U.S. patent application number 17/516839 was filed with the patent office on 2022-03-10 for spoonable smoothie and methods of production thereof.
The applicant listed for this patent is Kraft Foods Group Brands LLC. Invention is credited to Rachel Catherine Brown, Sara K. Cooper, Julia Lee Gregg-Albers, Allison M. Hibnick, Travis Larson, Andrew McPherson, Judith Gulten Moca, Hillary Sandrock, Hayley Theodorakakos.
Application Number | 20220071236 17/516839 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-10 |
United States Patent
Application |
20220071236 |
Kind Code |
A1 |
Gregg-Albers; Julia Lee ; et
al. |
March 10, 2022 |
SPOONABLE SMOOTHIE AND METHODS OF PRODUCTION THEREOF
Abstract
Disclosed is a spoonable smoothie with fibrous, non-chalky,
non-gritty texture. The spoonable smoothie has more than 34% by
weight of a combination of fruit and vegetable sources, a
texturant, a protein source, a vitamin source, and a mineral
source. In some embodiments, the spoonable smoothie may be produced
via high-pressure processing or thermal processing. In some
embodiments in which high-pressure processing is employed, acid
whey may be used to help obtain the non-chalky, non-gritty texture.
In other embodiments in which thermal processing is employed, order
of ingredients may be used to help obtain the non-chalky,
non-gritty texture. In those thermally processed embodiments, the
texturant and the protein source may be separately hydrated to
control the competition for water absorption between the texturant
and the protein source.
Inventors: |
Gregg-Albers; Julia Lee;
(Glenview, IL) ; Hibnick; Allison M.; (Buffalo
Grove, IL) ; Theodorakakos; Hayley; (Washington,
DC) ; Sandrock; Hillary; (Chicago, IL) ;
Cooper; Sara K.; (Chicago, IL) ; McPherson;
Andrew; (Mt. Prospect, IL) ; Brown; Rachel
Catherine; (Evanston, IL) ; Moca; Judith Gulten;
(Palatine, IL) ; Larson; Travis; (Glenview,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kraft Foods Group Brands LLC |
Chicago |
IL |
US |
|
|
Appl. No.: |
17/516839 |
Filed: |
November 2, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16397887 |
Apr 29, 2019 |
11191289 |
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17516839 |
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62664737 |
Apr 30, 2018 |
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International
Class: |
A23L 2/02 20060101
A23L002/02; A23L 2/66 20060101 A23L002/66; A23L 2/56 20060101
A23L002/56; A23L 2/60 20060101 A23L002/60; A23L 29/256 20060101
A23L029/256; A23L 33/15 20060101 A23L033/15; A23L 33/19 20060101
A23L033/19; B65B 25/00 20060101 B65B025/00; A23L 29/231 20060101
A23L029/231 |
Claims
1. A spoonable smoothie comprising: between about 34% and about 45%
by weight of a combination of fruit and vegetable sources, based on
a total weight of the spoonable smoothie; a texturant including at
least one of pectin, rice flour, tapioca flour, locust bean gum, or
a combination thereof; a protein source; and one or more of a
vitamin source and a mineral source.
2. The spoonable smoothie of claim 1, wherein the protein source
comprises whey protein isolate.
3. The spoonable smoothie of claim 1, wherein the protein source
comprises acid whey.
4. The spoonable smoothie of claim 1, wherein the spoonable
smoothie includes the mineral source and the mineral source
comprises calcium citrate.
5. The spoonable smoothie of claim 1, wherein the spoonable
smoothie has a degree of Brix between about 14 and about 18.
6. The spoonable smoothie of claim 1, wherein a zero shear
viscosity of the spoonable smoothie is between about 4500 Pas and
about 98,000 Pas when the spoonable smoothie is submitted to a flow
ramp test on a rheometer at a constant temperature of 5.degree.
C.
7. The spoonable smoothie of claim 1, wherein a yield stress of the
spoonable smoothie is between about 15 Pa and about 1620 Pa when
the spoonable smoothie is submitted to flow ramp test on a
rheometer at a constant temperature of 5.degree. C.
8. The spoonable smoothie of claim 1, wherein a firmness of the
spoonable smoothie is between about 115 Pa and about 1,790 Pa as
when the spoonable smoothie is submitted to a frequency sweep test
on a rheometer at a constant temperature of 5.degree. C.
9. The spoonable smoothie of claim 1, wherein a refrigerated shelf
life of the spoonable smoothie is at least about 45 days.
10. A method of producing a spoonable smoothie comprising:
hydrating a protein source to form a first mixture; separately
hydrating a pectin, an amount of a sweetener, and an amount of a
texturant to form a second mixture; separately shearing a fruit
source and a vegetable source; cold mixing and shearing together
the second mixture and the sheared fruit source and vegetable
sources to form a third mixture; adding the first mixture to the
third mixture and cold mixing and shearing together to form a final
mixture; heating the final mixture in a first heat exchanger;
cooling the final mixture in a second heat exchanger; cold filling
the final mixture into a package; and sealing the package.
11. The method of claim 10, wherein the protein source comprises
whey protein isolate.
12. The method of claim 10, wherein the texturant comprises at
least one of locust bean gum, tapioca flour, and rice flour.
