U.S. patent application number 13/443502 was filed with the patent office on 2012-08-02 for fruit and vegetable snacks.
This patent application is currently assigned to FRITO-LAY NORTH AMERICA, CIN.. Invention is credited to Ashish Anand, Varadharajan Radhamani Basker, Christopher John Cornwell, Brian Peter Jacoby, Dimitris Lykomitros, Vamshidhar Puppala, V.N. Mohan Rao.
Application Number | 20120196021 13/443502 |
Document ID | / |
Family ID | 42106829 |
Filed Date | 2012-08-02 |
United States Patent
Application |
20120196021 |
Kind Code |
A1 |
Anand; Ashish ; et
al. |
August 2, 2012 |
Fruit and Vegetable Snacks
Abstract
The present invention discloses formulations for vacuum baked
fruit and vegetable snack pieces that have a crispy, crunchy
texture similar to potato chip, corn based wafers, and other
popular snack items. A fruit or vegetable base is combined with
other ingredients and water to make a slurry, which is sheeted and
dried in a vacuum belt dryer, and separated into snack sized
pieces. In one embodiment, substantial amounts of solid inclusions
are combined with the slurry before drying.
Inventors: |
Anand; Ashish; (Plano,
TX) ; Basker; Varadharajan Radhamani; (Plano, TX)
; Cornwell; Christopher John; (Little Elm, TX) ;
Jacoby; Brian Peter; (Dallas, TX) ; Lykomitros;
Dimitris; (Amsterdam, NL) ; Puppala; Vamshidhar;
(McKinney, TX) ; Rao; V.N. Mohan; (Plano,
TX) |
Assignee: |
FRITO-LAY NORTH AMERICA,
CIN.
Plano
TX
|
Family ID: |
42106829 |
Appl. No.: |
13/443502 |
Filed: |
April 10, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12253409 |
Oct 17, 2008 |
8192784 |
|
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13443502 |
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Current U.S.
Class: |
426/560 ;
426/549; 426/573; 426/583; 426/615 |
Current CPC
Class: |
A23L 19/09 20160801 |
Class at
Publication: |
426/560 ;
426/615; 426/583; 426/549; 426/573 |
International
Class: |
A23L 1/212 20060101
A23L001/212; A21D 13/00 20060101 A21D013/00; A23L 1/05 20060101
A23L001/05; A23C 9/123 20060101 A23C009/123 |
Claims
1. A slurry comprising by weight: about 20% to about 55% fruit base
or vegetable base; about 5% to about 23% yogurt powder; about 0.5
to about 5% whey protein powder; and about 5% to about 60% added
water.
2. The slurry of claim 1 wherein said fruit base comprises at least
one of fruit puree concentrate and fruit powder.
3. The slurry of claim 1 wherein said vegetable base comprises at
least one of vegetable puree concentrate and vegetable powder.
4. The slurry of claim 1 further comprising about 1% to about 50%
flour.
5. The slurry of claim 1 further comprising a total moisture
content between about 25% and about 70%.
6. The slurry of claim 1 further comprising a Bostwick viscosity
value measured at a slurry temperature of about 75.degree. F. of
between about 2.5 centimeters in 30 seconds and about 13
centimeters in 30 seconds.
7. The slurry of claim 1 further comprising by weight: about 20% to
about 30% apple puree concentrate; about 20% to about 30% blueberry
puree concentrate; about 20% to about 30% whole grain flour; about
10% to about 15% said yogurt powder; about 0.70% to about 1.25%
said whey protein powder; about 6% to about 10% said added water;
and a Bostwick viscosity value measured at about 75.degree. F.
between about 6.5 centimeters in 30 seconds and about 7.5
centimeters in 30 seconds.
8. The slurry of claim 1 further comprising by weight: about 30% to
about 35% apple puree concentrate; about 5% to about 15% blueberry
puree concentrate; about 2% to about 3% strawberry powder; about 2%
to about 3% banana powder; about 10% to about 20% whole grain
flour; about 10% to about 20% said yogurt powder; about 4% to about
6% rice flour; about 0.70% to about 1.25% said whey protein powder;
about 15% to about 20% said added water; and a Bostwick viscosity
value measured at about 75.degree. F. between about 6 centimeters
in 30 seconds and about 7 centimeters in 30 seconds.
9. The slurry of claim 1 further comprising by weight: about 10% to
about 15% strawberry powder; about 7% to about 13% banana powder;
about 7% to about 13% apple puree concentrate; about 7% to about
13% said yogurt powder; about 4% to about 6% rice flour; about 1%
to about 1.5% said whey protein powder; about 50% to about 60% said
added water; and a Bostwick viscosity value measured at about
75.degree. F. between about 2 centimeters in 30 seconds and about 3
centimeters in 30 seconds.
