leavening
agent may be selected from the group consisting of sodium
bicarbonate, baking powder, sodium acid pyrophosphate, monocalcium
phosphate, sodium aluminum phosphate, and combinations thereof. The
chemical leavening agent will be added in an amount ranging between
0.05% and 5.0% by weight of the polymeric composition. The amount
added will depend upon the desired finished product, in particular,
the amount of product aeration.
[0008] Water is added to the dry blend as part of a liquid slurry
that is added to the dry blend before or after the addition of the
leavening agent. This forms a polymeric composition. The slurry is
added so that an amount of water is available to react with the
chemical leavening agent to thereby cause the formation of CO.sub.2
and, resulting in the aerated construction. Additionally, it is
preferred to add glycerin or propylene glycol, or similar
processing aids, in with the slurry. Sodium metabisulfite is also
preferred for inclusion in the slurry as it affects the softness of
the structure. The sodium metabisulfite will cleave sulfite bonds
and relax the protein. Magnesium stearate may also be used as a
processing aid to enhance flow and reduce stickiness.
[0009] Thus, the slurry, leavening agent, and dry blend are all
mixed together and heated at a temperature sufficient that the
polymeric composition will flow, but is not denatured, and that the
reaction between the leavening agent and the water may occur. As a
result, the polymeric composition entraps the CO.sub.2 causing an
aeration of the polymeric composition and forms an aerated
polymeric composition.
[0010] Dependent upon the desired characteristics of the end
product, the amount of bicarbonate, or leavening agent, and water
added will be varied. If a more aerated construction is desired,
the amount of bicarbonate will be increased. Water is important as
an additive, because this helps to plasticize the protein and allow
elasticizing of the protein.
[0011] It is preferred to extrude or injection mold the polymeric
composition to form the desired end product. However, other methods
may be used to form a finished product of a desired shape and size.
Following the shaping of the aerated polymeric composition, the
aerated polymeric composition is dusted or coated with a substance
to reduce sticking. Coatings could include starch dusting, spraying
with oil, or coating with cellulose or other compounds.
[0012] Once the shape of the extruded or injection molded product
has been formed, it is preferred to thermally set the aerated
polymeric composition to form a product. Thermal setting is desired
because it causes the protein to denature, and thereby causes the
individual protein strands to cross-link and associate with one
another. This will cause the resultant product to have a unique
structure and texture that is ductile, pliable, and somewhat
elastic.
[0013] After thermal or heat setting the product, it is preferred,
but not required, to polish the product. This can be achieved using
a variety of compositions and techniques, including adding
petrolatum to the product.
[0014] The resultant invention is advantageous for a variety of
reasons. The aerated polymeric composition is desired because it
has a pliable construction that is made from "natural" materials.
The product is additionally advantageous because it is made of
protein so that it will generally be considered healthier than
other compositions used to form similar products. Additionally, the
product is readily biodegradable, and exhibits unique textural and
functional attributes, which makes it desired for use in any of a
variety of industries.
DETAILED DESCRIPTION
[0015] The present invention relates to an aerated polymeric
composition, methods for forming the composition, and compositions
for use in forming the aerated polymeric composition. In
particular, the method relates to using a leavening agent or method
to aerate a protein polymer, preferably a plant protein polymer.
The method further includes denaturing an extruded or injection
molded polymeric product. The present invention further relates to
methods of using plant protein polymers to form the aerated
polymeric composition. The resulting aerated polymeric composition
is preferably used as a pet chew. The present invention, in
particular, relates to a pliable and flexible dog chew, whereby the
chew has an aerated construction, forming a porous structure.
Preferably, the chew is formed from plant protein polymers, such as
wheat gluten, which produce edible and digestible chews having
unique characteristics. Additionally, the present invention relates
to methods of making the chew and methods for using plant protein
polymer with a leavening agent. Alternatively the aerated polymeric
composition may include materials that discourage infestation and
consumption by animals. This composition may be used as a packing
material.
[0016] The pet chew generally has a smooth outer surface,
substantially free of indentations or protrusions. This chew, in
the alternative can be wrinkled to some degree on the outside. In
fact, in certain constructions, it is desired to have some degree
of wrinkling. The inner portion of the article is formed of air
cells or caverns, resulting from aeration. The size of those
caverns may vary, depending on the desired texture and use. This
inner portion provides the article with a spongy texture, making it
compressible, flexible and accordingly, pliable for the jaws (teeth
and gums) of a typical dog. The resultant product has memory, so
that when compressed, it returns to its original shape once force
is removed. As such, the resulting product, when applied to pets,
provides chewing satisfaction for a pet, but can be consumed and
swallowed in a comparatively shorter period of time, depending on
the formulation and the size and distribution of the air cells.
[0017] The resultant pet chew has a body that includes a
substantially sealed, non-porous, outer skin. The inner portion of
the pet chew is integral with the skin. The inner portion has a
porous construction and is substantially surrounded by the skin.
The inner portion includes a plurality of cavities or air pockets
to provide the body with elastic deformability and flexibility. The
pet chew may also include a grain protein, or a plant protein
polymer, in an amount ranging between about 20% and about 70%, and
a reducing agent, whereby disulfide bonds have been cleaved within
the pet chew in a range between about 2.0% and about 75%. The pet
chew preferably has a body with a length ranging between 1 inch and
10 inches, and a diameter ranging between 0.125 inches and 4
inches.
[0018] Additionally, the chew has a pliability equal to being bent
in half, without breaking. The shape of the chew will include a
round stick, which has cavities ranging between 0.0005 inches and
0.040 inches in diameter. Conversely, the chew can be a hollow
tube; however, the cavity size remains the same. Thus, the pet chew
product can be of a variety of shapes, lengths, and diameters. The
shape and size selected will depend upon the animal intended to
consume the product. The age and size of the animal will also
influence the finished product. Animals which are intended to
consume the product include, but are not limited to, dogs, cats,
birds, and small animals, such as hamsters, gerbils, chinchillas,
ferrets, rats, and mice. Forming methods have been demonstrated
through extrusion and injection molding, but other methods may also
be used.
[0019] The method for forming the aerated polymeric composition,
especially the pet chew, is dependent on the desired shape and the
resultant aerated properties. The method is initiated by selecting
a polymer for use in forming the product. The selected polymer and
resulting polymeric composition should be such that gas trapping
and rheological properties are provided to produce the unique
textures and functionalities of the resultant pet chew product.
Additionally, the flow properties of the selected polymer should
allow for processing through extrusion or injection molding
equipment.
[0020] A polymeric composition is used to form an aerated polymeric
composition. The polymeric composition includes an amount of a dry
blend, a slurry mixture, and a leavening agent. Once the polymeric
composition is heated, it is known as an aerated polymeric
composition. When the aerated polymeric composition is cured, or
heat set, it forms a pet chew. The polymeric composition includes
any of a variety of polymers and polymeric compositions, can
optionally serve as a carrier of other materials, and can be
flavored.
[0021] The dry blend includes an amount of a polymer equal to from
about 5% to about 85% by weight of the dry blend. Any polymer,
which can be aerated, consumed, and shaped into a desired
structure, may be used. Preferably, the polymer is a plant protein,
or grain protein; however, other proteins with the same
characteristics may be used. More preferably, the dry blend
includes an amount of plant protein equal to between about 20% and
about 70% by weight of the dry blend. Preferably, the plant protein
is a gluten composition. The definition of gluten is a tenacious
elastic protein substance, and includes, but is not limited to
proteins such as gliadin, glutenin, globulin, and albumin. The
gluten, when denatured, can form disulfide cross-links and hydrogen
bonding between the proteins or their constituent amino acids.
Wheat gluten is the most preferred gluten composition for use;
however, soy protein, corn gluten, and mixtures thereof may also be
used.
[0022] The selected plant protein is combined with other
constituents to form the dry blend. Other constituents included in
the dry blend include starch, flavors, colors, and reducing agents.
Preferably, starch is added in an amount ranging between about 5%
and about 50% by weight of the dry blend. A variety of starch types
can be used, such as corn, wheat, potato, and tapioca starches, and
mixtures thereof. The starches can be native or modified by
gelatinization or chemical treatment. The resultant starches can be
oxidized, acetylated, carboxymethyl, hydroxyethyl, hydrox-propyl,
high amylose, and alkyl-modified starches. The starches are added
to further modify the texture of the finished product.