13. The method of claim 10, further comprising adding a mineral
source to the first mixture.
14. The method of claim 13, wherein the mineral source comprises
calcium citrate.
15. The method of claim 10, further comprising adding a vitamin
source to the third mixture.
16. The method of claim 15, wherein the vitamin source comprises
thiamine hydrochloride.
17. A spoonable smoothie comprising: between about 15% and about
25% by weight of a dairy component, based on a total weight of the
spoonable smoothie; more than 20% by weight of a combination of
fruit and vegetable sources, based on the total weight of the
spoonable smoothie; a texturant including at least one of pectin,
rice flour, tapioca flour, and locust bean gum; and a protein
source.
18. The spoonable smoothie of claim 17, further comprising one or
more of a vitamin source and a mineral source.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/397,887, filed on Apr. 29, 2019, which
claims the benefit of U.S. Provisional Application No. 62/664,737,
filed on Apr. 30, 2018.
FIELD
[0002] This application relates generally to foods and beverages,
and more particularly to packaged food and beverage products
suitable for large-scale manufacture and distribution, for retail
sale to consumers.
BACKGROUND
[0003] Numerous food products combine fruits, berries and/or other
plant-based ingredients with yogurt and/or other dairy components
to provide desirable nutritional properties, including
fortification, in combination with desired flavor profiles,
textural characteristics and other organoleptic properties.
Maintaining desired properties of products such as smoothies over a
refrigerated shelf life suitable for large-scale distribution and
sale to consumers at retail outlets can be challenging. Flavor
profiles of smoothies containing ingredients such as fresh fruits
and berries can degrade rapidly over time due to oxidation and/or
other factors. High pressure processing (HPP), thermal treatments,
and/or various preservatives can be helpful with some issues, but
there is a need for improvement in this area, particularly where it
is desired to avoid or minimize use of artificial preservatives or
other artificial ingredients.
[0004] One challenge of producing a stable smoothie with one or
more proteinaceous ingredients is that difficulties may be
encountered in obtaining an acceptable texture. Another challenge
is that exposure to ultraviolet (UV) light over the course of a
product's shelf life can have deleterious effects on certain
properties, e.g., color and stability. A further challenge is that
addition of vitamins and minerals to enhance nutritional properties
can result in undesirable effects on organoleptic properties.
SUMMARY
[0005] In some embodiments, a spoonable smoothie includes between
about 34% and about 45% by weight of a combination of fruit and
vegetable sources, along with a texturant, a protein source, a
vitamin source, and a mineral source. In some such embodiments, a
fibrous, non-chalky, non-gritty texture is achieved using a whey
protein isolate or an acid whey as a protein source. In some
embodiments, the spoonable smoothie may be produced via
high-pressure processing or thermal processing. In some embodiments
in which high-pressure processing is employed, acid whey may be
used to help obtain the non-chalky, non-gritty texture. In some
embodiments in which thermal processing is employed, the order of
ingredient addition may help obtain the non-chalky, non-gritty
texture.
[0006] In one method of producing a spoonable smoothie, a protein
source is hydrated to form a first mixture. In one aspect of the
current disclosure, a mineral source may also be added to the first
mixture. A pectin, an amount of sweetener, and other texturants are
separately hydrated to form a second mixture. The method may
further include separately shearing at least one fruit source and
at least one vegetable source. The second mixture, the sheared
fruit source, and the vegetable source may be cold mixed and
sheared together to form a third mixture. The method may further
include adding color and flavor to the third mixture. The first
mixture may be then added to the third mixture and cold mixed and
sheared together to form a final mixture. The method may include
heating the final mixture in a first heat exchanger, then cooling
the final mixture in a second heat exchanger. The method may also
include cold filling the final mixture into a package and sealing
the package.
[0007] Another method of producing a spoonable smoothie may include
preparing a hot mix that includes a pectin, a sugar, and an amount
of hot water. The method may also include preparing a first cold
mix that includes at least one fruit source, at least one vegetable
source, and a yogurt. The method may further include preparing a
second cold mix that includes a whey protein source and an amount
of cold water. A final mixture may be formed by cold mixing and
shearing together the hot mix, the first cold mix, and the second
cold mix. The method may include packing the final mixture into a
package, then submitting the package to high-pressure
processing.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 is a block flow diagram for an exemplary process for
the production of a spoonable smoothie using high-pressure
processing.
[0009] FIG. 2 is a block flow diagram of an exemplary process for
separately hydrating the texturants for the production of a
spoonable smoothie using thermal processing.
[0010] FIG. 3 is a block flow diagram of an exemplary process for
separately hydrating the protein source for the production of a
spoonable smoothie using thermal processing.
[0011] FIG. 4 is a block flow diagram of an exemplary process for
preparing the fruits and vegetables sources for the production of a
spoonable smoothie using thermal processing.
[0012] FIG. 5 is a block flow diagram of an exemplary process for
the production of a spoonable smoothie using thermal
processing.
[0013] FIG. 6 is a graph showing the flows curves (viscosity as a
function of shear rate) for four samples of a spoonable smoothie
(i.e., a spoonable smoothie with: 1) whey protein isolate; 2) acid
whey in place of whey protein isolate; 3) iota carrageenan added;
and 4) homogenized yogurt) produced using high-pressure
processing.