10. The slurry of claim 1 further comprising by weight: about 30%
to about 50% carrot puree concentrate; about 20% to about 50% whole
grain flour; about 1% to about 5% said whey protein; about 8% to
about 15% said yogurt powder; and about 5% to about 15% said added
water.
11. The slurry of claim 1 further comprising by weight: about 14%
to about 18% apple concentrate; about 24% to about 28% peach
concentrate; about 21% to about 25% whole oat flour; about 20% to
about 24% said yogurt powder; about 0.5% to about 1.5% said whey
protein powder; about 10% to about 14% said added water; and a
Bostwick viscosity value measured at about 75.degree. F. between
about 12 centimeters in 30 seconds and about 13 centimeters in 30
seconds.
12. The slurry of claim 1 further comprising by weight: about 11%
to about 15% apple concentrate; about 11% to about 15% banana
concentrate; about 16% to about 20% strawberry concentrate; about
21% to about 25% whole oat flour; about 20% to about 24% said
yogurt powder; about 0.5% to about 1% said whey protein powder;
about 10% to about 14% said added water; and a Bostwick viscosity
value measured at about 75.degree. F. between about 12 centimeters
in 30 seconds and about 13 centimeters in 30 seconds.
13. The slurry of claim 1 further comprising by weight: about 7% to
about 11% apple concentrate; about 3% to about 7% banana
concentrate; about 4% to about 8% strawberry concentrate; about 40%
to about 44% whole oat flour; about 3% to about 7% said yogurt
powder; about 0.5% to about 1.5% said whey protein powder; about 3%
to about 7% rice flour; and about 25% to about 29% said added
water.
14. A snack piece comprising by weight: about 13% to about 67%
fruit solids or vegetable solids; about 14% to about 28% yogurt
solids; about 1% to about 6% whey protein solids; and less than
about 2% water.
15. The snack piece of claim 14 further comprising: about 2% to
about 60% flour solids.
16. The snack piece of claim 14 wherein said flour solids comprise
at least one of whole grain flour solids and modified flour
solids.
17. The snack piece of claim 14 wherein said fruit solids comprise
by weight: about 40% to about 60% apple solids; and about 40% to
about 60% blueberry solids.
18. The snack piece of claim 14 wherein said fruit solids comprise
by weight: about 6% to about 16% banana solids; about 6% to about
16% strawberry solids; about 50% to about 70% apple solids; and
about 16% to about 20% blueberry solids.
19. The snack piece of claim 14 wherein said fruit solids comprise
by weight: about 40% to about 50% strawberry solids; about 30% to
about 40% banana solids; and about 10% to about 30% apple
solids.
20. The snack piece of claim 14 additionally comprising: less than
about 5 grams of fat; about 1 gram or less of saturated fat; about
0 grams of trans-fatty acids; and less than 240 milligrams of
sodium.
21. The snack piece of claim 14 further comprising at least one
half serving of fruit or vegetables.
22. The snack piece of claim 14 wherein said vegetable solids
comprise about 100% carrot solids.
23. The snack piece of claim 14 further comprising at least one
serving of fruit or vegetables.
24. A snack piece comprising by weight: about 20% to about 95%
binder, wherein said binder comprises: about 13% to about 67% fruit
solids or vegetable solids; about 14% to about 28% yogurt solids;
about 1% to about 6% whey protein solids; and less than about 2%
water; and about 5% to about 80% solid inclusions.
25. The snack piece of claim 24 wherein said solid inclusions
comprise at least one of nuts or seeds.
26. The snack piece of claim 24 wherein said solid inclusions
comprise at least one of fruit pieces or vegetable pieces.
27. The snack piece of claim 24 wherein said binder further
comprises: about 2% to about 60% flour solids.
28. The snack piece of claim 24 further comprising between about
20% and 40% said binder, and between about 60% and about 80% said
solid inclusions.
Description
[0001] This application is a divisional of U.S. application Ser.
No. 12/253,409 entitled "Fruit and Vegetable Snacks" filed on Oct.
17, 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to a method for making an
improved snack food and more particularly to a method for making a
vacuum baked fruit and/or vegetable based snack food piece.
