U.S. patent application number 11/743873 was filed with the patent office on 2008-01-24 for nutritional bar and components.
This patent application is currently assigned to SLIM-FAST FOODS COMPANY, DIVISION OF CONOPCO, INC.. Invention is credited to Akhilesh Gautam, Mark Edward Johnke, Albert Johan Zwijgers.
Application Number | 20080020098 11/743873 |
Document ID | / |
Family ID | 32868273 |
Filed Date | 2008-01-24 |
United States Patent
Application |
20080020098 |
Kind Code |
A1 |
Gautam; Akhilesh ; et
al. |
January 24, 2008 |
NUTRITIONAL BAR AND COMPONENTS
Abstract
A nutrition bar which incorporates protein in the form of
nuggets having high levels of selected proteins. By use of the
nuggets of the invention, nutrition bars are formulated to have
elevated levels of protein, yet good taste and other organoleptic
properties. The nuggets according to the invention include greater
than 50 wt % of a non-soy protein selected from the group
consisting of milk protein, rice protein and pea protein,
especially between 51 wt % and 99 wt %, more preferably between 52
wt % and 95 wt %, most preferably 55 wt % or above. The milk
protein is preferably whey protein. The nuggets of the invention
are preferably made using an extrusion process wherein the
extrusion temperature is moderated so as to avoid damage to the
whey proteins and concomitant off-taste. In this preferred process
according to the invention, extrusion is conducted at temperatures
of from 60 to 140.degree. C., after which the protein is dried
using a belt/conveyor drier or a fluid bed drier. In an alternate
method of making the nuggets according to the invention, a lower
extrusion temperature of up to 90.degree. C. is used and one or
more supercritical fluids are injected prior to extrusion to form a
puffed product.
Inventors: |
Gautam; Akhilesh;
(Arlington, TN) ; Zwijgers; Albert Johan; (Veghel,
NL) ; Johnke; Mark Edward; (Collinville, TN) |
Correspondence
Address: |
UNILEVER INTELLECTUAL PROPERTY GROUP
700 SYLVAN AVENUE,
BLDG C2 SOUTH
ENGLEWOOD CLIFFS
NJ
07632-3100
US
|
Assignee: |
SLIM-FAST FOODS COMPANY, DIVISION
OF CONOPCO, INC.
West Palm Beach
FL
|
Family ID: |
32868273 |
Appl. No.: |
11/743873 |
Filed: |
May 3, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10371051 |
Feb 20, 2003 |
7220442 |
|
|
11743873 |
May 3, 2007 |
|
|
|
Current U.S.
Class: |
426/74 ; 426/465;
426/516; 426/648; 426/656 |
Current CPC
Class: |
A23J 3/225 20130101;
A23L 33/19 20160801; A23J 3/26 20130101; A23L 33/185 20160801; A23J
3/08 20130101 |
Class at
Publication: |
426/074 ;
426/465; 426/516; 426/648; 426/656 |
International
Class: |
A23L 1/304 20060101
A23L001/304; A23J 3/16 20060101 A23J003/16; A23J 3/26 20060101
A23J003/26 |
Claims
1. A nutritional bar comprising one or more extruded nuggets
comprising greater than 50 wt % of a non-soy protein selected from
the group consisting of whey protein, rice protein and pea
protein.
2. The nutritional bar according to claim 1 wherein said non-soy
protein is present in said nugget at a level of between 51 wt % and
99 wt %.
3. The nutritional bar according to claim 2 wherein said non-soy
protein is present in said nugget at a level of between 52 wt % and
95 wt %.
4. The nutritional bar according to claim 1 wherein said non-soy
protein is present in said nugget at a level of 55 wt % or
above.
5. The nutritional bar according to claim 1 wherein said non-soy
protein includes whey protein.
6. A process for preparing a protein-containing nugget comprising
extruding a composition comprising greater than 50 wt % of a
non-soy protein selected from the group consisting of whey protein,
rice protein and pea protein at a temperature not in excess of
140.degree. C. non-soy protein being present in said nugget at a
level of 55 wt. % or above.
7. The process according to claim 6 wherein the extrusion takes
place at a temperature within the range of from 70.degree. C.
through 130.degree. C.
8. (canceled)
9. The process according to claim 6 wherein said non-soy protein is
present in said nugget at a level of between 60 wt % and 95 wt
%.