[0014] FIG. 7 is a graph showing the flows curves (viscosity as a
function of shear rate) for four samples of a spoonable smoothie
produced using thermal processing.
[0015] FIG. 8 is a graph showing the flows curves (viscosity as a
function of shear rate) for another three samples of a spoonable
smoothie produced using thermal processing.
[0016] FIG. 9 is a graph showing frequency sweep test results for
four samples of a spoonable smoothie (i.e., a spoonable smoothie
with: 1) whey protein isolate; 2) acid whey replacing whey protein
isolate; 3) iota carrageenan added; and 4) homogenized yogurt)
produced using high-pressure processing.
[0017] FIG. 10 is a graph showing frequency sweep test results for
four samples of a spoonable smoothie produced using thermal
processing.
[0018] FIG. 11 is a graph showing frequency sweep test results for
another three samples of a spoonable smoothie produced using
thermal processing.
DETAILED DESCRIPTION
[0019] Described herein is a smoothie with a fibrous, non-gritty,
non-chalky, spoonable texture. The spoonable smoothie has a high
concentration of fruits and vegetables. In some embodiments, the
combination of fruit and vegetable sources is more than 20%, more
than 30%, more than 32%, more than 34%, more than 35%, more than
36%, more than 38%, more than 40%, or between 34% and 45% of the
total weight of the spoonable smoothie. In some embodiments, the
fruit sources may include, but are not limited to, apple, avocado,
apricot, blueberry, blackberry, banana, blood orange, boysenberry,
clementine, cherry, cantaloupe, coconut, cranberry, cucumber,
currant, date, dragonfruit, elderberry, fig, goji berry,
gooseberry, guava, grapefruit, grape, green pepper, honeydew,
juniper berry, kiwi, kumquat, lemon, lime, lychee, mango, mulberry,
nectarine, olive, orange, pineapple, passion fruit, papaya,
pomegranate, pear, plum, peach, persimmon, pluot, pomelo, pumpkin,
raspberry, strawberry, tamarind, tomato, watermelon, yuzu, or a
combination thereof. Some fruits may be considered vegetables. In
some embodiments, the vegetable sources may include, but are not
limited to, artichoke, asparagus, eggplant, alfalfa sprouts, bean
sprouts, black beans, chick peas, green beans, kidney beans,
lentils soy beans, peas, broccoli, broccoflower, cauliflower,
brussels sprouts, cabbage, carrot, celery, kale, spinach, bok choy,
chard, collard greens, mustard greens, lettuce, arugula, onions,
peppers, rhubarb, beets, ginger, parsnips, rutabaga, turnips,
radishes, sweetcorn, squash, potato, sweet potato, yam, zucchini,
or a combination thereof. Some vegetables may be considered fruits.
The fruit and vegetable sources may be in the form of puree, puree
concentrate, puree single strength, individual quick frozen (IQF),
fresh, frozen, fresh frozen, canned, dried, freeze-dried,
dehydrated, juice, milk, oil, natural coloring, natural flavoring,
or combinations thereof.
[0020] In some forms, the spoonable smoothie may also include
texturants, such as pectin, rice flour, tapioca flour, locust bean
gum, iota carrageenan gum, other starches, or a combination
thereof. Some texturants may also be considered a source of fiber.
In some embodiments, the pectin may include high methoxyl pectin,
low methoxyl pectin, or the like. In some aspects of the present
disclosure, texturants may also include high cellulose gum,
cellulose gel, guar gum, gellan gum, or a combination thereof. In
one aspect of the present disclosure, pectin LM12 may be used. In
some embodiments, the total amount of texturants may be in an
amount of 1.0% to 3.1%, 2.0% to 3.1%, 2.3% to 3.1%, 2.4% to 3.1%,
2.6% to 3.1%, or 2.8% to 3.1% of the total weight of the spoonable
smoothie. In some forms, the pectin may be in an amount of 0.20% to
0.35% or 0.25% to 0.30% of the total weight of the spoonable
smoothie. In some embodiments, rice flour may be in an amount of
1.0% to 2.0%, 1.25% to 1.75%, or 1.50% to 1.75% of the total weight
of the spoonable smoothie. In some embodiments, tapioca flour may
be in an amount of 0.2% to 1.2%, 0.4% to 1.0%, 0.5% to 1.0%, or
0.70% to 1.0% of the total weight of the spoonable smoothie. In
some embodiments, locust bean gum may be in an amount of 0.05% to
0.15%, 0.08% to 0.13%, or 0.10% to 0.13% of the total weight of the
spoonable smoothie.