[0004] 2. Description of Related Art
[0005] Snack pieces such as potato chips and corn based snack chips
and wafers are popular consumer items for which there exists a
great demand. Potato chips have a crispy texture and can be
prepared by cooking slices of whole potatoes. Snack chips can also
be created by using potato flakes or corn masa, water and other
ingredients to create a starchy dough. The dough is sheeted, cut
into pieces of a desired shape, and cooked. The dough is compressed
between a pair of counter rotating rollers that are located closely
together, thereby providing a pinch point through which the dough
is formed into sheets and cut into a desired shape. After the dough
is cut into pieces, the pieces are transported towards and through
an oven or fryer, which cooks the pieces. The snack pieces are then
sent to be packaged. Other types of snack foods, such as corn based
wafers, are sometimes thicker and less dense than potato chips, but
still have a crispy texture.
[0006] Although prior snack chips and wafers are popular and
healthy snack items, offering snack pieces that incorporate
alternative vegetables and fruits could provide consumers with
nutritional benefits that are different from those provided by
potatoes and corn. Fruits and non-potato vegetables are generally
good sources of vitamins, minerals and other healthy compounds such
as anti-oxidants. Different fruits and vegetables are rich in
different nutrients, and the United States Department of
Agriculture (USDA) recommends consumption of between 5 and 13
servings of a variety of fruit and vegetables per day, depending on
the specific individual's needs. According to the Food and Drug
Administration, a diet that is high in fiber can reduce a person's
risk of certain cancers, diabetes, digestive disorders, and heart
diseases, as well as aid weight management. Furthermore, vitamins
and minerals are widely recognized as part of a healthy diet, and
antioxidants may reduce the risk of heart disease and cancer.
Therefore, offering consumers snack items that incorporate fruits
and vegetables other than potatoes will be an improvement in the
art because consumers will be able to choose from a variety of
different snack foods that offer nutritional benefits that differ
from those offered by traditional potato chips and corn based snack
chips and wafers.
[0007] However, prior art fruit and vegetable snack foods generally
take the form of dehydrated slices of whole fruits or vegetables.
These prior art dehydrated slices are typically chewy and tough,
and do not have the crispy, crunchy texture desired by consumers
for snack items. Furthermore, it has proven difficult in the prior
art to provide fabricated snack products that are not nutritionally
different from traditional potato chips and corn-based snack
wafers. Consequently, the need exists for a fruit or vegetable
based snack piece with a crispy, crunchy texture.
SUMMARY OF THE INVENTION
[0008] The present invention provides a great tasting, healthy
snack piece having a high content of fruit or vegetable solids, and
a crispy, crunchy texture similar to snack chips, snack wafers, and
other snack items desired by consumers. In one embodiment, the
snack piece of the present invention preferably has at least 1/2
serving of vegetables or fruit per 1 ounce serving of snack pieces.
In another embodiment, the snack piece of the present invention has
at least 1 serving of vegetables or fruit per 1 ounce serving of
snack pieces.
[0009] In one aspect of the invention, a blend of fruit puree
concentrates and/or fruit powders is used as a healthy ingredient
in vacuum baked snack pieces. In another aspect of the invention, a
blend of vegetable puree concentrates and/or vegetable powders is
used as a healthy ingredient in vacuum baked snack pieces. In
either case, the snack pieces have a desirable crispy, crunchy
texture and retain a high percentage of health benefits and flavors
from the original ingredients due to the low temperatures used
during cooking. These as well as additional features and advantages
of the present invention will become apparent in the following
written description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features believed characteristic of the invention
are set forth in the appended claims. The invention itself,
however, as well as a preferred mode of use, further objectives and
advantages thereof, will be best understood by reference to the
following detailed description of illustrative embodiments when
read in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 is a flowchart indicating the processing steps for
one embodiment of the present invention.
DETAILED DESCRIPTION
[0012] The snack pieces of the present invention are high in
vegetable or fruit content. The nutritional goals for the snack
chips of the present invention include, per 1 ounce serving of
snack pieces: no more than 5 g of fat, 1 gram or less of saturated
fat, zero trans-fatty acids, and no more than 240 milligrams of
sodium. As used herein, the term fruit is used in the culinary
sense and includes those botanical fruits that are sweet and
fleshy. Examples of fruit include, without limitation, apple,
strawberry, blueberry, cranberry, plum, peach, mango, banana, pear,
grape and orange. The term vegetable is used herein in the culinary
sense and includes those plant fruits that are savory, as opposed
to sweet. Examples of vegetables include, without limitation,
pumpkin, tomato, carrot, onion, bell pepper, beet, cucumber,
broccoli and squash.
[0013] In one preferred embodiment, the snack pieces of the present
invention incorporate at least 1/2 serving of fruits or vegetables
per 1 ounce serving of the snack pieces. In another preferred
embodiment, the snack pieces of the present invention incorporate
at least 1 serving of fruits or vegetables per 1 ounce serving of
the snack pieces.