10. The process according to claim 6 wherein said non-soy protein
is present in said nugget at a level of 70 wt % or above.
11. The process according to claim 6 wherein subsequent to said
extrusion step, said ingredients are dried.
12. The process according to claim 11 wherein said drying is
conducted in a belt/conveyor dryer or a fluid bed dryer.
13-14. (canceled)
15. The nutrition bar according to claim 1 wherein said nugget
further comprises one or more minerals.
16. The nutrition bar according to claim 15 wherein the one or more
minerals are selected from the group consisting of Molybdenum,
Chromium, Selenium, Calcium, Manganese, Magnesium, Iron, and Zinc
and mixtures thereof.
17. The nutrition bar according to claim 16 wherein the one or more
minerals are present in the nugget at a level from 10% RDI to 45%
RDI.
Description
BACKGROUND OF THE INVENTION
[0001] Increasingly, a focus of modern preventive medicine is
weight reduction. Excessive weight is frequently cited in reports
concerning the surge in cases of type 2 diabetes. Moreover, obesity
is often mentioned in discussions of other modern diseases, such as
heart disease.
[0002] For years a debate has raged as to which class of nutrients,
fats or carbohydrates, are preferentially minimized to promote
weight loss. Recently, much consumer attention has focussed on
those who advocate reduction of carbohydrates and higher intakes of
unsaturated fat and/or protein.
[0003] An increasingly popular form for ingestion of nutrients for
those seeking to lose weight is the nutrition bar. The nutrition
bar provides a convenient vehicle for replacing a meal or for
supplementing meals as a snack. While consumers express a
preference for snacks and other foods which are more healthful and
which can assist them to achieve their weight loss goals, they show
little inclination to sacrifice the organoleptic properties of
their favorite foods. Therefore, the successful food formulator
must improve the nutrient value of the food while maintaining
desirable organoleptic properties. High protein levels are
particularly difficult to incorporate into good tasting foods since
popular proteins, such as soy, often have undesirable
aftertastes.
[0004] Lanter et al. U.S. Pat. No. 5,683,739 is directed to
extruded animal feed nuggets comprising between about 90 and 99 wt
% of at least one protein containing ingredient and between 1 and 6
wt % added fat. The nugget is prepared by plasticizing a blend of
at least one protein-containing ingredient, added fat, sulfur (if
present), and water, extruding the plasticized blend to form an
animal feed nugget, and drying the extruded nugget to a water
content of less than about 12 wt %. Protein sources mentioned
include oil seed meals such as soybean meal and cottonseed meal,
and animal byproduct meals such as meat meal, poultry meal, blood
meal, feather meal, and fish meal, plant byproduct meal such as
wheat middlings, soybean hulls, and corn byproducts and microbial
protein such as torula yeast and brewer's yeast. U.S. Pat. Nos.
5,540,932 and 5,120,565 also are directed to animal feed nuggets
which contain, or may contain, protein.
[0005] Carr WO 02/096208 (New Zealand Dairy Board) is directed to a
dried, enhanced solubility milk protein concentrate (MPC)
containing at least one monovalent salt added prior to drying.
Preferred salts are sodium and potassium salts. A method for
preparing the MPC includes providing an MPC having at least 70%
milk protein as dry matter in aqueous solution or suspension,
adding at least one monovalent salt in an amount that confers
enhanced solubility when dried, and drying the product. Preferably
between the salt addition step and the drying step, a dewatering
step, preferably by evaporation, or a concentration step by
ultrafiltration and/or diafiltration, is undertaken. The MPC of the
invention can be used in cheese manufacture. The ratio of casein to
whey protein is essentially that of milk.
[0006] According to Carr, a problem with MPCs and MPI (milk protein
isolates: >85% milk protein as dry matter) is that such products
are generally very insoluble at cold temperatures. A problem is
said to be that they are associated with the formation of nuggets
in the cheese. The solubility properties of the products are said
to make the dried MPCs and MPIs advantageous in the preparation of
a variety of products, for example, beverages. Also the dried MCPs
and MPIs can be used in cheese preparation to avoid nugget
formation.