[0021] Some embodiments may also include a protein source, such as
acid whey, whey protein isolate, soy, pea protein, or combinations
thereof. In some embodiments, the amount of the protein source may
be in an amount of 0.5% to 2.5%, 1.0% to 2.0%, 1.0% to 1.5%, or
1.1% to 1.3% of the total weight of the spoonable smoothie. Some
forms of the spoonable smoothie may also include a dairy component,
such as a yogurt. In some embodiments, the yogurt may be Greek,
Skyr or Icelandic, Australian, Balkan-style, Swiss-style, Labneh,
Lassi, Kefir, whole milk, reduced-fat, nonfat, unstrained, cow's
milk, goat's milk, sheep's milk, soy, rice, almond, coconut, or a
combination thereof. In some embodiments, the yogurt may also be
considered a protein source. In some embodiments, the dairy
component is between 15% and 25%, between 16% and 25%, between 17%
and 25%, between 18% and 25%, between 18% and 23%, or between 18%
and 21%.
[0022] Some embodiments of the spoonable smoothie may also include
a vitamin source, such vitamin A, vitamin B1 (thiamine), vitamin B2
(riboflavin), Vitamin B3 (niacin), Vitamin B5 (pantothenic acid),
Vitamin B6 (pyridoxine), Vitamin B7 (biotin) Vitamin B9 (folic
acid), vitamin B12 (cobalamin), Vitamin C, ascorbic acid, Vitamin
D, Vitamin E, Vitamin K, or a combination thereof. In some forms,
the vitamin source may be in an amount of 0.0004% to 0.025% of the
total weight of the spoonable smoothie. Some embodiments may
include a mineral source, such as iron, phosphorous, folate,
potassium, magnesium, calcium, selenium, sodium, zinc, or a
combination thereof. In some forms, the mineral source may be in an
amount of 0.2% to 0.4%, 0.25% to 0.35%, or about 0.345%. Some
embodiments of the spoonable smoothie may also include
preservatives.
[0023] Specific flavors for the spoonable smoothie may include but
not are limited to, e.g., triple berry-beet,
strawberry-banana-rhubarb, mango-pineapple-banana-carrot,
coconut-pineapple-banana-squash, green apple-kiwi-kale,
raspberry-peach, blueberry-apple, and harvest berry. Ranges of
product formulas that may be used in some embodiments are provided
below in Table 1.
TABLE-US-00001 TABLE 1 Ingredient Amount (%) Fruit and vegetable
sources 34-45 Dairy Component 18-22 Protein Source 1-3 Sugar
2.5-7.sup. Texturants 2-4 Color 0-3 Flavor 0-3 Vitamin 0-3 Mineral
0-3 Water 20-40 Preservatives 0-1
[0024] One challenge of producing a spoonable smoothie is the
effect of UV light exposure on the color, organoleptic properties,
and nutritional value, all of which affect the shelf life of the
spoonable smoothie. For example, when exposed to light for extended
periods, such as in a refrigerated dairy display case in a grocery
store, one or more protein components or other components may
degrade and/or break down. Protein degradation may result in a
change in color, texture, or taste of the spoonable smoothie.
Oxidation of unsaturated fatty acids may be associated with
off-flavors and/or loss of nutrients. This oxidation may occur
rapidly under exposure to high intensity light, or over a longer
period of time under exposure to less intense fluorescent lighting.
Light may also affect nutritional ingredients such as vitamins and
minerals in the spoonable smoothie. For example, riboflavin
(Vitamin B2) can be destroyed by ultraviolet light. To combat
detrimental effects of light exposure, the package containing the
spoonable smoothie may be opaque or may be surrounded by a
non-transparent label. A translucent/transparent package may be
more attractive to a potential customer, and can provide a benefit
by enabling potential purchasers to view the contents, but may
allow the spoonable smoothie to be more susceptible to light
exposure. In some embodiments, the sides of the package may be
covered by a non-transparent label, but the bottom of the package
may be transparent. In some embodiments, a light blocking barrier
may be employed to reduce deleterious effects of light exposure.
Increasing amounts of one or more fruit and/or vegetable components
while decreasing amounts of one or more sources of protein and/or
unsaturated fatty acids (e.g., by decreasing amounts of dairy
components) in the spoonable smoothie composition may reduce
deleterious effects of light exposure. Further, employing a low-fat
or no-fat dairy source or yogurt or an oxygen barrier may help
reduce or prevent issues with off notes detected as a result of the
oxidation.
[0025] Another challenge of producing a smoothie with a fibrous,
non-chalky, spoonable texture is avoiding protein coagulation or
sedimentation that may cause grittiness. In some embodiments, the
order of ingredients added may help prevent protein precipitation,
coagulation, or sedimentation. For example, it is believed that
whey protein isolate and pectin may directly compete for water
absorption, and that if the whey protein isolate absorbs too much
water, then the resulting texture of the smoothie may be grainy. If
the pectin absorbs too much water, then the resulting texture of
the smoothie may be gel-like. Adding the pectin and the whey
protein isolate at the same time may impair the functionality of
one or both of the pectin and the whey protein isolate. However, it
is believed that when a non-processed form of whey, such as acid
whey, replaces the whey protein isolate in the same amounts, the
grainy or gel-like texture may be avoided. In some embodiments,
whey protein isolate and pectin may be hydrated separately to
ensure that each ingredient only absorbs the desired amount of
water to create the unique, fibrous, non-gritty, non-chalky,
spoonable texture. Additional embodiments to help prevent protein
sedimentation or coagulation may include the presence of buffering
salts to increase pH, the replacement of pectin with iota
carrageenan gum (as seen in the use of almond milk), and the
addition of muriatic acid to lower the pH below 2.