[0014] The United States Department of Agriculture (USDA) defines a
serving of fruit or vegetables as 1/2 cup of chopped fruit or
vegetables, respectively. For example, 1/2 cup of chopped raw
apples constitutes 1 serving of apples, and 1/2 cup of chopped or
sliced raw tomatoes constitutes 1 serving of tomato under the USDA
guidelines. A serving of fruit or vegetables can be understood as
having a moisture content and a solids content. Vegetable solids
and fruit solids are defined herein as the non-water components of
vegetables and fruits, respectively. Thus, a serving of vegetables
comprises a vegetable solids content on a dry basis and a serving
of fruit comprises a fruit solids content on a dry basis. The USDA
National Nutrient Database for Standard Reference defines the
weight of the edible portion of a fruit or vegetable in that 1/2
cup and defines the average moisture and thus the fruit solids or
vegetable solids content of the edible portion of a fruit or
vegetable. Table 1, for example, depicts the nutrient profile for
1-cup or 125 grams of raw apples as accessed at
http://www.nal.usda.gov/fnic/foodcomp/search/.
TABLE-US-00001 TABLE 1 Raw Apples 1.00 X 1 Nutrient cup, chopped or
sliced Proximates Units 125 g Water g 106.95 Energy kcal 65 Energy
kj 272 Protein g 0.33 Total lipid (fat) g 0.21 Ash g 0.24
Carbohydrate, by difference g 17.26 Fiber, total dietary g 3.0
Sugars, total g 12.99 Sucrose g 2.59 Glucose (dextrose) g 3.04
Fructose g 7.38 Lactose g 0.00 Maltose g 0.00 Galactose g 0.00
Starch g 0.06
[0015] USDA National Nutrient Database for Standard Reference,
Release 20 (2007)
[0016] As used herein, a serving of fruit or a serving of
vegetables is defined as the amount of fruit solids or vegetable
solids content that is equivalent to 1/2 cup (118 cubic
centimeters) of chopped fruit or vegetables on a dry basis based on
the USDA National Nutrient Database for Standard Reference, Release
20, 2007, which is incorporated herein by reference. According to
Table 1, one cup of chopped or quartered raw apples weighs 125
grams, has a water content of 85.56% by weight and a fruit solids
content of 14.44%. One fruit serving of raw apples (1/2 cup) has a
total weight of 62.5 grams. Consequently, 9.025 grams (14.44%
solids content.times.62.5 grams total weight) of apple solids in a
finished product is equivalent to one serving of fruit. Thus, a
snack piece having a one-half fruit serving would have
approximately 4.51 grams of apple solids in a 1 ounce serving of
snack pieces, and a snack piece having one fruit serving would have
approximately 9.025 grams of apple solids in a 1 ounce serving of
snack pieces.
[0017] Consequently, in one embodiment, vegetable or fruit
ingredients can be used in accordance with the present invention in
an amount sufficient to provide for a one-half fruit or vegetable
serving, and in another preferred embodiment in an amount
sufficient to provide for one fruit or vegetable serving. As used
herein, one serving of fruit or one serving of vegetables is
defined as the amount of fruit or vegetable solids that is
equivalent to 1/2 cup (118 cubic centimeters) of a chopped fruit or
vegetables on a dry basis based on the USDA National Nutrient
Database for Standard Reference, Release 20, 2007, which is
incorporated herein by reference.
[0018] In one embodiment of the present invention, fruit puree
concentrate is used as an ingredient in a slurry that is capable of
being deposited onto a belt in the form of a sheet, cooked under
vacuum conditions and cut into snack pieces. Fruit puree
concentrate, as used herein, is a fruit puree that has a portion of
water removed, so that the solids content of the fruit is
concentrated. In another embodiment, vegetable puree concentrate is
used as an ingredient in a slurry that is spread into a sheet,
cooked under vacuum, and cut into snack pieces. Fruit puree
concentrate and vegetable puree concentrate typically comprise
between about 25% and about 75% fruit or vegetable solids by
weight, depending on the fruit or vegetable used. In a preferred
embodiment, the fruit puree concentrate or vegetable puree
concentrate comprises between about 30% and about 60% moisture by
weight. In still another embodiment, fruit or vegetable powder can
be used as an ingredient in the slurry. As used herein, the term
"fruit base" refers to fruit puree concentrate, fruit powder or
mixtures thereof. As used herein, the term "vegetable base" refers
to vegetable puree concentrate, vegetable powder or mixtures
thereof.