[0007] Bhaskar et at. WO 01/41578 is directed to dried milk protein
concentrates and their use. The invention includes a process of
cheese manufacture using dried MPC or MPI having at least 70% dry
matter as milk protein.
[0008] Rizvi et al. U.S. Pat. Nos. 5,120,559 and/or 5,417,992
disclose use of supercritical fluids, such as CO.sub.2 to extrude a
food product.
[0009] WO 01/56402 discloses an alpha lipoic acid food supplement
for increasing lean muscle mass and strength. A source of amino
acids may be included. Whey protein is said to be a preferred
source of amino acids. Whey protein isolates, whey peptides, whey
protein concentrate or hydrolyzed Whey protein may be used. Other
proteins which may be used include casein, other milk proteins, and
albumins. The food supplements can be in a variety of forms such as
protein bars.
[0010] Portman U.S. Pat. No. 6,051,236 is directed to a nutritional
composition in dry powder form for optimizing muscle performance
during exercise. The compositions may be in the form of an energy
bar. Proteins such as calcium caseinate, whey protein concentrate,
whey protein isolate, soy protein, casein hydrolysate, meat protein
concentrate and yeast concentrate are mentioned.
[0011] Gilles et al. U.S. Pat. No. 6,248,375 (Abbott Labs)
discloses solid matrix materials designed for the person with
diabetes. It includes a source of fructose in combination with at
least one nonabsorbent carbohydrate. The two component carbohydrate
system is said to blunt the postprandial carbohydrate response. One
of the forms for administration mentioned is nutritional bars.
Gilles et al. mention Ensure.RTM. Glucerna.RTM. Nutritional Bars as
having 14% of total calories as protein in the form of soy protein,
calcium caseinate, and corn protein. Choice dm.RTM. Bar is cited as
a nutritional bar for people with diabetes and including 17.1%
total calories as protein in the form of calcium caseinate, soy
protein isolate, whey protein concentrate, toasted soybeans, soy
nuggets (soy protein isolate, rice flour, malt, salt) and peanut
butter. Gluc-O-Bar.RTM. is said to be a medical food designed for
use in management of diabetes which includes up to 23% of total
calories as protein in the form of soy protein isolate, non fat dry
milk, and peanut flour.
[0012] Gilles et al. use protein which it is said can include any
proteins suitable for human consumption, including casein, whey,
milk protein, soy, pea, rice, corn, hydrolyzed protein and mixtures
thereof. The typical amount of protein will be about 10%, to about
25% of total calories, most preferably about 15 to about 20% of
total calories. It is said that the solid matrix nutritional
compositions may be made by cold extrusion techniques.
[0013] Proteint of St. Paul, Minn. makes a nugget having a whey
protein level of 50%.
[0014] Nuvex of Blue Earth, Minn. makes a nugget having a whey
protein level of 50%.
[0015] Various other foods have been described which mention
nuggets which may include proteins. These include U.S. Pat. Nos.
6,086,941, 6,010,738.
[0016] Anon, "Nutraceuticals-International," 2000, Vol 5, p. 25
(from abstract number 548502) reports that a new milk-protein
hydrolysate, Prodiet F200, which is claimed to help people cope
with stress, has been marketed by a French company, Ingredia. It is
said to be suitable for functional foods such as chocolate bars.
Also, a product based on hydrolysed why protein, Proxime Alpha sold
by Borculo Domo Ingredients, is said to have beneficial effects on
stress.
[0017] Swartz, ML, "Milk proteins and hydrolysates in nutritional
foods," "Food Ingredients Europe: Conference Proceedings, London,
October 1994, published in "Maarssen: Processs Press Europe," 1994,
73-81 (from Abstract number 373368) is a review of recent
developments in production of milk proteins and hydrolysates for
nutritional products. Application of milk proteins in 3 specific
types of nutritional products, including sports bars, are said to
be discussed in detail.
[0018] Swartz, ML, "Food-Marketing-&-Technology", vol 9, 4, 6,
9-10, 12, 20 (from abstract number 1995-08-P0036) is a review of
the nutritional value, functional properties and applications of
milk proteins and milk protein hydrolysates. Applications in
functional foods such as food bars for athletes are considered.