[0026] After the spoonable smoothie is produced, high-pressure
processing (HPP) or a thermal process may be employed to inactivate
spoilage organisms and/or to otherwise increase stability. In some
embodiments, HPP may occur for about 4 to 6 minutes, or
specifically about 5 minutes, at a pressure of between 58 k Psi and
87 k Psi, between 63 k Psi and 87 k Psi, between 68 k Psi and 87 k
Psi, between 73 k Psi and 87 k Psi, between 78 k Psi and 87 k Psi,
between 80 k Psi and 87 k Psi, or about 86 k Psi and at a
temperature of about 0.degree. C. to about 10.degree. C., or
specifically at about 5.degree. C. In some embodiments, thermal
processing may be completed in a tube-in-tube heat exchanger,
shell-and-tube heat exchanger, plate heat exchanger,
scraped-surface heat exchanger, or other apparatus. In some
embodiments, the thermal processing may occur at about 160.degree.
F. to 180.degree. F., or at about 170.degree. F., for about 20 to
40 seconds, or specifically about 30 seconds. Any of the processes
may be carried out in a manner that hinders or prevents denaturing
or precipitation of proteins. The hindrance or prevention of
protein coagulation may ultimately prevent the release of free
water from the matrix, which may help maintain the unique,
homogenous, fibrous texture of the spoonable smoothie. This texture
may be somewhere between that of a full-fat dairy yogurt and a full
fat, high-protein Greek yogurt. This texture may be spoonable,
non-chalky, non-gritty, and/or fibrous, may have a water activity
greater than about 0.85 and a degree of Brix of 13 to 24, about 14
to about 18, or about 14.5.
[0027] In some embodiments of the spoonable smoothie produced using
HPP, further adjustments may be made to ensure the desired
consistency of a smoothie with a fibrous, non-gritty, spoonable
texture. For example, when HPP is employed to inactivate spoilage
organisms, the resulting embodiment may not have the desired
viscosity, mouth feel, and firmness. However, the use of acid whey
rather than whey protein isolate as a protein source may help
improve the viscosity to the fibrous, non-gritty, spoonable
texture. In other aspects of producing a spoonable smoothie using
HPP, an increased amount of iota carrageenan may also improve the
viscosity of the spoonable smoothie. In yet other embodiments, the
use of homogenized yogurt may also improve the viscosity of the
spoonable smoothie.
[0028] FIG. 1 shows a method 100 of producing a spoonable smoothie
using high-pressure processing. The method 100 includes preparing a
hot mixture 102 from an amount of pectin, an amount of sugar, and
an amount of hot water to hydrate the pectin. The hot water may be
at a temperature of between 90.degree. F. and 120.degree. F.,
between 95.degree. F. and 110.degree. F., or about 100.degree. F.
In some embodiments with gums, such as iota carrageenan, the gums
may also be added to the hot mixture to avoid fish eyes (i.e.,
undesirable clumping of the gum). The addition of sugar in the
pectin/water mixture may help disperse the pectin at a later step.
The method 100 also includes separately preparing a first cold
mixture 104 from a fruit source, a vegetable source, and a yogurt.
The method 100 further includes preparing a second cold mixture 106
from a whey protein source, such as acid whey, and an amount of
cold water to hydrate the whey protein source. The method 100
includes combining, cold mixing, and shearing 108 the hot mixture
and both cold mixtures together to form a final mixture. The method
100 includes filling 110 the final mixture into packages. The
method 100 further includes processing 112 the packages through
high-pressure processing to inactivate microorganisms.
[0029] Another method of producing a spoonable smoothie shows a
first mixture created from an amount of protein source and an
amount of water to hydrate the protein source. Separately, a second
mixture is created from an amount of pectin and an amount of water
to hydrate the pectin. Vegetable and fruit sources are sheared
together to form a third mixture. The first, second, and third
mixtures are cold mixed and sheared together with an amount of
sweetener, an amount of yogurt, and an amount of a texturant to a
final mixture. Any natural colors or flavors may also be added. The
final mixture is heated in a first heat exchanger, transferred to a
hold tube, then cooled in a second heat exchanger. The final
mixture is then cold filled into a package, which is then sealed.
In some embodiments, the final mixture may be ambient filled into
the package.
[0030] FIGS. 2-5 show an exemplary method 200 of the production of
a spoonable smoothie. FIG. 2 shows a process 202 for separately
hydrating pectin. The texturants and pectin may be pre-blended in
their dry states with about 50% of the sugar using a ribbon
blender. About 75% of the total water required may be added to a
high shear mixer 204, such as a Breddo mixer. The pre-blended
texturant/sugar mixture may be metered into the high shear mixer
204 over a period of about 10 to about 30 minutes. The resulting
texturant/sugar slurry may be mixed for a minimum of about 10
additional minutes from the time of the last powder addition. The
texturant/sugar slurry may be directly added to a batch tank/high
shear mixer 206. A pump 208, such as a Likiwifier pump, and a shear
pump 210, such as a Silverson or a Dispax, may help transfer the
texturant/sugar slurry between the mixer 204 and the batch
tank/high shear mixer 206.