[0023] Reducing agents are added as a processing aid. The reducing
agents improve flavor characteristics and reduce damage to the
protein caused by heat and shear. Reducing agents available for use
include those selected from the group consisting of the alkali
metal and ammonium sulfites, bisulfites, metabisulfites, and
nitrites, and mercaptoethanol, cystein, cysteamine, ascorbic acid,
and mixtures thereof. The reducing agents are included in the
formulation at a level of at least 0.01% by weight of the dry
blend. Alternatively, the reducing agents are included in the
formulation at a level of between about 0.01% and about 3% by
weight of the dry blend. Preferably, the reducing agents are
included in the formulation at a level of between about 0.01% and
about 0.5% by weight of the dry blend. The reducing agent cleaves
the disulfide bonds in the formulation in a range between 2.0% and
about 75%.
[0024] Flavors, for example, beef, chicken, or other flavors,
attractive to the senses of dogs, can be added to the formulation.
Any of a variety of flavors can be used to impart taste
characteristics to the finished product. Flavors, typically meat
(chicken, beef, pork, etc.), fruit and the like, can be added to
the mixture in the extruder. For example, beef flavoring may be
added by placing beef broth, beef stock, or concentrated flavors
into the extruder. Also, compositions such as liquid smoke, for
example, Charsol C-10 can be added as flavoring. The flavors are
added according to taste.
[0025] Colors may also be part of the extrusion mixture and added
thereto at any time during the extrusion. These colors can include
for example, Carmel coloring, Red (for example Red #40), Yellow
(for example, Yellow #5 Lake), and the like. The colors may be
added to the extrusion mixture. The amount added is dependent upon
the finished color desired.
[0026] The method for forming a polymeric composition includes
mixing a slurry mixture with the dry blend. The slurry can include
water, humectants, and processing aids. The formulation includes an
amount of water necessary to promote polymer formation. An amount
of water, up to about 30% by weight, more preferably up to about
25% by weight and, most preferably, from about 10% to about 20% by
weight of the slurry may be included. The slurry has an amount of
water ranging between about 5% and about 25% by weight of the
polymer composition. The water, as detailed above, acts as a
plasticizer, hydrates the protein to make it functional, and reacts
with the sodium bicarbonate to form the gas for aeration of the
polymer.
[0027] A humectant is normally used at a level equal to from about
5% to about 80% by weight in the slurry and, more preferably, from
about 10% to about 50% by weight of the slurry. The preferred class
of humectants include those selected from the group consisting of
glycerol, diglycerol, propylene glycol, triethylene glycol, urea,
sorbitol, mannitol, maltitol, hydrogenated corn syrup, polyvinyl
alcohol, polyethylene glycol, C.sub.12-C.sub.22 fatty acids, and
metal salts of such fatty acids, and mixtures thereof. The most
preferred plasticizer is glycerol or glycerin. The formulations of
this invention also include processing aids, cellulose, flavors,
and colors.
[0028] An amount of a leavening agent is mixed with the dry blend
and slurry mixture to form a polymeric composition. The leavening
agent can be added to the dry blend prior to the addition of the
slurry, or can be added after the addition of the slurry. It is,
however, preferred to aerate the polymeric composition during
extrusion. This will contribute to the desired texture of the chew.
Aeration, that forms the caverns, or a plurality of gas bubbles, in
the article or chew, typically occurs as a result of adding a
leavening agent, such as bicarbonate, to the extrusion mixture.
[0029] Leavening agents, such as sodium bicarbonate, react with
water in the extrusion mixture, forming a gas that aerates the
extruded aerated polymeric composition. A leavening agent is a
compound that produces a gas in the presence of heat. Chemical
leavening agents from the following chemical families can be used:
carbonates, bicarbonates, phosphates, or other chemical additives
used separately, or in combination, which produce a gas when
reacted under heat and/or in the presence of water. For example,
the leaving agent may be selected from the group consisting of
sodium bicarbonate, baking powder, sodium acid pyrophosphate,
monocalcium phosphate, sodium aluminum phosphate, and combinations
thereof. Also, injection of a compressed gas into the polymeric
composition within the extruder or injection molding screw can
produce the same effect. Gaseous CO.sub.2, compressed air,
nitrogen, helium, and combinations thereof can be added to the
extrusion mixture for this aeration step. It is preferred to use
chemical leavening agents to form the aerated structure. It is more
preferred to use sodium bicarbonate or baking powder. As such, any
of a variety of compositions and methods can be practiced to
promote aeration. The chemical leavening agent is added in a
variety of amounts. Preferably, the chemical leavening agent is
added in an amount ranging between about 0.05% and about 5.0% by
weight of the polymeric composition. More preferably, the chemical
leavening agent is added in an amount ranging between about 0.5%
and about 2.5% by weight of the polymer mix.
[0030] As such, aeration occurs before or after forming the
homogeneous, flowable aerated polymeric composition, but before
forming into the finished shape and subsequent product.
[0031] The polymer composition is heated under moderate
temperatures and mild sheer force to create a substantially
homogeneous mixture and flowable formulation. The flowable
formulation is mildly heated and formed into desired shapes using
extrusion or injection molding.
[0032] It is preferred that the polymeric composition formulation
not be subjected to excessive heat during the process prior to
shaping, as this will denature more than about 10% by weight of the
protein contained in the formulation. Therefore, it is desired to
process and form the flowable polymeric composition formulation
without damaging the protein constituent by heat or sheer forces
until after formation of the desired shape. The flowable
formulation can be made by using a variety of macro-molecules in
combination with plasticizers, which can be shaped, extruded, or
injection-molded.
[0033] The polymeric composition is heated to form an aerated
polymeric composition, which can be extruded or injection molded
into a polymeric composition pet chew. The extruding temperature
preferably ranges between about 25.degree. C. and about 75.degree.
C.
[0034] It is important to maintain the temperature of the mixture
within the extrusion barrel at a temperature below about 70.degree.
C. It is also important that the temperature of the mixture, as it
exits the die of the extruder, does not exceed about 80.degree. C.
and, preferably, the temperature should be below about 65.degree.
C.
[0035] As such, the polymeric composition is processed into a
flowable homogeneous mixture through extrusion technologies using
single or twin screw extruders. The flowable polymeric composition
can be formed into pellets off of the extruder system for
subsequent use in injection molding or the flowable polymeric
composition can be formed into the finished shape directly off of
the extrusion system. If the flowable polymeric composition is to
be used in injection molding, the pellets would be processed
through injection molding equipment so that the temperature of the
flowable polymeric composition does not exceed about 80.degree. C.
through the screw and into the mold. Also, these formulations can
be mixed and processed directly as virgin material in conventional
injection molding equipment.
[0036] The handling of the flowable polymeric composition is
noticeably difficult due to its sticky nature. It is essential that
the flowable polymeric composition is coated immediately after
extrusion to eliminate sticking and to maintain individual pieces.
A wide range of coating can be used, such as starches, oils,
emulsifiers, release agents, fibers, etc. It is preferred to use
starch to dust and coat the surface of the flowable polymeric
composition soon after it exits the extruder die. It is more
preferred to use cornstarch.
[0037] After extrusion, the aerated polymeric composition is heat
set by curing at a temperature ranging between about 80.degree. C.
and about 145.degree. C. The temperatures are such that the protein
polymer is denatured. The aerated polymeric composition pet chew is
denatured by heating the chew at a temperature ranging between
about 80.degree. C. and about 145.degree. C. to form a heat set pet
chew.
[0038] Once the flowable aerated polymeric composition is
denatured, it is a fixed polymeric composition. Through either
process, the chemical leavening is reacted through single acting or
double acting gas release. Depending on the desired effect,
aeration can be produced within the extruder and, if desired, a
second gassing can be achieved within the injection molding screw
or upon heating during the denaturing process.
[0039] After the product is heat set, it can be polished to remove
the coating initially applied, up-stream in the process, to prevent
individual products from readily sticking together. This step can
be achieved by applying corn or wheat starch to the surface or by
applying heat. It is most preferred to apply cornstarch.
Lubricants, such as mineral oil, petroleum jellies, for example,
petrolatum, waxes, and blends thereof may also be applied in post
processing steps to prevent the finished products from sticking
together. Most preferably, the product is polished with cornstarch,
followed by petrolatum.
[0040] Following the heat denaturing of the extruded polymeric
material, it is desired to remove the appearance of the starch
dusting to make the appearance more acceptable to consumers. The
starch is polished from the surface of the fixed polymeric material
using petrolatum and typical confectionary polishing techniques.