[0019] Kaufman WO 01/33976 (Children's Research Hospital) is
directed to a method for treating a type 2 diabetic to decrease
hypoglycemic episodes and/or diminish fluctuations in blood glucose
outside of the normal range, which comprises administering to the
subject in an effective appetite suppressing amount a food
composition, which can be a bar, which includes a slowly absorbed
complex carbohydrate such as uncooked cornstarch. Soy protein, whey
protein and casein hydrolysate are mentioned as possible protein
sources.
[0020] Keating et al. EP 768 043 (Bristol Meyers-Squibb) is
directed to a nutritional composition for use by diabetics
containing a controlled absorbed carbohydrate component. The
carbohydrate component contains a rapidly absorbed fraction such as
glucose or sucrose, a moderately absorbed fraction such as certain
cooked starches or fructose and a slowly absorbed fraction such as
raw corn starch. Preferred protein sources are said to include whey
protein, sodium caseinate, or calcium caseinate, optionally
supplemented with amino acids. Other preferred protein sources
include protein hydrolysates such as soy protein hydrolysate,
casein hydrolysate, whey protein hydrolysate, other animal and
vegetable protein hydrolysates and mixtures thereof. Among the
forms mentioned which the invention can take are a nutritional bar
or cookie. The nutritional bars and cookies are preferably baked.
The bar is made by cold forming or extrusion. The granola bar of
example 1 includes skim milk powder and peanuts.
[0021] EP 306 733 is directed to a sugar free binder for foods
which contains sugar substitute and protein hydrolysate in a weight
ratio of 3:1 to 1:3 in agglomerated form (as granules).
[0022] DeMichele et al. U.S. Pat. No. 6,444,700 (Abbott Labs) is
directed to immunonutritional products said to be useful-in
reducing the immunological suppression said to result from stress.
Solid nutritional compositions such as bars are mentioned. Soy
proteins are mentioned as possible ingredients for the solid
compositions.
[0023] Despite the many previous efforts to formulate bars with
proteins, there is still a need for a good tasting nutrition bar
having elevated levels of protein.
SUMMARY OF THE INVENTION
[0024] The present invention is directed especially to a nutrition
bar which incorporates protein in the form of nuggets having high
levels of selected proteins. By use of the nuggets of the
invention, nutrition bars are formulated to have elevated levels of
protein, yet good taste and other organoleptic properties.
[0025] The nuggets according to the invention include greater than
50 wt % of a non-soy protein preferably selected from the group
consisting of milk protein, rice protein and pea protein or
mixtures thereof, especially between 51 wt % and 99 wt %, more
preferably between 52 wt % and 95 wt %, most preferably 55 wt % or
above. The milk protein is preferably whey protein.
[0026] The nuggets preferably include one or more of: a coloring
agent at less than 1 wt %, especially from 0.01 to 0.5 wt %; flour,
especially rice flour, at from 2-8 wt %; and starch, which may for
example be tapioca starch or rice starch, at from 20-30 wt %.
[0027] The nuggets are preferably present in the nutritional bars
of the invention at levels from 5 to 75 wt %, more preferably from
10 to 50 wt %.
[0028] A difficulty associated with preparation of nuggets having
elevated levels of certain proteins is the sensitivity of the
proteins to high temperatures typical of the extrusion process
normally used to make the nuggets. Especially is this true of whey
proteins. The nuggets of the invention are preferably made using an
extrusion process wherein the extrusion temperature is moderated so
as to avoid damage to the selected non-soy proteins and concomitant
off-taste. In this preferred process according to the invention,
extrusion is conducted at temperatures of from 60.degree. C. to
140.degree. C., especially from 70.degree. C. to 130.degree. C.,
after which the protein is dried using a belt/conveyor drier and/or
a fluid bed drier.
[0029] In an alternate method of making the nuggets according to
the invention, supercritical fluids are injected into the extruder
to permit use of lower extrusion temperatures, e.g., up to
95.degree. C., and even the most temperature sensitive proteins,
eg, whey. Supercritical fluid which remains in the product after
mixing is used to control the final product density by expansion of
the product as it exits the extruder die.
[0030] The nuggets of the invention may, of course, be used in
applications other than the nutritional bars herein.
[0031] Nuggets can have a variety of cross sections, e.g.,
circular, rectangular or square, and generally are bite sized
particles having a maximum volume of 35 mm.sup.3 and a minimum
volume of 4 mm.sup.3 preferably between 10 mm.sup.3 and 25
mm.sup.3. Typically, they will include at least protein, and will
often include in addition one or more (preferably all) of: flour
(especially rice flour), an additional starch source and,
optionally a coloring agent.
