METHOD FOR MAKING FOOD PRODUCTS WITH HIGH FIBER AND REDUCED CALORIES

Abstract

A method of making a starch based food product selected from baked goods, breads, cakes, cereals, pasta, and pastries, and having 1 to 3.25 calories per gram, on a dry weight basis. The method comprises the step of mixing a type IV resistant starch with ingredients of the food product (optionally with flavor enhancers which do not raise the calories above 3.25 calories per gram), in a sufficient amount wherein a total dietary fiber content of the prepared food product, arising from the type IV resistant starch, comprises 14-60% of the prepared food product, by weight, after subsequent preparing of the prepared food product at the temperature of at least 100° C. The food product is prepared for consumption at the temperature of at least 100° C.

Claims

1. A method of making a starch based food product selected from the group consisting of baked goods, breads, cakes, cereals, pasta, and pastries, wherein the food product is prepared from ingredients subjected to a temperature of at least 100° C. prior to consumption use, and wherein the prepared food product has 1 to 3.25 calories per gram, on a dry weight basis, wherein the method comprises the steps of: a) mixing a type IV resistant starch with ingredients of the food product, in a sufficient amount wherein a total dietary fiber content of the prepared food product, arising from the type IV resistant starch, comprises 14-60% of the prepared food product, by weight, after subsequent preparing of the prepared food product at the temperature of at least 100° C., b) optionally adding flavor enhancers to the food product, while maintaining the calorie level of the food product to be no greater than 3.25 calories per gram of the food product, and c) preparing the food product at the temperature of at least 100° C.

2. The method of claim 1 wherein the food product is selected from the group consisting of cookies, cakes, crisps, instant noodles, crackers, cheese crackers, pasta, muffins, brownies, breakfast cereals, pizza crust, bread, doughnuts; biscuits, pie, wafers and egg noodles.

3. The method of claim 1 wherein the added resistant starch is in the form of one of a batter, a mix and a dough for making the prepared food product at the temperature of at least 100° C.

4. The method of claim 1 with herein the food product is prepared to have in the range of 1 to 2.66 calories per gram, on a dry weight basis in the prepared food product.

5. The method of claim 1 wherein the starch is a sole flour ingredient of the prepared food product.

6. The food product of claim 1 wherein a flour ingredient of the prepared food is comprised of starch and gluten.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0030] It has been experimentally determined that the amount of resistant starch that can be added to a product varies greatly depending on the type (RS-III, RS-II, or RS-IV) of the resistant starch being utilized. In extensive experiments it was found that:

[0031] When RS-III was used, then when the Percentage of the Final Food Product which is Resistant to Digestion (“PFFPRD”) was above around 11%, creation of a product acceptable in organoleptic evaluation was unable to be made. Somewhat acceptable results were obtained at around 7% PFFPRD.

[0032] When RS-II was used, then when the PFFPRD was above around 20% creation of a product acceptable in organoleptic evaluation was unable to be made. Somewhat acceptable results were obtained at around 14% PFFPRD.

[0033] Surprisingly when RS-IV was used, then even when the PFFPRD was as high as 60% a product acceptable in organoleptic evaluation was readily obtained.

[0034] Another way at looking at this is seeing the Percentage of the Flour-Component which is Resistant (“PFCR”) to digestion as compared to the total flour component (column D). This percentage is stated in a different way in the prior art patents in Table 2, which typically give the Percentage of the Starch which is Resistant to digestion (second column) and Percentage of the Flour-component which was Replaced with Starch (third column). These two factors were taken and multiplied to arrive at the Percentage of the Flour-component which is Resistant to digestion (fourth column). In all the experiments cited in the existing patent literature, the PFCR was at most 23.5%.

[0035] In further extensive experiments it was found that

[0036] When RS-III was used, then when the PFCR was 30%, creating a product acceptable in organoleptic evaluation was not possible. Somewhat acceptable results were obtained at 15% PFCR.

[0037] When RS-II was used, then when the PFCR was 60% creating a product acceptable in organoleptic evaluation was not possible. Somewhat acceptable results were obtained at 30% PFCR.