[0019] FIG. 1 depicts a flowchart for one embodiment of the method
of the present invention. The fruit and vegetable bases 102 can be
mixed 106 with one or a combination of other ingredients 104
including yogurt powders, whey protein powders, flours and water to
manipulate the viscosity or Bostwick value of the slurry 108, and
optimize the flavor, texture and nutritional content of the
resulting snack pieces. Including whey protein powder in the slurry
mixture causes the slurry to foam as it dries under vacuum
conditions, which lightens the texture of the resulting snack
piece. Flours, such as whole grain flours and modified flours,
increase the viscosity of the slurry sheet and give the resulting
snack piece a desirable wholesome, crunchy texture. Whole grain
flours can also impart into the snack piece the health benefits of
the flours' constituent whole grains.
[0020] In one embodiment, the method used to make the snack pieces
of the present invention involves spreading or depositing 110 the
vegetable or fruit slurry over a conveyor belt and cooking or
drying the slurry under vacuum conditions 112. The conveyor belt is
a continuously rotating belt that is designed to convey objects
placed on it from one end of the belt to the other. Underneath the
belt is a heating element that heats any product placed on the
belt. In a preferred embodiment, at least two different heating
zones are provided. Preferably, the cooking temperature is kept
below about 110.degree. C. in order to preserve the natural color,
flavor and nutritional qualities of the fruit or vegetable
ingredients used in the snack pieces. The fruit and vegetable
slurries used with the present invention are heat sensitive. Thus,
traditional oven drying does not produce a suitable final product
because the sugars present in the slurries easily brown.
Additionally, the fruit and vegetable flavors and nutrients easily
volatize and escape during heated baking.
[0021] In one embodiment, the conveyor belt and heating element are
contained inside a vacuum chamber. The pressure inside the vacuum
chamber is preferably variable. The pressure levels used in
accordance with the method of the present invention range from
about 2 Torr to about 60 Torr. Furthermore, the pressure level
inside the vacuum chamber is varied throughout the cooking process.
In a preferred embodiment, the pressure level at the beginning of
the cooking process is higher than the pressure level at the end of
the process. Cooking under vacuum conditions allows the slurry
sheet to be dried at much lower temperatures than are feasible on a
commercial scale under atmospheric conditions, and allows
practitioners of the present invention to vary the product
formulation and chamber pressure to optimize the product texture
and flavor.
[0022] In one embodiment, the fruit or vegetable base is first
mixed together with water, yogurt powder, and whey protein to form
a slurry. In one embodiment, the slurry comprises between about 20%
and about 55% fruit or vegetable base (powders, puree concentrates,
or mixtures thereof), between about 5% and about 23% yogurt powder,
between about 0.5% and about 5% whey protein powder, and between
about 5% and about 60% added water. The slurry preferably comprises
an overall moisture content between about 25% and about 70%. In
another embodiment flour comprises between about 1% and about 50%
of the slurry. The flour used in accordance with one embodiment
comprises at least one of whole grain flours and modified flours.
All percentages used herein are by weight unless otherwise noted.
Furthermore, each ingredient comprises a moisture component and a
solids component. For example, yogurt powder comprises a moisture
component and a yogurt solids component, and the yogurt solids are
defined as the non-water components of the yogurt powder.
[0023] In another embodiment, the fruit or vegetable slurry is used
as a binder and mixed with whole or recognizable solid inclusions.
In one embodiment, the solid inclusions comprise nuts or seeds.
Examples of nuts include, without limitation, peanut, almond,
pistachio, cashew, Brazil nut, pecan, hazelnut and walnut. In a
preferred embodiment, the nuts or seeds are fully cooked/roasted
prior to being combined with the slurry described above. The vacuum
belt dryer will not appreciably cook or roast the nuts during
vacuum dehydration, so such steps must occur prior to entry into
the vacuum belt dryer. The resulting snack is novel because it
combines cooked or roasted nuts with a fruit or vegetable based
binder that is extremely heat sensitive, as described above. This
novel combination of a roasted component with a heat sensitive
component has not been taught or suggested by the prior art. In one
embodiment, the slurry comprises between about 20% and about 40% of
the total mixture of solid inclusions and slurry. In another
embodiment, the solid inclusions comprise between about 60% and
about 80% of the total mixture of solid inclusions and slurry. In
another embodiment, the solid inclusions comprise recognizable
pieces of fruits or vegetables. These solid inclusions are also
heat sensitive, which makes them ideal for use in the vacuum belt
dryer with the slurries described above.
[0024] In one preferred embodiment, the slurry comprises about 20%
to about 30% apple puree concentrate, about 20% to about 30%
blueberry puree concentrate, about 20% to about 30% whole grain
flour, about 10% to about 15% said yogurt powder, about 0.70% to
about 1.25% said whey protein powder, about 6% to about 10% said
added water, and has a Bostwick viscosity value between about 6.5
centimeters in 30 seconds and about 7.5 centimeters in 30
seconds.