The polishing agent is heated above its melting point and applied
to the surface of the fixed polymeric composition. Usage rate of
petrolatum is preferred to be less than about 2% by weight, and a
more preferred level is less than about 1% by weight. Other types
of materials can be used to cover or remove the starch from the
surface of the fixed polymeric composition, such as vegetable oils,
natural waxes, parafins, glycerin, and water sprays.
[0041] Alternatively, the aerated polymeric composition may be used
as a packing material. The composition includes a dry blend
comprising a compound selected from the group consisting of a plant
protein polymer, processing aids, materials that discourage
infestation, and materials that discourage consumptions by humans
as well as by pets. For example, the composition may include an
amount of Cedar oil of from about 0.5% to about 1% by weight of the
composition and an amount of a bittering agent of from about 1% to
about 3% by weight of the composition.
[0042] The invention will now be described by way of Examples.
EXAMPLES
Example 1
[0043] A method for producing co-extruded pet chews was practiced.
In particular, tests were conducted to determine if dog chews could
be co-extruded using a protein polymeric material. Products with
and without a leavening agent were made. As such, the present
invention relates to methods for co-extruding protein polymers,
that are aerated and formed into pet treats or chews. The extruders
used in this Example were an X-85 single screw extruder and a TX-57
twin screw extruder, both are manufactured by the Wenger
Manufacturing Co. Any shape can be used to demonstrate this
invention; however, in the present Example, a bone shape was used,
with a round center for the secondary extrusion. The X-85 was used
to form the outside extrusion flow, and the TX-57 was used to form
the inside extrusion flow. The polymeric material used for both the
inside and outside extrusion flows was a flowable formulated
protein polymer. The base polymer formula consisted of the
following constituents: TABLE-US-00001 % by weight Constituent (dry
mix) Wheat Gluten 87.87 Flavor 4.36 Sodium Hexametaphosphate 2.49
Cellulose 2.49 Glycerol Monostearate 2.00 Magnesium Stearate
0.80
[0044] This mixture was used to form a dry mix equal to 100 lbs.
Next, a slurry was formed, with the slurry consisting of 18.5 lbs.
of glycerin, 2 lbs. of water, and 0.1 lbs. of sodium metabisulfate.
The slurry was intended to plasticize the material.
[0045] Slurry, in the amount of 26 parts by weight, was added to
100 parts of the dry mix in the extrusion process. The extruder
conditions were such that the feed rates yielded 225 lbs/hr. The
extruder barrel temperature did not exceed 60.degree. C. The die
temperatures were maintained below 66.degree. C., and the extruder
screws were running at 120 rpm. Following extrusion, the formed
polymeric mixture was heated in a convection oven at a temperature
ranging between 88.degree. C. and 110.degree. C. to denature the
protein.
[0046] The polymer was extruded using the mentioned devices to
determine whether a suitable product could be formed using this
method. The test runs were as follows, with the inside polymer
described, followed by the outside polymer. Any varying conditions
or constituents are also described.
[0047] Test Run No. 1: Protein Polymer/Protein Polymer, standard
set-up was used.
[0048] Test Run No. 2: Protein Polymer/Protein Polymer, increased
gap between front die and internal die.
[0049] Test Run No. 3: Protein Polymer/Baking Powder, mixed with
Protein Polymer.
[0050] It was observed that an unstable process occurred throughout
the three extrusions; however, samples were collected to test the
concept.
[0051] A second set of tests was conducted. The extrusion was
changed to cause a reversal of flows at the die to achieve better
skin and allow the center to extrude at a higher moisture to reduce
surges. The second set of runs were as follows:
[0052] Test Run No. 4: Protein Polymer/Protein Polymer.
[0053] Test Run No. 5: Protein Polymer/Protein Polymer with
bicarbonate--200 lb. batch, 11/2% baking powder, center
formulation.
[0054] Test Run No. 6: Protein Polymer/Protein Polymer with
Rice--20% addition both outside and inside.
[0055] Test Run No. 7: Protein Polymer/Starch Polymer.
[0056] From the above tests or runs, it was observed that
co-extrusion of a protein polymeric material was possible with no
unique capital beyond equipment to converge flows. It was also
demonstrated from these tests that a polymeric material could be
aerated to achieve a unique texture and product.
Example 2
[0057] The trials of Example 1 were further continued. In this
Example, 9 test runs were conducted. The present Example relates to
the continued development of formulations for a unique pet chew, as
well as texture and shape configuration development. The Example is
directed to aerating the protein polymer and on the merging of two
different polymeric materials, a starch polymer and a protein
polymer. Resultantly, a unique product with dual textures was
produced. The protein polymeric material was ductile, while the
starch polymer was more crystalline. New configurations were
evaluated, as well as co-extrusion configurations. The below
information discloses recipe information, preconditioning
information, and extrusion information. The extrusion information
for the runs was as follows: TABLE-US-00002 Run Number 1 2 3 DRY
RECIPE INFORMATION: Dry Recipe Moisture % wb 6.87 6.87 Dry Recipe
Density kg/m.sup.3 485 485 485 Dry Recipe Rate kg/hr 50 50 50 Feed
Screw Speed rpm 11 9 9 PRECONDITIONING INFORMATION: Preconditioner
Speed rpm 350 350 350 Steam Flow to Preconditioner kg/hr Water Flow
to Preconditioner kg/hr Preconditioner Additive 1 Rate kg/hr 17.4
13.9 17.4 Preconditioner Discharge Temp. .degree. C. 20 27 27
Moisture Entering Extruder % wb 10.53 10.18 EXTRUSION INFORMATION
Extruder Shaft Speed rpm 130 150 150 Extruder Motor Load % 40 37 34
Steam Flow to Extruder kg/hr Water Flow to Extruder kg/hr 1 1.8 1
Control/Temperature 1st Head .degree. C. 50/49 50/50 50/50
Control/Temperature 2nd Head .degree. C. 60/61 60/61 60/60
Control/Temperature 3rd Head .degree. C. 60/61 60/56 60/63
Control/Temperature 4th Head .degree. C. 60/60 50/50 50/50
Control/Temperature 5th Head .degree. C. 50/50 45/45 45/42
Control/Temperature 6th Head .degree. C. Control/Temperature 7th
Head .degree. C. Control/Temperature 8th Head .degree. C.
Control/Temperature 9th Head .degree. C. Head/Pressure kPa 5/564
5/645 5/500 Belt Speed m/min Knife Drive Speed rpm FINAL PRODUCT
INFORMATION Extruder Discharge Moisture % wb 12.49 Extruder
Discharge Rate kg/hr FINAL PRODUCT INFORMATION Extruder Discharge
Density kg/m.sup.3 Extruder Discharge Temp .degree. C. Dryer
Discharge Density kg/m.sup.3 Extruder Performance Stable Stable
Stable Duration of Run min Final Product Description Protein Shell
Protein Shell Protein Shell Customer Recipe Number 3 3 3 Run Rating
Good Good Good REFERENCE NUMBERS: Main Recipe Precond. Additive 1
Recipe Extruder Additive 1 Recipe Preconditioner Configuration 389
389 389 Extruder Configuration 1092 1092 1092 Die and Knife
Configuration 5074 5074 5074 Dryer Formula 12343 12344 12345
Micronizer Formula Product Analysis 13591 13592 Run Number 4 5 6
DRY RECIPE INFORMATION: Dry Recipe Moisture % wb 6.65 7.09 Dry
Recipe Density kg/m.sup.3 502 480 500 Dry Recipe Rate kg/hr 50 50
50 Feed Screw Speed rpm 10 10 10 PRECONDITIONING INFORMATION:
Preconditioner Speed rpm 350 350 350 Steam Flow to Preconditioner
kg/hr Water Flow to Preconditioner kg/hr Preconditioner Additive 1
Rate kg/hr 17.4 17 17 Preconditioner Discharge Temp. .degree. C. 28
26 27 Moisture Entering Extruder % wb 11.3 11.29 10.94 EXTRUSION
INFORMATION Extruder Shaft Speed rpm 150 130 130 Extruder Motor
Load % 34 34 34 Steam Flow to Extruder kg/hr Water Flow to Extruder
kg/hr 1 1.5 1.5 Control/Temperature 1st Head .degree. C. 50/50
50/49 50/51 Control/Temperature 2nd Head .degree. C. 60/61 50/50
50/50 Control/Temperature 3rd Head .degree. C. 60/68 50/50 50/50
Control/Temperature 4th Head .degree. C. 50/50 50/50 50/50
Control/Temperature 5th Head .degree. C. 45/45 45/45 45/45
Control/Temperature 6th Head .degree. C. Control/Temperature 7th
Head .degree. C. Control/Temperature 8th Head .degree. C.