[0031] FIG. 3 shows a process 212 for separately hydrating the
protein source. A whey protein isolate may be separately hydrated
in a manner where foaming is minimized, such as a high shear mixing
process under vacuum, for example, a Semi Bulk system 214. The
remaining 25% of the water may be warmed and added to the Semi Bulk
system 214. However, the water should not exceed 130.degree. F. to
prevent protein denaturation. In some methods, the water is between
110.degree. F. and 130.degree. F. or about 120.degree. F. The whey
protein isolate may be drawn into the solution through a commingle
nozzle. Due to the high shear created by the circulation of water
to incorporate the whey protein isolate, a vacuum may be needed
during hydration to prevent foaming. Minerals, such as calcium
citrate, may also be added and mixed in with the whey protein
isolate at this step. A pump 216, such as a Likiwifier pump, and a
shear pump 218 may help transfer the protein/mineral slurry between
the mixer 214 and the batch tank/high shear mixer 206.
[0032] Any vitamins powdered forms which may be needed for the
desired formulation may be mixed in with the remaining 50% of the
sugar. This mixing may take place in a bag, a vat, a tank, or any
other appropriate container.
[0033] With respect to the fruit and vegetable sources, some
formulations of the spoonable smoothie may require fruit or
vegetable ingredients not available as purees. If any ingredients
are individually quick frozen (IQF), then those IQF ingredients may
be slacked out in refrigerated conditions and processed in a high
shear chopping process to create a puree. FIG. 4 shows the process
220 for preparing the fruit and vegetable sources. The IQF fruits
and vegetables may be added to a grinder hopper 222 before grinding
in a grinder 224. The grinded IQF fruits and vegetables may be
combined with fruit and vegetable purees in a puree hopper 226. The
resulting fruit and vegetable mix may be directly added to the
batch tank/high shear mixer 206 via pump 228.
[0034] Referring to FIG. 5, all fruit and vegetable purees, any
other fruit and vegetable sources, and any desired yogurt may be
added to the batch tank/high shear mixer 206 to blend with the
texturant/sugar slurry. Flavor may then be added to the batch
tank/high shear mixer 206. The sugar and vitamin combination may
then be added to the batch tank/high shear mixer 206. The color may
be added after or before the vitamin/sugar combination or the
flavor. Lastly, the protein/mineral slurry may be added to the
batch tank/high shear mixer 206 to help prevent denaturation of the
protein. After a possible recirculation to help prevent the
texturants from clogging the system, the final mixture may be
emptied from the batch tank/high shear mixer 206.
[0035] The final mixture may be pumped to a balance tank 230, then
directly to two scraped surface heat exchangers 232, 234. The first
heat exchanger 232 may preheat the final mixture to approximately
140.degree. F. The second heat exchanger 234 may heat the final
mixture to between 172.degree. F. and 175.degree. F. The final
mixture may then enter a hold tube 236 designed to provide a
minimum of 170.degree. F. throughout hold for a minimum of about 30
seconds. The flow rate of the final mixture may be approximately 10
to 12 gallons per minute. From the hold tube, the final mixture may
enter a series of three double-walled scraped surface heat
exchangers 238, which may reduce the final mixture to a temperature
between 50.degree. F. and 60.degree. F. after the third heat
exchanger. The final mixture may be maintained at a temperature
below about 75.degree. F. to maintain a desired quality. In some
methods, the final mixture is cooled to between 30.degree. F. and
45.degree. F., between 35.degree. F. and 40.degree. F., or about
42.degree. F. The final mixture may proceed to a holding tank 240,
filling/sealing machinery 242, and then packaging 244.
[0036] The mouth texture and spoonability of the spoonable smoothie
may be quantified by analyses of the viscosity of the embodiments
disclosed herein. The zero shear viscosity, representative of mouth
texture, is related to the internal structure of the sample and is
independent of applied strain. Yield stress, the minimum stress
required for the material to start flowing, is estimated as the
product of zero shear viscosity and critical shear rate, where
critical shear rate is the minimum shear rate at which the material
starts shear thinning. Yield stress is representative of the
spoonability of the sample.
[0037] Samples of the spoonable smoothies were analyzed by a
Discovery Hybrid Rheometer DHR-3 (TA Instruments located in New
Castle, Del.). A flow ramp test was executed to determine
viscosity, as a measured function of shear rate between 0.001 (1/s)
and 1000 (1/s) at a constant temperature of 5.degree. C. Total ramp
time was 900 s with data collected at 30 points per decade.
Viscosity was tested for embodiments produced using HPP and for
embodiments produced using thermal processing.
[0038] Four of the samples analyzed were produced by HPP (shown in
Table 2). Sample 1 is a control sample produced with whey protein
isolate as the protein source and locust bean gum as a texturant.
Sample 2 is a sample produced with acid whey as the protein source
and locust bean gum as a texturant. Sample 3 is a sample produced
with whey protein isolate as the protein source and iota carageenan
as a texturant. Sample 4 is a sample produced with whey protein
isolate as the protein source and locust bean gum as a texturant,
except that the dairy source is a homogenized yogurt. Seven of the
samples were produced by thermal processing (shown in Tables 3). In
all samples, the base includes the fruit and vegetable sources and,
if any, flavors, colors, vitamins, and minerals.