[0025] In another preferred embodiment, the slurry comprises about
30% to about 35% apple puree concentrate, about 5% to about 15%
blueberry puree concentrate, about 2% to about 3% strawberry
powder, about 2% to about 3% banana powder, about 10% to about 20%
whole grain flour, about 10% to about 20% said yogurt powder, about
4% to about 6% rice flour, about 0.70% to about 1.25% said whey
protein powder, about 15% to about 20% said added water, and has a
Bostwick viscosity value between about 6 centimeters in 30 seconds
and about 7 centimeters in 30 seconds.
[0026] In still another preferred embodiment, the slurry comprises
about 10% to about 15% strawberry powder, about 7% to about 13%
banana powder, about 7% to about 13% apple puree concentrate, about
7% to about 13% said yogurt powder, about 4% to about 6% rice
flour, about 1% to about 1.5% said whey protein powder, about 50%
to about 60% said added water, and has a Bostwick viscosity value
between about 2 centimeters in 30 seconds and about 3 centimeters
in 30 seconds. In another embodiment, the slurry comprises between
about 30% and about 50% carrot puree concentrate, about 20% to
about 50% whole grain flour, about 1% to about 5% whey protein,
about 8% to about 15% yogurt powder, and about 5% to about 15%
added water.
[0027] In yet another preferred embodiment, the slurry comprises
about 14% to about 18% apple concentrate, about 24% to about 28%
peach concentrate, about 21% to about 25% whole oat flour, about
20% to about 24% yogurt powder, about 0.5% to about 1.5% whey
protein powder, about 10% to about 14% added water, and has a
Bostwick viscosity value between about 12 centimeters in 30 seconds
and about 13 centimeters in 30 seconds. In another preferred
embodiment, the slurry comprises about 11% to about 15% apple
concentrate, about 11% to about 15% banana concentrate, about 16%
to about 20% strawberry concentrate, about 21% to about 25% whole
oat flour, about 20% to about 24% yogurt powder, about 0.5% to
about 1% whey protein powder, about 10% to about 14% added water,
and has a Bostwick viscosity value between about 12 centimeters in
30 seconds and about 13 centimeters in 30 seconds. In still another
preferred embodiment, the slurry comprises about 7% to about 11%
apple concentrate, about 3% to about 7% banana concentrate, about
4% to about 8% strawberry concentrate, about 40% to about 44% whole
oat flour, about 3% to about 7% yogurt powder, about 0.5% to about
1.5% whey protein powder, about 3% to about 7% rice flour, and
about 25% to about 29% added water.
[0028] The slurry created in accordance with the present invention
must have a consistency sufficient to allow it to remain on the
conveyor belt without dripping or running off the sides of the belt
as it dries. However, it should also be fluid enough to settle into
a sheet of approximate uniform thickness once it is deposited onto
the belt. Therefore, in a preferred embodiment, the Bostwick
viscosity for the vegetable or fruit slurry is between about 2
centimeters in 30 seconds and about 13 centimeters in 30 seconds
when measured at 75.degree. F. Such a slurry can be pumped into the
vacuum chamber and deposited onto the conveyor belt to form a
reasonably uniform sheet, but will not drip off the sides of the
belt, even when the belt has sidewalls. The sheet thickness depends
largely on the Bostwick viscosity and the rate at which the slurry
is deposited onto the belt. In one embodiment, the sheet thickness
ranges between about 0.5 millimeters and about 10 millimeters. The
slurry is preferably deposited onto the belt 112 through a nozzle
that moves laterally across the belt as the belt turns.
[0029] Before, during or after the deposition of the slurry sheet
on the belt, the pressure level inside the vacuum chamber is
reduced to between about 5 Torr and about 60 Torr, and the
temperature of the heating element under the belt is fixed between
about 75.degree. C. and about 110.degree. C. As the moisture
content of the slurry sheet is reduced, the pressure inside the
chamber is reduced. In one embodiment, when the moisture content of
the slurry sheet has been reduced to a final level between about 1%
and about 2%, the pressure level inside the vacuum chamber is
between about 2 Torr and about 6 Torr.