Control/Temperature 9th Head .degree. C. Head/Pressure kPa 5/538
5/422 5/432 Belt Speed m/min Knife Drive Speed rpm FINAL PRODUCT
INFORMATION Extruder Discharge Moisture % wb 12.7 12.62 14.75
Extruder Discharge Rate kg/hr Extruder Discharge Density kg/m.sup.3
Extruder Discharge Temp .degree. C. Dryer Discharge Density
kg/m.sup.3 Extruder Performance Stable Stable Stable Duration of
Run min Final Product Description Protein Shell Protein Shell
Protein Shell Customer Recipe Number 5 6 9 Run Rating Good Good
Good REFERENCE NUMBERS: Main Recipe Precond. Additive 1 Recipe
Extruder Additive 1 Recipe Preconditioner Configuration 389 389 389
Extruder Configuration 1092 1092 1092 Die and Knife Configuration
5074 5074 5074 Dryer Formula 12346 12347 12348 Micronizer Formula
Product Analysis 13593 13594 13596 Run Number 7 8 9 DRY RECIPE
INFORMATION: Dry Recipe Moisture % wb 6.87 Dry Recipe Density
kg/m.sup.3 485 485 500 Dry Recipe Rate kg/hr 50 50 50 Feed Screw
Speed rpm 10 10 10 PRECONDITIONING INFORMATION: Preconditioner
Speed rpm 350 350 350 Steam Flow to Preconditioner kg/hr Water Flow
to Preconditioner kg/hr Preconditioner Additive 1 Rate kg/hr 17 17
17 Preconditioner Discharge Temp. .degree. C. 28 29 29 Moisture
Entering Extruder % wb 10.67 EXTRUSION INFORMATION Extruder Shaft
Speed rpm 130 110 110 Extruder Motor Load % 38 27 32 Steam Flow to
Extruder kg/hr Water Flow to Extruder kg/hr 1.5 1.5 1.5
Control/Temperature 1st Head .degree. C 50/50 50/52 50/49
Control/Temperature 2nd Head .degree. C. 50/52 50/50 50/50
Control/Temperature 3rd Head .degree. C. 50/50 50/49 50/50
Control/Temperature 4th Head .degree. C. 50/51 50/52 50/50
Control/Temperature 5th Head .degree. C. 45/45 45/45 45/45
Control/Temperature 6th Head .degree. C. Control/Temperature 7th
Head .degree. C. Control/Temperature 8th Head .degree. C.
Control/Temperature 9th Head .degree. C. Head/Pressure kPa 5/592
5/230 5/270 Belt Speed m/min 21 Knife Drive Speed rpm FINAL PRODUCT
INFORMATION Extruder Discharge Moisture % wb 11.88 Extruder
Discharge Rate kg/hr Extruder Discharge Density kg/m.sup.3 Extruder
Discharge Temp .degree. C. Dryer Discharge Density kg/m.sup.3
Extruder Performance Stable Stable Duration of Run min Final
Product Description Protein Shell RD Protein RD Protein Shell Shell
Customer Recipe Number 5 6 9 Run Rating Good Good Good REFERENCE
NUMBERS: Main Recipe Precond. Additive 1 Recipe Extruder Additive 1
Recipe Preconditioner Configuration 389 389 389 Extruder
Configuration 1092 1092 1092 Die and Knife Configuration 5074 5075
5075 Dryer Formula 12349 12350 12351 Micronizer Formula Product
Analysis 13596 13594 13596
[0058] The drying conditions for each run was as follows:
TABLE-US-00003 Dryer Formula Number Model Number 12343 12344 12345
Number of Sections Zone 1 Temperature .degree. C. 100 110 Zone 2
Temperature .degree. C. 100 110 Zone 3 Temperature .degree. C. 100
110 Zone 4 Temperature .degree. C. Zone 5 Temperature .degree. C.
Zone 6 Temperature .degree. C. Retention Time-Pass 1 min 6.8 5.4
Retention Time-Pass 2 min 11.3 11.3 Retention Time-Pass 3 min
Retention Time-Cooler min Dryer Formula Number Model Number 12346
12347 12348 Number of Sections Zone 1 Temperature .degree. C. 110
110 110 Zone 2 Temperature .degree. C. 110 110 110 Zone 3
Temperature .degree. C. 110 110 110 Zone 4 Temperature .degree. C.
Zone 5 Temperature .degree. C. Zone 6 Temperature .degree. C.
Retention Time-Pass 1 min 5.4 5.4 5.4 Retention Time-Pass 2 min
11.3 9.4 9.4 Retention Time-Pass 3 min Retention Time-Cooler min
Number of Sections Zone 1 Temperature .degree. C. 110 110 110 Zone
2 Temperature .degree. C. 110 110 110 Zone 3 Temperature .degree.
C. 110 110 110 Zone 4 Temperature .degree. C. Zone 5 Temperature
.degree. C. Zone 6 Temperature .degree. C. Retention Time-Pass 1
min 5.4 5.4 5.4 Retention Time-Pass 2 min 11.3 11.3 11.3 Retention
Time-Pass 3 min Retention Time-Cooler min Product Analysis Number 1
2 3 4 5 6 Dry Recipe % wb 6.87 6.87 6.65 7.09 6.87 Preconditioner
Discharge 10.53 10.18 11.3 11.29 10.94 10.67 % wb Extruder
Discharge % wb 12.49 12.7 12.62 14.75 11.88
[0059] From above, wb stands for wet basis. TABLE-US-00004 9486 -
Recipe Reference Number Customer Recipe Ref: 1 Kg Pounds Percent
Ingredient Supplier Lot #: 107.62 237.27 79.09 Durum Wheat Flour
North Dakota Mill 20125 3502001 12.11 26.70 8.90 Wheat Gluten
Midwest Grain Prod. 944301-09-17 0.10 0.21 0.07 Sodium
Metabisulfite 6.12 13.50 4.50 Corn Syrup Solids Krystar LK3K10A
6.12 13.50 4.50 Gelatin (250 Bloom) Leiner Davis Gelatin OK421-3
0.45 0.99 0.33 Sodium Propionate 0.76 1.68 0.56 Myvaplex 1.50 3.30
1.10 Cheese Powder International Ingredients 0.53 1.17 0.39
Titanium Dioxide 0.76 1.68 0.56 Yellow #6 136.08 300.00 100.00
[0060] Comments: RECIPE MIXED TWO TIMES; dry blend for X-85
TABLE-US-00005 9487 - Recipe Reference Number Customer Recipe Ref:
1 Kg Pounds Percent Ingredient Supplier Lot #: 17.51 38.60 38.60
Corn Syrup Cargill Inc. 140122 17.51 38.60 38.60 Propylene Glycol
Harcross Organics 47-2700 6.76 14.90 14.90 Choice White Grease Hahn
& Phillips Grease 3.58 7.90 7.90 Phosphoric Acid VW & R
OM080815594 45.36 100.00 100.00
[0061] Comments: Slurry for X-85: Add 11.2% of this to Recipe #1
TABLE-US-00006 9487 - Recipe Reference Number Customer Recipe Ref:
3 Kg Pounds Percent Ingredient Supplier Lot #: 2.72 6.00 2.00
Glycerol Monostearate Cargill Inc. 1.09 2.40 0.80 Magnesium
Stearate Harcross Organics 0.14 0.30 0.10 Red #40 Cel Lake Warner
Jenkinson AL1157 124.67 274.86 91.62 Vital Wheat Gluten Midwest
Grain 944301-09-17 0.68 1.50 0.50 Beef Broth 5401 IDF 1234 3.39
7.47 2.49 Sodium Prayon A001218 Herametophosphate 3.39 7.47 2.49
Solka-Flok 900 FS & D 1932501217 136.08 300.00 100.00
[0062] Comments: Dry blend for TX-57: Add 26% of customer's slurry
to this. Mixed 11/3 times. TABLE-US-00007 9489 - Recipe Reference
Number Customer Recipe Ref: 4 Kg Pounds Percent Ingredient Supplier
Lot #: 22.68 50.00 100.00 Customer's slurry recipe 22.68 50.00
100.00
[0063] Comments: Pounds listed do not indicate pounds used
TABLE-US-00008 9490 - Recipe Reference Number Customer Recipe Ref:
5 Kg Pounds Percent Ingredient Supplier Lot #: 40.36 88.97 88.97
Vital Wheat Gluten Midwest Grain 944301-09-17 0.68 1.50 1.50 Beef
Broth IDF 1234 1.13 2.49 2.49 Sodium Hexometaphosphate Prayon
1932501217 1.13 2.49 2.49 Solka-Flok 900 FS & D 0.91 2.00 2.00
Glycerol Monostearate 0.36 0.80 0.80 Magnesium Stearate 0.11 0.25
0.25 Red #40 AL Lake Warner Jenkinson AL1157 0.68 1.50 1.50 Sodium
Bicarbonate 45.36 300.00 100.00
[0064] TABLE-US-00009 9491 - Recipe Reference Number Customer
Recipe Ref: 6 Kg Pounds Percent Ingredient Supplier Lot #: 80.03
176.44 88.22 Vital Wheat Gluten Midwest Grain 944301-09-17 2.72
6.00 3.00 Beef Broth IDF 1234 2.26 4.98 2.49 Sodium