[0032] For a more complete of the above and other features and
advantages of the invention, reference should be made to the
following description of the preferred embodiments
DETAILED DESCRIPTION OF THE INVENTION
[0033] Preferred sources for the non-soy protein used in the
present invention include sources of whey protein such as whey
protein isolate and whey protein concentrate, sources of rice
protein such as rice flour and rice protein concentrate, and
sources of pea protein. Additional protein sources which may be
present within the nugget or within the bar external to the nugget
include one or more of dairy protein source, such as whole milk,
skim milk, condensed milk, evaporated milk, whey, milk solids
non-fat, etc. The dairy source may contribute dairy fat and/or
non-fat milk solids such as lactose and milk proteins, e.g. whey
proteins and caseins. Especially preferred, to minimize the caloric
impact, is the addition of protein as such rather than as one
component of a food ingredient such as whole milk. Preferred in
this respect are protein concentrates such as one or more of whey
protein concentrate, milk protein concentrate, caseinates such as
sodium and/or calcium caseinate, isolated soy protein and soy
protein concentrate. Total protein levels within the nutrition bars
of the invention, including protein in the nuggets, are preferably
within the range of 3 wt % to 40 wt %, especially from 3 wt % to 20
wt %.
[0034] The nuggets of the invention include greater than 50 wt % of
protein selected from the group consisting of milk protein, rice
protein and pea protein and mixtures thereof, especially between 51
wt % and 99 wt %, more preferably between 52 wt % and 95 wt %, most
preferably 55 wt % or above. Other ingredients which may be present
in the nuggets would include one or more of other proteins, such as
those listed above, lipids, especially triglyceride fats, and
carbohydrates, especially starches. Particularly where the nuggets
are made using the moderated temperature extrusion process
described below, it is advisable that the remaining ingredients be
no more sensitive to heat degradation (e.g., have the same or lower
degradation point) than the selected non-soy protein.
[0035] The source for any fat used in the nutrition bars, whether
internal or external to the nugget, is preferably vegetable fat,
such as for example, cocoa butter, illipe, shea, palm, palm kernal,
sal, soybean, safflower, cottonseed, coconut, rapeseed, canola,
corn and sunflower oils, or mixtures thereof. However, animal fats
such as butter fat may also be used if consistent with the desired
nutritional profile of the product. Preferably the amount of fat in
either the nugget or the bar as a whole, is not more than 45 wt %,
especially not more than 35 wt %, preferably from 0.5 to 10 wt %,
still preferably from 0.5 to 5 wt %.
[0036] Carbohydrates can be used within the nugget at levels of
from 1% to 49%. In addition to sweeteners mentioned below, examples
of suitable carbohydrates include starches such as are contained in
rice flour, flour, tapioca flour, tapioca starch, and whole wheat
flour and mixtures thereof. Carbohydrates can be used outside the
nuggets within the bar as well. Levels of carbohydrates in the bar
as a whole will typically comprise from 5 wt % to 90 wt %,
especially from 20% to 65 wt %.
[0037] If it is desired to include a bulking agent in the nutrition
bars, within or external to the nuggets, a preferred bulking agent
is inert polydextrose. Other conventional bulking agents which may
be used alone or in combination include maltodextrin, sugar
alcohols, corn syrup solids, sugars or starches. Total bulking
agent levels in the nuggets of the invention, and in the
nutritional bars of the invention, will preferably be from about 0%
to 20 wt %, preferably 0.5% to 16%. Polydextrose may be obtained
under the brand name Litesse.
[0038] Flavorings are preferably added to the nutrition bar in
amounts that will impart a mild, pleasant flavor. The flavoring may
be in the nuggets or external to the nuggets in the bar, provided
that processing is not adversely affected. The flavoring may be any
of the commercial flavors employed in nutrition bars, such as
varying types of cocoa, pure vanilla or artificial flavor, such as
vanillin, ethyl vanillin, chocolate, malt, mint, yogurt powder,
extracts, spices, such as cinnamon, nutmeg and ginger, mixtures
thereof, and the like. It will be appreciated that many flavor
variations may be obtained by combinations of the basic flavors.