TABLE-US-00002 TABLE 2 Samples produced via high-pressure
processing method Amount (%) Ingredient Sample 1 Sample 2 Sample 3
Sample 4 Base 44.52 46.20 43.32 44.82 Dairy Component 19 19 19 19
Protein Source 1.18 13.5 1.18 1.18 Texturants 1.30 1.30 2.5 1.0
Sugar 3.0 3.0 3.0 3.0 Water 31 17 31 31
TABLE-US-00003 TABLE 3 Samples produced via thermal processing
method Amount (%) Ingredient Sample 5 Sample 6 Sample 7 Sample 8
Sample 9 Sample 10 Sample 11 Base 41.455 46.862 42.991 45.922
43.322 42.315 42.345 Dairy Component 19 19 19 19 19 19 19 Protein
Source 1.18 1.18 1.18 1.18 1.18 1.18 1.18 Texturants 2.905 2.925
3.025 3.050 3.050 2.900 3.050 Sugar 7.0 6.70 7.00 6.70 2.720 2.800
4.950 Water 28.46 23.333 26.84 24.148 30.728 31.805 29.475
[0039] FIG. 6 is the graph data generated when the rheometer
analyzed the viscosity of the four samples in Table 2 as a function
of shear rate at a constant temperature. FIG. 7 is the graph of
data generated when the rheometer analyzed the viscosity of Samples
5-8 in Table 3 as a function of shear rate at a constant
temperature. FIG. 8 is the graph of data generated when the
rheometer analyzed the viscosity of Samples 9-11 in Table 3 as a
function of shear rate at a constant temperature.
[0040] The data from the analyses and resulting graphs were fit to
the Williamsons Model:
.eta. = .eta. 0 1 + ( c .times. .times. .gamma. . ) 1 - n
##EQU00001##
[0041] where, .eta.=viscosity at a shear rate of {dot over
(.gamma.)}; .eta..sub.0=zero shear viscosity; c=rate constant (the
inverse of the rate constant will give the critical shear rate
where the material will begin shear thinning); n=flow index (n will
vary between 0 and 1); and K=consistency; it is the viscosity at a
shear rate of 1.0 (1/s) and can be estimated using the CROSS model
as
.eta. = .eta. 0 1 + ( c ) 1 - n . ##EQU00002##
[0042] The Williamsons Model calculated the zero shear viscosity
(representing mouth texture) and critical shear rate, from which
yield stress (representing spoonability) was calculated. As shown
below in Table 4, Samples 2-11 had improved mouth texture (greater
zero shear viscosity) and spoonability (greater yield stress) than
the control (Sample 1). In some embodiments, the zero shear
viscosity may be at least 4,500 Pas; at least 4,600 Pas; at least
4,700 Pas; at least 4800 Pas; at least 4900 Pas; at least 5000 Pas;
at least 5500 Pas; at least 6000 Pas; at least 6500 Pas; at least
7000 Pas; at least 7500 Pas; at least 8000 Pas; at least 8500 Pas;
at least 9000 Pas; at least 10,000 Pas; at least 15,000 Pas; at
least 20,000 Pas or between about 4500 Pas and 98,000 Pas. In some
embodiments, the yield stress may be at least 10 Pa, at least 15
Pa, at least 20 Pa, at least 25 Pa, at least 30 Pa, at least 35 Pa,
at least 40 Pa, at least 50 Pa, at least 100 Pa, at least 200 Pa,
at least 300 Pa, at least 400 Pa, at least 500 Pa, at least 1,000
Pa, at least 1,500 Pa, or between about 15 Pa and about 1620
Pa.
TABLE-US-00004 TABLE 4 Infinite Zero Shear Shear Critical Viscosity
Viscosity Shear Rate Flow Yield Stress Sample (Pa s) (Pa) (1/s)
Index (Pa) 1 1281 0.0691 0.0020 0.22 3 2 17628 0.0941 0.0007 0.14
1612 3 97223 0.6385 0.0036 0.00 349 4 26797 0.1024 0.0010 0.02 28 5
4675 0.1024 0.0050 0.16 23 6 4531 0.1162 0.0035 0.18 16 7 7794
0.0826 0.0032 0.17 25 8 6928 0.1372 0.0045 0.13 31 9 8447 0.0983
0.0035 0.14 29 10 8853 0.0770 0.0027 0.16 24 11 6913 0.1147 0.0047
0.13 32
[0043] The firmness of the spoonable smoothie may be measured in a
frequency sweep test which represents the gel strength of the
embodiments disclosed herein. Samples of the spoonable smoothies
were analyzed by a Discovery Hybrid Rheometer DHR-3 (TA Instruments
located in New Castle, Del.). A frequency sweep test was executed
to determine the linear viscoelastic properties of the material, as
a measured function of frequency at a test temperature of 5.degree.
C. The test geometry was a 40 mm cross hatched parallel plate with
60 mm cross hatched bottom plate with a geometry gap of 2 mm.
Firmness was measured for Samples 1-11 produced using HPP or
thermal processing.