Hexametaophosphate Prayon A001218 2.26 4.98 2.49 Solka Flok 900 FS
& D 1932501217 1.81 4.00 2.00 Glycerol Monostearate 0.73 1.60
0.80 Magnesium Stearate 0.23 0.50 0.25 Red #40 AL Lake Warner
Jenkinson AL1157 0.68 1.50 0.75 Sodium Bicarbonate 90.72 200.00
100.00
[0065] TABLE-US-00010 9492 - Recipe Reference Number Customer
Recipe Ref: 7 Kg Pounds Percent Ingredient Supplier Lot #: 107.62
237.27 79.09 Durum Wheat Flour North Dakota Mill 20125 3502001
12.11 26.70 8.90 Wheat Gluten Midwest Grain 944301-09-17 0.10 0.21
0.07 Sodium Metabisulfite 6.12 13.50 4.50 Corn Syrup Solids Krystar
LK3K10A 6.12 13.50 4.50 Gelatin Kindt & Knox Gelatin 0.45 0.99
0.33 Sodium Propionate 0.76 1.68 0.56 Myvaplex Quest International
2001020105 1.50 3.30 1.10 Cheese Powder International Ingredients
0.53 1.17 0.39 Titanium Dioxide 0.76 1.68 0.56 Yellow #6 136.08
300.00 100.00
[0066] Comments: Mixed 1 time TABLE-US-00011 9493 - Recipe
Reference Number Customer Recipe Ref: 8 Kg Pounds Percent
Ingredient Supplier Lot #: 107.62 237.27 79.09 Durum Wheat Flour
North Dakota Mill 20125 3502001 12.11 26.70 8.90 Wheat Gluten
Midwest Grain 944301-09-17 0.10 0.21 0.07 Sodium Metabisulfite 6.12
13.50 4.50 Corn Syrup Solids Krystar LK3K10A 6.12 13.50 4.50
Gelatin Kindt & Knox Gelatin 0.45 0.99 0.33 Sodium Propionate
0.76 1.68 0.56 Myvaplex Quest International 2001020105 1.50 3.30
1.10 Cheese Powder International Ingredients 0.53 1.17 0.39
Titanium Dioxide 0.76 1.68 0.56 Yellow #6 Warner Jenkinson AL0343
136.08 300.00 100.00
[0067] Comments: Made another 200 lb. batch TABLE-US-00012 9494 -
Recipe Reference Number Customer Recipe Ref: 9 Kg Pounds Percent
Ingredient Supplier Lot #: 80.35 177.14 88.48 Vital Wheat Gluten
Midwest Grain 944301-09-17 2.72 6.00 3.00 Beef Broth IDF 1234 2.26
4.98 2.49 Sodium Hexametaphosphate Prayon A001218 2.26 4.98 2.49
Solka Flok 900 FS & D 1932501217 1.81 4.00 2.00 Glycerol
Monostearate 0.73 1.60 0.80 Magnesium Stearate 0.23 0.50 0.25 Red
#40 AL Lake Warner Jenkinson AL1157 0.45 1.00 0.50 Sodium
Bicarbonate 90.81 200.20 100.00
[0068] Starch polymer pellets used herein were comprised of
cellulose addition, chlorophyll, and chlorophyll coarse rice flour
(30-40 mesh), and colored with chlorophyll. Rolled sheets of starch
polymer (plain) 300 pcs at 150 lbs. were also used.
[0069] The runs below pertained to non-aerated polymers. The
analysis of the runs is as follows:
[0070] Run No. 1: This run related to the initial die set-up.
Formula No. 5 for starch and beef flavored No. 1 protein polymer
were co-extruded. The formula was non-aerated. It was observed that
a fairly good extrusion was produced. The starch flow was
restricted due to die opening versus volume of extruder capacity.
The TX-57 extruded was used to form the protein shell. Note that
Run Nos. 1 and 3 were best, but had higher slurry.
[0071] Run No. 2: The die was modified so that the front die had an
open nipple so that it protruded beyond the outside plane of the
protein. Formula No. 5 for starch and Beef No. 1 Protein Polymer
were used. The formula was non-aerated. Same as Run No. 1, but
modified final insert to be more open to allow increased filling.
Correcting the slurry ratio made the product not weld together as
well. The feed holes in the back die show in the final product.
[0072] Run No. 3: The die was modified so that the front die had an
open nipple so that it protruded beyond the outside plane of the
protein. A higher slurry level was used to achieve better
appearance. The formula was non-aerated. Very good appearance,
slightly sticky, welds seemed to improve, observed to be the best
run. Increased slurry rate to higher level--improved shape--smooth,
uniform.
[0073] Run No. 4: The die was modified so that the front die had an
open nipple so that it protruded beyond the outside plane of the
protein. An aerated protein was formed. Formula No. 2 Beef, with
1.5% bicarbonate, plus Formula No. 5 starch was used. Dry recipe
with 1.5% sodium bicarbonate.
[0074] Good expansion and texture for a protein polymer were
observed.
[0075] Run No. 5: This run relates to aerated protein polymer
having--0.75% bicarbonate. Beef broth was added and increased to
3%; Color Red #40 Lake 0.25%. The starch polymer used was the same
as all previous runs; no changes were made to the starch polymer.
Expansion under control and good solid extrusion and shape
resulted. The product was heated in a convection oven at
110.degree. C. for 14.7 minutes. Some increased expansion occurred
in the Dryer.
[0076] Run No. 6: This run relates to an aerated protein polymer
having 0.5% bicarbonate/3% beef broth/color 0.25%. The starch
polymer was the same as previous runs. Very good shape and
expansion, almost as much as 0.75, visually. Cure: 110.degree.
C.--14.7 minutes (5.4 minutes, top, and 9.3 minutes, bottom). Best
expanded product. The starch polymer extruded best when cooked.
Lowered bicarbonate to 0.5% was stable, as long as the inlet was
cleaned every few minutes.
[0077] Run No. 7: This run relates to a protein polymer containing
no leavening agent. Protein Polymer--Back to Beef No. 1 with 0.5%
beef broth and no bicarbonate. The starch polymer was the same as
previous runs. Intent of the run was to duplicate Run No. 3--but
fill pin had been straightened. Cure: 110.degree. C.--14.8 minutes.
No bicarbonate.
[0078] Run No. 8: This run relates to a protein polymer containing
no leavening agent. Co-Extruded Tube. Protein Polymer--Formula Beef
No. 1, no bicarbonate, with 0.5% beef broth. The starch polymer was
the same as previous runs. No bicarbonate, round rod.
[0079] Run No. 9: This run relates to an aerated protein polymer
with a modified die. Co-Extruded Tube. Protein Polymer--Formula
Beef No. 7, with 0.5 bicarbonate. Starch Polymer--same as previous
runs. Round rod with 0.5% bicarbonate.
[0080] It was observed that co-extruded pet chews containing two
uniquely different polymers can be produced. Further, it was
observed that a protein polymer can be aerated to produce a variant
texture and densities. Co-extruded chews of aerated protein and
starch in a targeted shape could be produced.
Example 3
[0081] The present Example discloses a process for producing
protein polymer chew sticks, which are intended as pet chews for
older dogs, which have difficulty chewing harder materials, and for
those dogs which typically do not chew. A Wenger TX57 twin screw
extruder was selected as the device for extrusion.
[0082] The pet treats were formed by extruding the protein
polymeric formula into a rope that was cut into various lengths. As
seen below, a number of processes and formulations were tried to
determine the preferred method and formula for producing a desired
resultant product. The extrudate was then heated to denature the
protein.