The nutrition bars are flavored to taste. Suitable flavorants may
also include seasoning, such as salt, and imitation fruit or
chocolate flavors either singly or in any suitable combination.
Flavorings which mask off-tastes from vitamins and/or minerals and
other ingredients are preferably included in the products of the
invention, in the nuggets and/or elsewhere in the product.
[0039] The nuggets and bar may include colorants, if desired, such
as caramel colorant.
[0040] If desired, the nuggets of the invention may include
processing aids such as calcium chloride.
[0041] The nuggets may also include emulsifiers. Typical
emulsifying agents may be phospholipids and proteins or esters of
long chain fatty acids and a polyhydric alcohol. Lecithin is an
example. Fatty acid esters of glycerol, polyglycerol esters of
fatty acids, sorbitan esters of fatty acids and polyoxyethylene and
polyoxypropylene esters of fatty acids may be used but organoleptic
properties, or course, must be considered. Mono- and di-glycerides
are preferred. If present in the nuggets, emulsifiers may be used
in amounts of about 0.03% to 0.3%, preferably 0.05% to 0.1%. The
same emulsifiers may also be present in the nutrition bar, again at
levels overall of about 0.03% to 0.3%, preferably 0.05% to 0.1%.
Emulsifiers may be used in combination, as appropriate. Among fiber
sources which may be included in the compositions of the invention
are fructose oligosaccharides such as inulin, guar gum, gum arabic,
gum acacia, oat fiber, cellulose and mixtures thereof. The
compositions preferably contain at least 2 grams of fiber per 56 g
serving, especially at least 5 grams of fiber per serving. As
indicated above, additional bulking agents such as maltodextrin,
sugar alcohols, corn syrup solids, sugars, starches and mixtures
thereof may also be used. Total bulking agent levels in the
products of the invention, including fibers and other bulking
agents, will preferably be from about 0% to 20%, especially from 1
to 15 wt %. The fiber and the bulking agent may be present in the
nuggets or in the bar external to the nuggets provided that
processing is not impaired.
[0042] Carrageenan may be included in the bars of the invention,
internal or external to the nuggets, eg, as a thickening and/or
stabilizing agent. Cellulose gel and pectin are other thickeners
which may be used alone or in combination.
[0043] Generally the nutrition bars which incorporate the nuggets
of the invention will be naturally sweetened. The sweetener may be
included in the nugget or in the bar provided that it does not
interfere with the processing of the nugget (eg, sweetener will not
be used in the nugget if it is unstable at the moderate
temperatures, where the moderate temperature extrusion process is
used). Natural sources of sweetness include sucrose (liquid or
solids), glucose, fructose, and corn syrup (liquid or solids),
including high fructose corn syrup and high maltose corn syrup and
mixtures thereof. Other sweeteners include lactose, maltose,
glycerine, brown sugar and galactose and mixtures thereof. Levels
of sugars and sugar sources preferably result in sugar solids
levels of up to 50 wt %, preferably from 5 to 18 wt %, especially
from 10 to 17 wt % of the nutrition bar.
[0044] If it is desired to use artificial sweeteners, these may
likewise be present in the nugget or within the bar external to the
nugget, provided that it does not interfere with processing. Any of
the artificial sweeteners well known in the art may be used, such
as aspartame, saccharine, Alitame.RTM. (obtainable from Pfizer),
acesulfame K (obtainable from Hoechst), cyclamates, neotame,
sucralbse, mixtures thereof and the like. The sweeteners are used
in varying amounts of about 0.005% to 1 wt % on the bar, preferably
0.007% to 0.73% depending on the sweetener, for example. Aspartame
may be used at a level of 0.05% to 0.15%, preferably at a level of
0.07% to 0.11%. Acesulfame K is preferred at a level of 0.09% to
0.15%.