[0030] Next, the dried slurry sheet is optionally allowed to cool
and harden on the belt before it is separated into individual
pieces 114. During the cooling phase, the temperature of the
heating element under the belt is reduced to between about
20.degree. C. and about 40.degree. C. The cooled, dried sheet is
then fractured, or broken up into snack sized pieces, which can be
accomplished by impacting the dried sheet with a guillotine-like
blade at predetermined intervals to fracture the sheet into pieces,
or by cutting the sheet into desired pieces. Alternatively, the
slurry sheet can be cut into individual snack pieces as it is
drying, but after the slurry sheet has been dried to a moisture
level and consistency that allows the sheet to be cut into
individual snack sized pieces that do not expand, resettle, and
reform a continuous sheet after the pieces are cut.
[0031] In one embodiment, the snack piece of the present invention
comprises about 13% to about 67% fruit solids or vegetable solids,
about 14% to about 28% yogurt solids, about 1% to about 6% whey
protein solids, and about 1% to about 2% water. In another
embodiment, the snack piece of the present invention further
comprises about 2% to about 60% flour solids. In one embodiment,
the composition of the fruit solids in the snack of the present
invention comprises about 40% to about 60% apple solids, and about
40% to about 60% blueberry solids. In another embodiment, the
composition of the fruit solids in the present invention comprises
about 6% to about 16% banana solids, about 6% to about 16%
strawberry solids, about 50% to about 70% apple solids, and about
16% to about 20% blueberry solids. In another embodiment, the
composition of the fruit solids of the present invention comprises
about 40% to about 50% strawberry solids, about 30% to about 40%
banana solids, and about 10% to about 30% apple solids. In still
another embodiment of the present invention, the vegetable solids
comprise about 100% carrot solids.
Example 1
[0032] A first ingredient mixture comprising, by weight, about
25.81% apple puree concentrate, about 25.81% blueberry puree
concentrate, about 24.81% whole oat flour, about 13.90% yogurt
powder, about 0.99% whey protein, and about 8.68% added water was
mixed in a Hobart mixer until a relatively homogenous slurry was
formed. The Bostwick viscosity value for the first slurry was
approximately 7.0 centimeters in 30 seconds.
[0033] The slurry was dried using a Bucher DryBand vacuum belt
dryer. A feed pump was used to pump the slurry through a nozzle and
deposit the slurry onto a rotating belt. The slurry settled on the
belt into a sheet about 5 millimeters to about 10 millimeters
thick. The pressure level inside the chamber was initially 13.5
Torr and the temperature of the heating element underneath the belt
was approximately 100.degree. C.
[0034] At approximately 18 minutes into the process, the pressure
level inside the chamber had been raised to 21 Torr. About fifty
three minutes after that, the pressure level inside the chamber had
been reduced to 7.5 Torr. At this point, the temperature heating
element under the belt was reduced to about 40.degree. C., and the
sheet was allowed to cool for approximately 23 minutes. While the
sheet was cooling, the vacuum level inside the chamber was further
reduced to 6.0 Torr. The moisture content of the dried sheet was
between about 1.5% and about 2% by weight, and it was broken into
snack sized pieces after it was removed from the vacuum chamber.
The total dwell time of the first sheet inside the vacuum chamber
was approximately 94 minutes.
Example 2
[0035] A second ingredient mixture comprising, by weight, about
33.33% apple puree concentrate, about 9.52% blueberry puree
concentrate, about 14.29% whole oat flour, about 2.38% strawberry
powder, about 2.38% banana powder, about 4.76% rice flour, about
15.24% yogurt powder, about 0.95% whey protein, and about 17.14%
added water was mixed in a Hobart mixer until a relatively
homogenous slurry formed. The Bostwick viscosity value for the
second slurry was approximately 6.5 centimeters in 30 seconds.
[0036] This second slurry was pumped into the Bucher vacuum belt
dryer as described in Example 1 above. The slurry settled into a
sheet having a thickness between about 5 millimeters and about 10
millimeters. The pressure level inside the chamber was initially
set at 21 Torr and the temperature of the heating element under the
belt was set at a temperature between about 85.degree. C. and about
100.degree. C.
[0037] After the slurry sheet dried inside the chamber for
approximately eleven minutes, the pressure level had been raised to
22.5 Torr. Approximately forty four minutes later, the vacuum level
had been reduced to 5.25 Torr. At this point, the temperature of
the heating element under the belt was reduced to between
30.degree. C. and 40.degree. C., and the sheet was allowed to cool
for approximately 23 minutes. While the sheet was cooling, the
vacuum level inside the chamber was further reduced to 3 Torr. The
moisture content of the dried sheet was between about 1.5% and
about 2% by weight, and it was broken into snack sized pieces after
it was removed from the vacuum chamber. The total dwell time of the
second sheet inside the vacuum chamber was approximately 72
minutes.