[0083] The formulas used were as follows: TABLE-US-00013 9683 -
Recipe Reference Number Kg Pounds Percent Ingredient 49.68 109.52
87.27 Wheat Gluten 1.43 3.16 2.52 Sodium Haxematte Phosphate 1.43
3.16 2.52 Solka Flok 900 0.46 1.02 0.81 Magnesium Stearate 1.72
3.80 3.03 Beef Broth 0.44 0.97 0.77 Caramel Color 1.15 2.53 2.02
Glycerol Monostearate 0.23 0.50 0.40 Red #40 Lake 0.38 0.84 0.67
Sodium Bicarbonate 56.93 125.50 100.01
[0084] Comments: Recipe mixed 3 times TABLE-US-00014 9684 - Recipe
Reference Number Kg Pounds Percent Ingredient 90.99 200.60 87.87
Glycerin 3.63 8.00 3.50 Liquid Smoke, Charsol C-10 0.50 1.10 0.48
Sodium Meta Bisulfate 8.44 18.60 8.15 Water 103.56 228.30
100.00
[0085] TABLE-US-00015 9685 - Recipe Reference Number Kg Pounds
Percent Ingredient 45.36 100.00 99.75 Mix #1 0.11 0.25 0.25 Sodium
Bicarbonate 45.47 100.25 100.00
[0086] TABLE-US-00016 9686 - Recipe Reference Number Kg Pounds
Percent Ingredient 103.67 228.56 87.27 Wheat Gluten 2.99 6.60 2.52
Sodium Hexametaphosphate 2.99 6.60 2.52 Solka Flok 900 0.96 2.12
0.81 Magnesium Stearate 3.60 7.94 3.03 Beef Broth 0.91 2.02 0.77
Caramel Color 2.40 5.29 2.02 Glycerol Monostearate 0.48 1.05 0.40
Red #40 Lake 0.40 0.88 0.34 Sodium Bicarbonate 118.41 261.05
99.68
Comments: Recipe mixed 3 times
[0087] The information on the process parameters are as listed
below. In the reference number section, the specific number of the
above recipes for each Run is listed. TABLE-US-00017 Run Number 1 2
3 DRY RECIPE INFORMATION: Dry Recipe Moisture % wb 6.49 Dry Recipe
Density kg/m.sup.3 462 462 462 Dry Recipe Rate kg/hr 58 58 58 Feed
Screw Speed rpm 10 10 10 PRECONDITIONING INFORMATION:
Preconditioner Speed rpm 350 350 350 Steam Flow to Preconditioner
kg/hr Water Flow to Preconditioner kg/hr Preconditioner Additive 1
Rate kg/hr 17.4 17.9 18.4 Preconditioner Discharge Temp. .degree.
C. 28 29 30 Moisture Entering Extruder % wb 11.79 13.07 EXTRUSION
INFORMATION: Extruder Shaft Speed rpm 112 112 112 Extruder Motor
Load % 42 43 39 Steam Flow to Extruder kg/hr Water Flow to Extruder
kg/hr 6.9 6.9 7.2 Control/Temperature 1st Head .degree. C. 30/30
25/25 25/23 Control/Temperature 2nd Head .degree. C. 30/29 25/25
25/23 Control/Temperature 3rd Head .degree. C. 30/32 30/29 30/30
Control/Temperature 4th Head .degree. C. 30/27 30/29 30/26
Control/Temperature 5th Head .degree. C. 30/36 30/36 30/34
Control/Temperature 6th Head .degree. C. Control/Temperature 7th
Head .degree. C. Control/Temperature 8th Head .degree. C.
Control/Temperature 9th Head .degree. C. Head/Pressure kPa 5/4970
5/5440 5/3880 Knife Drive Speed rpm FINAL PRODUCT INFORMATION:
Extruder Discharge Moisture % wb 17.81 18.42 18.16 Extruder
Discharge Rate kg/hr Extruder Discharge Density kg/m.sup.3 Extruder
Discharge Temp .degree. C. Dryer Discharge Density kg/m.sup.3
Extruder Performance Stable Stable Duration of Run min 20 20 20
Final Product Description Protein Protein Dog Protein Dog Chew Dog
Chew Chew Customer Recipe Number 1 3 4 Run Rating Good Good
REFERENCE NUMBERS: Main Recipe 9683 9685 9686 Precond. Additive 1
Recipe 9684 9684 9684 Extruder Additive 1 Recipe Preconditioner
Configuration 389 389 389 Extruder Configuration 1092 1092 1092 Die
and Knife Configuration 5198 5198 5199 Dryer Formula 12563 12564
12565 Micronizer Formula Product Analysis 13831 13832 13833 Run
Number 4 5 6 DRY RECIPE INFORMATION: Dry Recipe Moisture % wb Dry
Recipe Density kg/m.sup.3 462 462 462 Dry Recipe Rate kg/hr 58 58
69 Feed Screw Speed rpm 10 10 13 PRECONDITIONING INFORMATION:
Preconditioner Speed rpm 350 350 350 Steam Flow to Preconditioner
kg/hr Water Flow to Preconditioner kg/hr Preconditioner Additive 1
Rate kg/hr 18.4 18.4 20.5 Preconditioner Discharge Temp. .degree.
C. 30 30 36 Moisture Entering Extruder % wb EXTRUSION INFORMATION
Extruder Shaft Speed rpm 112 112 111 Extruder Motor Load % 39 38 55
Steam Flow to Extruder kg/hr Water Flow to Extruder kg/hr 7.2 7.2 9
Control/Temperature 1st Head .degree. C. 25/23 25/25 25/25
Control/Temperature 2nd Head .degree. C. 25/23 25/25 25/25
Control/Temperature 3rd Head .degree. C. 30/30 30/30 30/30
Control/Temperature 4th Head .degree. C. 30/26 30/31 30/31
Control/Temperature 5th Head .degree. C. 30/34 30/35 30/35
Control/Temperature 6th Head .degree. C. Control/Temperature 7th
Head .degree. C. Control/Temperature 8th Head .degree. C.
Control/Temperature 9th Head .degree. C. Head/Pressure kPa 5/3880
5/4450 5/5780 Knife Drive Speed rpm FINAL PRODUCT INFORMATION
Extruder Discharge Moisture % wb Extruder Discharge Rate kg/hr
Extruder Discharge Density kg/m.sup.3 Extruder Discharge Temp
.degree. C. Dryer Discharge Density kg/m.sup.3 Extruder Performance
Stable Duration of Run min 10 10 15 Final Product Description
Protein Protein Dog Protein Dog Chew Dog Chew Chew Customer Recipe
Number 4 1 1 Run Rating Good REFERENCE NUMBERS: Main Recipe 9686
9683 9683 Precond. Additive 1 Recipe 9684 9684 9684 Extruder
Additive 1 Recipe Preconditioner Configuration 389 389 389 Extruder
Configuration 1092 1092 1092 Die and Knife Configuration 5199 5199
5199 Dryer Formula 12566 12567 12568 Micronizer Formula Product
Analysis Run Number 7 8 DRY RECIPE INFORMATION: Dry Recipe Moisture
% wb Dry Recipe Density kg/m.sup.3 462 462 Dry Recipe Rate kg/hr 68
68 Feed Screw Speed rpm 13 13 PRECONDITIONING INFORMATION:
Preconditioner Speed rpm 350 350 Steam Flow to Preconditioner kg/hr
Water Flow to Preconditioner kg/hr Preconditioner Additive 1 Rate
kg/hr 22.5 22.5 Preconditioner Discharge Temp. .degree. C. 30
Moisture Entering Extruder % wb 10.38 EXTRUSION INFORMATION:
Extruder Shaft Speed rpm 112 112 Extruder Motor Load % 52 52 Steam
Flow to Extruder kg/hr Water Flow to Extruder kg/hr 9 9
Control/Temperature 1st Head .degree. C. 25/25 25/25
Control/Temperature 2nd Head .degree. C. 25/25 25/25
Control/Temperature 3rd Head .degree. C. 30/31 30/31
Control/Temperature 4th Head .degree. C. 30/31 30/31
Control/Temperature 5th Head .degree. C. 30/36 30/36
Control/Temperature 6th Head .degree. C. Control/Temperature 7th
Head .degree. C. Control/Temperature 8th Head .degree. C.