[0045] Calcium is preferably present in the nutrition bars at from
10 to 30% RDA, especially about 25% RDA. The calcium source is
preferably dicalcium phosphate. For example wt. % levels of
dicalcium phosphate may range from 0.5 to 1.5%. In a preferred
embodiment, the product is fortified with one or more vitamins
and/or minerals and/or fiber sources, in addition to the calcium
source. These may include any or all of the following:
[0046] Ascorbic acid (Vitamin C), Tocopheryl Acetate (Vitamin E),
Biotin (Vitamin H), Vitamin A Palmitate, Niacinamide (Vitamin B3),
Potassium Iodide, d-Calcium Pantothenate (Vitamin B5),
Cyanocobalamin (Vitamin B12), Riboflavin (Vitamin B2), Thiamine
Mononitrate (Vitamin B1), Molybdenum, Chromium, Selenium, Calcium
Carbonate, Calcium Lactate, Manganese (as Manganese Sulfate),
Magnesium (e.g., as magnesium phosphate) Iron (as Ferric
Orthophosphate) and Zinc (as Zinc Oxide). The vitamins and minerals
are preferably present at from 5 to 45% RDI, especially 5 to 20%
RDI, most especially from about 15% RDI. Preferably, fiber sources
are present in the product at greater than 0.5 wt. % and do not
exceed 6 wt. %, especially 5 wt. %. The vitamins and/or minerals
may be included within, or external to, the nuggets, provided that
processing and human absorption are not impaired.
[0047] Ingredients which, if present, will generally be found
within the bar but external to the nuggets include, but are not
limited to, rolled oats, chocolate chips or other chocolate pieces,
cookie and/or cookie dough pieces, such as oatmeal cookie pieces,
brownie pieces, fruit pieces, such as dried cranberry, apple, etc.,
vegetable pieces such as rice, honey and acidulants such as malic
and citric acids, leavening agents such as sodium bicarbonate and
peanut butter.
[0048] The nuggets of the invention are preferably made by one of
two methods, although it is anticipated that alternative methods
may be possible. In the first method according to the invention,
the nuggets are made using an extrusion process wherein the
extrusion temperature is moderated so as to avoid damage to the
whey (or other selected non-soy) proteins and concomitant
off-taste. In this process, it is expected that a blend of the
selected proteins may, for instance, be made having a selected
protein content of greater than 50 wt %, up to 70 or 80% or higher.
A moisture level of from 10 to 35 wt %, preferably from 15 to 25 wt
% prior to extrusion is preferred. An extruder such as a twin screw
extruder may be employed. Preferred extrusion temperatures are in
the range of between 70 and 130.degree. C., so as not to reach
temperatures at which the proteins perceptibly degrade. This
embodiment is preferred for rice and pea proteins, especially at
the upper ends of the temperature ranges. After extrusion, a cutter
may be used to cut the extrudates into the desired length of the
nuggets.
[0049] In accordance with the first method, the temperature
sensitivity of the selected non-soy proteins makes it undesirable
to achieve in the extruder temperatures high enough adequately to
dry the extrudate. Therefore, a drying step is used subsequent to
extrusion to achieve the desired level of moisture. The drying step
may comprise, for instance, a belt/conveyor dryer or a fluid bed
dryer.
[0050] In the second process embodiment of the invention, super
critical fluids are used in the extruder, such as is set forth in
Rizvi et al. U.S. Pat. Nos. 5,120,559 and/or 5,417,992, the
disclosures of which are hereby incorporated by reference. In this
embodiment, the nugget ingredients, eg non-soy protein, rice flour,
additional carbohydrate and coloring agent, plus water, are
introduced to the feed board and fed to the orifice from which the
product is extruded. Water/moisture levels will generally be from
3-15, preferably 4-10 wt %. Prior to extrusion, a supercritical
fluid, such as supercritical CO.sub.2 is introduced into the
extruder. Upon extrusion through the extrusion orifice, the
supercritical fluid expands, thereby imparting to the product a
desirable expanded texture, e.g., puffing, which is otherwise only
possible with elevated temperatures suitable for causing the
moisture to boil. Since such elevated temperatures are desirably
avoided to prevent degradation of the protein, use of the
supercritical fluid permits extrusion of a puffed product including
temperature sensitive proteins, such as whey, by avoiding the
elevated temperatures. In this alternative process, the temperature
in the extruder to which the nugget ingredients are subjected is
preferably not more than 95.degree. C., especially within the range
of from 70 to 90, especially up to 85.degree. C., more preferably
no higher than 80.degree. C.
[0051] For CO.sub.2, the supercritical fluid may be at, for
example, a pressure of at least about 72.9 atmospheres and a
temperature of at least about 31.degree. C.