[0044] FIG. 9 is the graph of data generated when the rheometer
analyzed the firmness of Samples 1-4 as a function of frequency at
a constant temperature. FIG. 10 is the graph of data generated when
the rheometer analyzed the firmness of Samples 5-8 as a function of
frequency at a constant temperature. FIG. 11 is the graph of the
data generated when the rheometer analyzed the firmness of Samples
9-11 as a function of frequency at a constant temperature.
[0045] G1 is the firmness of a sample at the frequency of 1 rad/s.
Complex viscosity is viscosity during forced harmonic oscillation
of shear stress (i.e., how viscous the sample remains when both
stress and strain vary harmonically with time). Relaxation time may
be indicative of network structure of a material. Samples with
stronger network structures will have longer relaxation times. As
shown below in Table 5, Samples 2-11 had improved firmness (greater
G1) and stronger network structures (longer relaxation times),
except Sample 2, than the control (Sample 1). In some embodiments,
the firmness may be at least 70 Pa, at least 100 Pa, at least 110
Pa, at least 120 Pa, at least 130 Pa, at least 140 Pa, at least 150
Pa, at least 160 Pa, at least 170 Pa, at least 180 Pa, at least 190
Pa, at least 200 Pa, at least 210 Pa, at least 220 Pa, at least 500
Pa, at least 1,000 Pa, at least 1,500 Pa, or between about 115 Pa
and about 1790 Pa.
TABLE-US-00005 TABLE 5 Complex Viscosity G1 (Pa) CV1 Relaxation
Sample Firmness (Pa) Time 1 47.830 45.176 2.876 2 77.272 72.601
2.744 3 1786.988 1749.067 4.776 4 115.488 111.573 3.742 5 140.074
136.193 4.159 6 138.965 134.468 3.834 7 197.341 192.167 4.281 8
199.504 194.442 4.354 9 193.837 189.117 4.448 10 215.787 210.660
4.505 11 223.807 217.984 4.298
[0046] Yet another challenge to producing a smoothie with a
fibrous, non-gritty, spoonable texture may occur when the mixture
is fortified with minerals and vitamins, or a combination thereof.
Specifically, the addition of riboflavin as a source of Vitamin B2
may add (or intensify) an orange color. In some embodiments,
thiamine hydrochloride may be used instead of riboflavin, which may
help prevent any undesirable orange coloring. In some embodiments,
addition of calcium carbonate as a source of the mineral, calcium,
may cause unwanted precipitation in the spoonable smoothie, which
may result in an undesirable texture. In some embodiments, calcium
citrate may replace calcium carbonate, and may help provide a more
desirable texture. The calcium citrate may be added with sugar
later in the process rather than with the whey protein isolate when
the whey protein isolate is hydrated.
[0047] In some embodiments, there is provided a spoonable smoothie
product that is entirely or almost entirely natural (with minimal
or no artificial ingredients, preservatives, colors, or flavors)
with a refrigerated shelf life of at least 15 days, at least 30
days, at least 45 days, or between about 142 days. In some
embodiments, the product may have a longer refrigerated shelf life,
e.g., 60 days, 75 days, 90 days, or 142 days. In some embodiments,
the product may be packaged in a polymeric cup made of
polypropylene, PET, or other food grade materials, with a peelable
foil lid.
[0048] In some embodiments, the cup may be entirely or partly
transparent or translucent. This may result in the smoothie
composition being exposed to light during its shelf life. Ideally,
in addition to having microbial stability for its entire shelf
life, the product will also have flavor and color stability as well
as nutritional stability for its entire shelf life, when exposed to
light typically associated with retail display, e.g., light
intensity typically associated with a refrigerated display case in
a supermarket. In some embodiments, the smoothie will have a color,
texture and flavor comparable to those of a freshly made smoothie
made from fresh fruit and other fresh ingredients, including a
fibrous texture obtained by use of a blender, wherein bits of pulp
and/or other solids, seeds, or fibrous materials contribute to a
desirable mouthfeel. In some embodiments, the bits of pulp and/or
other solids, seeds, or fibrous materials may not be larger than
the width of a drinking straw such that they may be drinkable
through a straw. In some embodiments, the smoothie may leave little
to no mouth coating after it is consumed. In some embodiments, the
spoonable smoothie may have a vibrant color. In some embodiments,
the pH of the spoonable smoothie may be 3.6 to 4.3, and preferably
3.6 to 4.0.
[0049] The spoonable smoothie may be self-supporting, so that a
spoonful of the smoothie composition in any particular spoon may,
if desired, have a volume greater than a spoonful of liquid in the
same spoon, while still being flowable. Particularly, the smoothie
may have a viscosity between about 10,000 Pas to about 30,000 Pas,
or between about 15,000 Pas and 17,000 Pas at refrigerated
temperatures. All viscosities refer to zero shear viscosity
measured using the rheometer by TA Instruments. In some
embodiments, the viscosity and the texture may be somewhere between
that of a full-fat dairy yogurt and of a high-protein Greek
yogurt.
CONCLUSION
[0050] Each of the various features described above may be used in
combination with any other compatible features described above, or
with features not described herein. Various aspects of the products
and processes described herein are further described in the
following claims. Unless otherwise noted, all percentages are
percentages by weight.
* * * * *