Control/Temperature 9th Head .degree. C. Head/Pressure kPa 5/4840
5/4840 Knife Drive Speed rpm FINAL PRODUCT INFORMATION: Extruder
Discharge Moisture % wb 18.86 Extruder Discharge Rate kg/hr
Extruder Discharge Density kg/m.sup.3 Extruder Discharge Temp
.degree. C. Dryer Discharge Density kg/m.sup.3 Extruder Performance
Stable Stable Duration of Run min 20 10 Final Product Description
Protein Dog Chew Protein Dog Chew Customer Recipe Number 2 1 Run
Rating Fair Good REFERENCE NUMBERS: Main Recipe 9683 Precond.
Additive 1 Recipe 9684 9684 Extruder Additive 1 Recipe
Preconditioner Configuration 389 389 Extruder Configuration 1092
1092 Die and Knife Configuration 5199 5199 Dryer Formula 12569
12570 Micronizer Formula Product Analysis 13834
[0088] The material extruded and processed was of a soft aerated
protein polymeric material intended for use as a chew. The shapes
were round sticks and hollow tube chews. A five head set-up on a TX
57 magnum extruder was used. The ratio of length to diameter in the
extruder was 25.5/1 L/D ratio. The round stick was about 1'' in
diameter (die hole to be 0.5''-0.75'' diameter). The hollow tube
was about 1''-1.25'' in diameter. The tube was cut to 5''-6'' in
length. The tube wall thickness was approximately 0.125''.
[0089] Sample Run No. 1 included hexamatophosphate. It was observed
that when the amounts of slurry was reduced, there was some ripping
of the surface of the extrudate. The slurry was reduced to 17.3
kg/hr slurry from 57 kg/hr dry. When slurry was less than 17 kg/hr,
there appeared a ripping effect of the die on the surface of the
extrudate. Expansion off of the die was controlled.
[0090] Sample Run No. 1 had an oven temperature of 110.degree. C.,
110.degree. C., 90.degree. C. There was significant expansion and
subsequent shrinking, leading to shriveled surface.
[0091] The second half of Sample 1 had an oven temperature of
95.degree. C., 95.degree. C., and 70.degree. C. There was less
expansion and improved surface, but still some light shriveling. It
had pretty good texture and firmness.
[0092] Sample Run No. 2. A round stick having a 5/16'' hole was
formed.
[0093] Formula No. 1B was used, which had 0.75% bicarbonate
(hexametaphosphate used). The oven temperature was 95.degree. C.,
95.degree. C., 80.degree. C.--expansion similar to the 0.5%
bicarbonate. A much softer chew was produced that was noticeably
easier to rip. It was observed that the texture was too soft.
[0094] In Sample No. 3, a round stick, having a 3/8'' hole was
produced using Formula No. 4. Formula No. 1 C --0.25% bicarbonate
(sodium hexametphosphate used). The oven temperature was 88.degree.
C., 88.degree. C., 80.degree. C. A product with a good appearance
after thermal heat set resulted. There was minimal surface
shriveling.
[0095] Sample No. 4, Run No. 104: Round Stick, 3/8'' hole. Formula
No. 1C--0.25% bicarbonate (sodium hexametphosphate used). The oven
temperature was 88.degree. C., 88.degree. C., 80.degree. C. A good
appearance after thermal heat set resulted. Again, there was
minimal surface shriveling.
[0096] Sample No. 5, Run No. 106: Round Stick, 3/8'' hole. Formula
No. 1-0.5% bicarbonate (sodium hexametaphosphate). The oven
temperature was 88.degree. C., 88.degree. C., 80.degree. C. Good
appearance out of dryer, but wrinkled later.
[0097] Sample No. 6, Run No. 107: Round Stick, 3/8'' hole. Formula
No. 1-0.5% bicarbonate (sodium hexametaphosphate). The oven
temperature was 88.degree. C., 88.degree. C., 80.degree. C.
Increased slurry rates 10% to reduce surface wrinkling. Thought to
be a result of increased surface area, due to larger hole.
[0098] Sample No. 7, Run No. 108: Round Stick, 3/8'' hole. Formula
No. 1-0.5% bicarbonate (sodium hexametaphosphate). The oven
temperature was 88.degree. C., 88.degree. C., 80.degree. C. Cut
short--Increased slurry rates 10% to reduce surface wrinkling.
Thought to be a result of increased surface area, due to larger
hole.
[0099] It was determined that a mono-extruded aerated protein
polymeric material could be produced. Additionally, the selected
die affected the texture and performance of the material flow. As
such, a chew with a smooth surface and soft, pliable, aerated
construction, was produced. It was observed that all of the
formulations exhibited a significant stick character and had an
affinity to stick.
Example 4
[0100] In the present Example, a Beef Geriatric Dental Chew
(Protein Based) was produced. In the Example, a new formulation was
tested. In particular, it was desired to reproduce Run No. 6 from
Example 3 to evaluate coatings to reduce sticking and allow
processing through the heating steps to denature the protein
without sticking. Application of coatings before and/or after heat
setting were evaluated. As such, the conditions of the present
Example were identical to those of Example 3. The formulation was
as follows: TABLE-US-00018 % by weight Ingredient 65.68% Wheat
Gluten 1.89% Sodium Trimetaphosphate 1.89% Solka-Flok 900 0.60%
Magnesium Stearate 2.28% Beef Broth, spray dried 0.57% Caramel
Color P330 1.52% Glycerol Monostearate 0.30% Red #40 Lake 0.25%
Sodium Bicarbonate 20.06% Glycerin 0.80% Liquid Smoke, Charsol C-10
0.11% Sodium Metabisulfite 1.86% Water 2.20% Est. Process water and
Cond. 100.00%
[0101] Pet chews similar to those in Example 3 were again produced,
but under varying conditions. The procedure for Run No. 3, from
Example 3, was again used.
[0102] The beef flavored chews were aerated with 0.25%
bicarbonate.
[0103] Variables applied to the finished product were:
TABLE-US-00019 Mineral Oil Petrolatum - 33.degree. C. melt point
Solka Flok 33.degree. C. melt point Microcrystaline Cellulose
Silica Cornstarch (Staley) Cellulose (Solka Flok 900)
[0104] The runs were as follows:
[0105] The product showed excellent appearance. TABLE-US-00020 Run
Number 020715-101 020715-102 020715-103 DRY RECIPE INFORMATION: Dry
Recipe Moisture % wb 6.12 Dry Recipe Density kg/m.sup.3 469 469 469
Dry Recipe Rate kg/hr 58 58 58 Feed Screw Speed rpm 10 10 10
PRECONDITIONING INFORMATION Preconditioner Speed rpm 400 400 400
Steam Flow to Preconditioner kg/hr Water Flow to Preconditioner
kg/hr Preconditioner Additive 1 Rate kg/hr 18 18 18 Preconditioner
Additive 2 Rate kg/hr Weight in Preconditioner kg Preconditioner
Retention Time min Preconditioner Discharge Temp. .degree. C. 26 27
28 Moisture Entering Extruder % wb EXTRUSION INFORMATION Extruder
Shaft Speed rpm 112 111 111 Extruder Motor Load % 35 39 40 Steam
Flow to Extruder kg/hr Water Flow to Extruder kg/hr 9.9 10 10.1
Extruder Additive Rate kg/hr Control/temperature 1st Head .degree.