[0052] The nutritional bars may be made by known methods provided
that the nuggets are not exposed to temperatures which cause
degradation of their ingredients, especially the proteins.
[0053] Extruded nutritional bars may be made by cooking a syrup
containing liquid (at ambient temperature) ingredients and then
mixing with dry ingredients. The mixture is then extruded onto a
conveyor belt and cut with a cutter. The nuggets of the invention
are included among the dry ingredients. The nuggets should only be
added to the syrup when the syrup is at a temperature below that at
which any of the nugget components degrade. Supercritical fluid
extrusion of the bar as a whole at reduced temperatures can also be
considered. Syrup ingredients may include components such as corn
syrup, glycerine, lecithin and soybean oil or other liquid oils. In
addition to the nuggets, other dry components include grains,
flours, maltodextrin and milk powders.
[0054] Nutritional bars in the form of granola bars may be made by
cooking the syrup, adding the dry ingredients, blending the syrup
and dry ingredients in a blender, feeding the blended mix through
rollers and cutting with a cutter.
[0055] The bars of the invention may be coated, eg with milk
chocolate or yogurt flavored coating.
[0056] Typically, excluding moisture lost during processing, the
uncoated bars of the invention will be made from 30-50 wt % syrup,
especially 35-45%, and 50-70 wt % dry ingredients, especially 55-65
wt %. Generally coated bars according to the invention will be made
from 30-50 wt % syrup, especially 35-45 wt %, 40-50 wt % dry
ingredients, especially 40-45% and 0-30 wt % coating, especially
5-25 wt %, particularly 10-20 wt % coating.
[0057] Using one of the two preferred methods of the invention, it
is believed that nuggets having greater than 50 wt %, especially
greater than 60%, more preferably greater than 70 or 80% of
selected non-soy proteins selected from the group consisting of
milk protein, rice protein and pea protein. can be achieved.
[0058] It can be expected that the nuggets of the invention may be
used in various types of nutrition bars including, without
limitation, snack bars and meal replacement bars. One example would
be granola bars. The bars of the invention may be coated in whole
or in part, e.g. with a yogurt flavored coating or a milk chocolate
coating.
EXAMPLE 1
Prophetic
[0059] A blend of rice flour, whey protein isolate and whey protein
concentrate is mixed to provide a protein content of between 50 and
70%. A twin screw extruder with more than two barrel sections is
used. The mixture is extruded through a die of a predetermined
shape. The temperature in the two zones closest to the die is set
between 70 and 130 C. The temperature of the mixture does not
exceed 130.degree. C. during extrusion. The feed material is fed
into the extruder at a fixed rate with moisture content between 15
to 40%. At steady state the samples are collected. The excess
moisture is dried using a belt/conveyor drier. A cutter is used to
cut the extrudates to obtain the desired length of the nuggets. The
nuggets thus obtained are included in a nutrition bar at a level of
60 wt % and a good tasting bar, without appreciable off-taste, is
obtained.
EXAMPLE 2
Prophetic
[0060] The process of Example 1 is carried out, except that the
blend used is a rice protein concentrate/rice flour blend having a
protein content between 50 and 80%, and a fluid bed dryer is
employed to dry the product.
EXAMPLE 3
Prophetic
[0061] Whey protein (55 wt % based on dry ingredients), rice flour,
starch and water are mixed in an extrusion cooker to provide
moisture content of from 3 to 15 wt %. The mixture is heated to
85.degree. C. A twin screw extruder with more than two barrel
sections is used. Supercritical carbon dioxide is mixed with the
nugget ingredients. The mixture is extruded through a die of a
predetermined shape. A cutter is used to cut the extrudates to get
the desired length of the nuggets. The nuggets thus obtained are
included in a nutrition bar at a level 6-60%. A good tasting bar,
without appreciable off-taste, is obtained.
[0062] Unless stated otherwise or required by context, the terms
"fat" and "oil" are used interchangeably herein. Unless otherwise
stated or required by context, percentages are by weight.
[0063] It should be understood of course that the specific forms of
the invention herein illustrated and described are intended to be
representative only, as certain changes may be made therein without
departing from the clear teaching of the disclosure. Accordingly,
reference should be made to the appended claims in determining the
full scope.
* * * * *