Example 3
[0038] A third ingredient mixture comprising, by weight, about
12.6% strawberry powder, about 10.1% banana powder, about 10.7%
apple puree concentrate, about 9.4% yogurt powder, about 1.3% whey
protein, and about 56% added water was mixed in a Hobart mixer
until a relatively homogenous slurry was formed. The Bostwick
viscosity value for the third slurry was about 2.5 centimeters in
30 seconds.
[0039] This third slurry was pumped into the Bucher vacuum belt
dryer as described in Example 1 above. The slurry settled into a
sheet having a thickness between about 5 millimeters and about 10
millimeters. The pressure level inside the chamber was initially
set at 13.5 Torr and the temperature of the heating element under
the belt was set at a temperature between about 88.degree. C. and
about 100.degree. C.
[0040] After the slurry sheet dried inside the chamber for
approximately five minutes, the pressure level had been raised to
20.25 Torr. Approximately eighty one minutes later, the vacuum
level had been reduced to 5.25 Torr. At this point, the temperature
heating element under the belt was reduced to between 38.degree. C.
and 40.degree. C., and the sheet was allowed to cool for
approximately 4 minutes. While the sheet was cooling, the vacuum
level inside the chamber remained at 5.25 Torr. The moisture
content of the dried sheet was between about 1.5% and about 2% by
weight, and it was broken into snack sized pieces after it was
removed from the vacuum chamber. The total dwell time of the third
sheet inside the vacuum chamber was approximately 90 minutes.
Example 4
[0041] A fourth ingredient mixture comprising, by weight, about
18.1% strawberry powder, about 12.4% banana powder, about 12.4%
apple puree concentrate, about 22.7% whole oat flour, about 21.8%
yogurt powder, about 0.8% whey protein, and about 11.8% added water
was mixed in a Hobart mixer until a relatively homogenous slurry
was formed. The Bostwick viscosity value for the fourth slurry was
about 12.75 centimeters in 30 seconds.
[0042] This fourth slurry was pumped into the Bucher vacuum belt
dryer as described in Example 1 above. The slurry settled into a
sheet having a thickness between about 5 millimeters and about 10
millimeters. The pressure level inside the chamber was initially
set at about 23 Torr and the temperature of the heating element
under the belt was set at a temperature of about 82.degree. C.
[0043] After the slurry sheet dried inside the chamber for
approximately 83 minutes, the pressure level had dropped to about 6
Torr. At this point, the temperature heating element under the belt
was reduced to about 20.degree. C., and the sheet was allowed to
cool for between about 10 and about 20 minutes. While the sheet was
cooling, the vacuum level inside the chamber remained at about 6
Torr. The moisture content of the dried sheet was between about
1.5% and about 2% by weight, and it was broken into snack sized
pieces after it was removed from the vacuum chamber.
Example 5
[0044] A fifth ingredient mixture comprising, by weight, about
26.4% peach puree concentrate, about 16.5% apple puree concentrate,
about 22.7% whole oat flour about 21.8% yogurt powder, about 0.8%
whey protein, and about 11.8% added water was mixed in a Hobart
mixer until a relatively homogenous slurry was formed. The Bostwick
viscosity value for the fifth slurry was about 12.5 centimeters in
30 seconds.
[0045] This fifth slurry was pumped into the Bucher vacuum belt
dryer as described in Example 1 above. The slurry settled into a
sheet having a thickness between about 5 millimeters and about 10
millimeters. The pressure level inside the chamber was initially
set at about 23 Torr and the temperature of the heating element
under the belt was set at a temperature of about 100.degree. C.
[0046] After the slurry sheet dried inside the chamber for
approximately 75 minutes, the pressure level had dropped to about 6
Torr. At this point, the temperature heating element under the belt
was reduced to about 20.degree. C., and the sheet was allowed to
cool for between about 10 and about 20 minutes. While the sheet was
cooling, the vacuum level inside the chamber remained at about 6
Torr. The moisture content of the dried sheet was between about
1.5% and about 2% by weight, and it was broken into snack sized
pieces after it was removed from the vacuum chamber.
[0047] The fruit chips described in the above examples contained at
least 1 serving of fruit. They also had a crispy, crunchy texture
similar to that of other popular consumer snack items, such as
potato crisps and snack wafers. In addition, the fruit and
vegetable chips disclosed herein met or exceeded the other
preferred nutritional goals. Specifically, the chips disclosed
above had, per 1 ounce serving, less than 5 g of fat, 1 gram or
less of saturated fat, zero trans-fatty acids, and no more than 240
milligrams of sodium. In sum, the result is a healthy, nutritious
snack piece high in vegetable or fruit content and having a crispy
texture similar to a potato and corn based snack pieces.
* * * * *
References