C. 25/26 25/27 25/27 Control/temperature 2nd Head .degree. C. 25/28
25/28 25/28 Control/temperature 3rd Head .degree. C. 30/33 30/33
30/34 Control/temperature 4th Head .degree. C. 25/38 25/38 25/39
Control/temperature 5th Head .degree. C. 25/42 25/42 25/42
Control/Temperature Die Spacer .degree. C. 5 5 5 Head/Pressure kPa
3260 3240 3720 Head/Pressure kPa Head/Pressure kPa Belt Speed m/min
Knife Drive Speed rpm BPV % Closed % FINAL PRODUCT INFORMATION
Extruder Discharge Moisture % wb Extruder Discharge Rate kg/hr
Extruder Discharge Density kg/m.sup.3 Extruder Discharge Temp
.degree. C. Dryer Discharge Density kg/m.sup.3 Extruder Performance
Stable Stable Stable Duration of Run min Final Product Description
Protein Protein Protein DogChew DogChew DogChew Customer Recipe
Number 1 1 1 Run Rating Good Poor Good REFERENCE NUMBERS Main
Recipe 9822 9822 9822 Precond Additive Recipe 1 9823 9823 9823
Preconditioner Configuration 389 389 389 Extruder Configuration
1092 1092 1092 Die and Knife Configuration 5271 5271 5271 Dryer
Formula 12727 12728 12729 Product Analysis 13959 Run Number
020715-104 020715-105 DRY RECIPE INFORMATION: Dry Recipe Moisture %
wb 6.3 Dry Recipe Density kg/m.sup.3 Dry Recipe Rate kg/hr 60 60
Feed Screw Speed rpm 10 10 PRECONDITIONING INFORMATION
Preconditioner Speed rpm 400 400 Steam Flow to Preconditioner kg/hr
Water Flow to Preconditioner kg/hr Preconditioner Additive 1 Rate
kg/hr 18 18 Preconditioner Additive 2 Rate kg/hr Weight in
Preconditioner kg Preconditioner Retention Time min Preconditioner
Discharge Temp. .degree. C. 29 29 Moisture Entering Extruder % wb
9.96 EXTRUSION INFORMATION Extruder Shaft Speed rpm 112 111
Extruder Motor Load % 39 36 Steam Flow to Extruder kg/hr Water Flow
to Extruder kg/hr 11.4 11.7 Extruder Additive Rate kg/hr
Control/temperature 1st Head .degree. C. 25/27 25/28
Control/temperature 2nd Head .degree. C. 25/29 25/29
Control/temperature 3rd Head .degree. C. 30/33 30/33
Control/temperature 4th Head .degree. C. 25/39 25/38
Control/temperature 5th Head .degree. C. 25/42 25/42
Control/Temperature Die Spacer .degree. C. 5 5 Head/Pressure kPa
3430 3290 Head/Pressure kPa Head/Pressure kPa Belt Speed m/min
Knife Drive Speed rpm BPV % Closed % FINAL PRODUCT INFORMATION
Extruder Discharge Moisture % wb 22.68 Extruder Discharge Rate
kg/hr Extruder Discharge Density kg/m.sup.3 Extruder Discharge Temp
.degree. C. Dryer Discharge Density kg/m.sup.3 Extruder Performance
Stable Stable Duration of Run min Final Product Description Protein
Dog Protein Dog Chew Chew Customer Recipe Number 3 3 Run Rating
Good Excellent REFERENCE NUMBERS Main Recipe 9824 9824 Precond
Additive Recipe 1 9823 9823 Preconditioner Configuration 389 389
Extruder Configuration 1092 1092 Die and Knife Configuration 5271
5271 Dryer Formula 12730 12731 Product Analysis 13960 Dryer Formula
Number Model Number 12727 12728 12729 Number of Sections Zone 1
Temperature .degree. C. 90 90 90 Zone 2 Temperature .degree. C. 90
90 90 Zone 3 Temperature .degree. C. 90 90 90 Zone 4 Temperature
.degree. C. Zone 5 Temperature .degree. C. Zone 6 Temperature
.degree. C. Retention Time-Pass 1 min 4.9 4.9 4.9 Retention
Time-Pass 2 min 9.8 9.8 9.8 Retention Time-Pass 3 min Retention
Time-Cooler min Fan Speed 1 rpm 1775 1775 1775 Fan Speed 2 rpm 1775
1775 1775 Fan Speed 3 rpm 1775 1775 1775 Fan Speed 4 rpm Dryer
Formula Number Model Number 12730 12731 Number of Sections Zone 1
Temperature .degree. C. 90 90 Zone 2 Temperature .degree. C. 90 90
Zone 3 Temperature .degree. C. 90 90 Zone 4 Temperature .degree. C.
Zone 5 Temperature .degree. C. Zone 6 Temperature .degree. C.
Retention Time-Pass 1 min 4.9 4.9 Retention Time-Pass 2 min 9.8 9.8
Retention Time-Pass 3 min Retention Time-Cooler min Fan Speed 1 rpm
1775 1775 Fan Speed 2 rpm 1775 1775 Fan Speed 3 rpm 1775 1775 Fan
Speed 4 rpm Product Analysis Number 13831 13832 13833 13834 Dry
Recipe % wb 6.49 Preconditioner Discharge % wb 11.79 13.07 10.38
Extruder Discharge % wb 17.81 18.42 18.16 18.86 Product Analysis
Number 13959 13960 Dry Recipe % wb 6.12 6.3 Preconditioner
Discharge % wb 9.96 Extruder Discharge % wb 22.68
[0106] Materials from Run No. 1 (cornstarch coated protein polymer
sticks post heat treatment and cooled) were taken and placed in
continuous tumbler for polishing. Petrolatum (snow white) was
melted and drizzled onto pile of sticks. The pile consisted of
about 1/2 of the total number of sticks. All were loaded into the
tumbler, one handful at a time, alternating between drizzled and
non-drizzled sticks. It was determined that too much petrolatum was
applied, and towels were added to wipe off some excess. Residence
time in the tumbler was variable, depending on angle of
tumbler.
[0107] The product was run through a couple of times until all
surfaces were polished. Approximate time=7 minutes, but can be
shortened if the petrolatum was more uniformly applied, and tumbler
was placed level the whole time. It took more time due to the
non-coated products getting completely polished.
[0108] The results are as follows:
[0109] Run No. 1: Cornstarch was dusted onto the extruded protein
polymeric mixture immediately following extrusion and prior to
cutting the extruded product. There was no sticking through the
down stream processing and Dryer. The product was allowed to sit
hot for 30 minutes in the tub, with no sticking.
[0110] It was determined that the starch dusting was very apparent
following exit from the dryer. The extruded product needed to be
polished to improve the starchy coated appearance.
[0111] Run No. 2: Solka-Flok was used instead of cornstarch Did not
cover well, and sticking occurred.
[0112] Run No. 3: Silica dioxide was used instead of cornstarch
[0113] Not as good of apparent coverage as cornstarch; however,
exhibited virtually the same non-sticking qualities. Appearance was
slightly less powder coverage.
[0114] Note: Run Nos. 1-3 were conducted under the same
conditions.
[0115] Run No. 4: Mineral oil was applied to the ropes, prior to
cutting. Atomized mineral oil was used via a ventury nozzle. The
coated and cut pieces were tumbled in a Rotary Continuous Tumbler
with slight angle to maximize residence time. This product
exhibited fairly good non-sticking characteristics; however, after
setting in bags, there is slight sticking of product. Clumps of
sticks are easily broken apart; however, the short cut pieces of
the clumps were more difficult to separate.
[0116] It was concluded that the composition that produced the best
performance for eliminating stickiness was the use of cornstarch;
however, the dusty appearance is not acceptable until it is
polished with petrolatum. The second best performance was mineral
oil coating prior to cutting. This, however, exhibited minor
clumping issues later. Not tried, but should work very well, is
spraying petrolatum prior to cutting. The silica dioxide worked
farily well, however, not as well as starch, and needed to be
polished after heat setting.
Example 5
[0117] A method for producing an aerated polymeric composition to
be used as packing material. The packing material is biodegradable.
The extruder used in this Example was a twin screw extruder. The
base polymer formula consisted of the following constituents:
TABLE-US-00021 % by weight Constituent (dry mix) Wheat Gluten 90.47
Cedar oil 0.75 Bittering Agent 2.00 Cellulose 2.49 Glycerol
Monostearate 2.00 Magnesium Stearate 0.80 Baking Powder 1.50
[0118] This mixture was used to form a dry mix equal to 100 lbs.
Next, a slurry was formed, with the slurry consisting of 18.5 lbs.
of glycerin, 2 lbs. of water, and 0.1 lbs. of sodium metabisulfate.
The slurry was intended to plasticize the material.
[0119] Slurry, in the amount of 26 parts by weight, was added to
100 parts of the dry mix in the extrusion process. The extruder
conditions were such that the feed rates yielded 225 lbs/hr. The
extruder barrel temperature did not exceed 60.degree. C. The die
temperatures were maintained below 66.degree. C., and the extruder
screws were running at 120 rpm. Following extrusion, the formed
polymeric mixture was heated in a convection oven at a temperature
ranging between 88.degree. C. and 110.degree. C. to denature the
protein. The process yielded an aerated polymeric composition to be
used as packing material.
[0120] Thus, there has been shown and described an aerated
polymeric composition which fulfills all the objects and advantages
sought therefore. It is apparent to those skilled in the art,
however, that many changes, variations, modifications, and other
uses and applications to the aerated polymeric composition are
possible, and also such changes, variations, modifications, and
other uses and applications which do not depart from the spirit and
scope of the invention are deemed to be covered by the invention,
which is limited only by the claims which follow.
* * * * *