[0038] When RS-IV was used, then even when PFCR was 80%, creation of a product acceptable in organoleptic evaluation was readily possible.

[0039] The rationale behind this discovery seems to be that since RS-III's retrogradation destroys its granular structure:

[0040] a) RS-III has a higher level of water absorption which makes it difficult to form into a dough, with textural issues when creating a dry product and not allowing the granules to fully swell; and

[0041] b) the particles of RS-III are irregular and amorphous, with no definite size or shape, resulting in a grainy texture in finished products

[0042] In contrast, RS-II maintains more of the granular structure, and therefore performs better in formulations. But since its granular structure is unprotected, it is often broken down to an extent in processing, resulting in similar negative effects to those observed in RS-III.

[0043] RS-IV has cross-links which provide a protective barrier not only against digestive enzymes (amylase), but also of the granular structure. This makes it the most workable and acceptable form for the products claimed in this patent.

[0044] Consequently, in accordance with the present invention and included there are all products utilizing RS-IV with a PFFRD from 14-60%, and/or a PFCR from 25-80%. Additionally, all products utilizing RS-II with a PFFRD from 14-20% and/or a PFCR from 25-30% are within the scope of the present invention.

EXPERIMENTAL EXAMPLES

[0045] The resistant starches which were used for these experiments fit into three of the resistant starch categories described above, namely types II, III, and IV. FiberSym 70 and FiberSym 80 are type IV resistant starches derived from wheat and potato starches, with 70% and 80% resistant starch content, respectively, and are supplied by MGP Ingredients, Inc. GemStar R70 is also a type IV resistant starch derived from wheat starch with 70% resistant starch content. It is manufactured by Manildra Group USA using an undisclosed process, which the manufacturer claims is not identical to that employed in the FiberSym starches. Novelose 260 is a type II resistant starch with 60% resistant starch, and Novelose 330 is a type III resistant starch with 30% resistant starch. Both of the Novelose starches are derived from corn starch, and are supplied by National Starch and Chemical Company. ActiStar 11700 is a type III resistant starch derived from tapioca starch (maltodextrin), with 50% resistant starch content, and is supplied by Cargill Inc. Other non-resistant starches used as controls in the experiments include unmodified potato and corn starches.

[0046] Unmodified potato and corn starches exhibit low water binding capacity, of about 91% and 95% their weight in water, respectively. These starches also leach significant quantities of amylose, and to a higher degree in corn starch than in potato.

[0047] The chemical treatment undergone by FiberSym 70 and FiberSym 80 to become partially resistant to digestion allows the granular structure of the starch to remain intact, except for some minor shrinkage, resulting in the maintenance of a low water binding capacity, of about 70% and 80% their weight in water, for FiberSym 70 and FiberSym 80 respectively. Additionally, the processing reduces the amount of amylose leakage from the granules. The GemStar R70 performs similarly to the FiberSym.

[0048] Novelose 260 (RS type II) is considered a “natural” resistant starch, and its granular structure is unaffected during the processing. Its water binding capacity is somewhat elevated, however, since it is able to bind 115% of its weight. By contrast, in Novelose 330 (RS type III) the entire starch, even the enzyme-susceptible component, is altered during processing through thermal retrogradation, and the entire granular structure is lost. Its water binding capacity increases to 200% of its weight. ActiStar 11700 performs similar to the Novelose 330.

[0049] Olean is an indigestible oil (sucrose polyester) supplied by the Procter & Gamble Company, and approved by the FDA for use in fried snack products, such as the crisp experiments described below.

[0050] I. Cookies

[0051] These experiments were conducted by combining and blending the dry ingredients thoroughly, in the order given below. The wet ingredients were then combined in the order given below and added to the dry ingredients. Water was added until it formed an acceptable batter. In cases where too much water was added, additional starch was added to compensate, as recorded below. The dough was then formed into 10 flattened circular cookies 1.5-inches in diameter (similar to standard “Nilla” wafers), placed onto a greased cookie sheet, and baked at 375 Fahrenheit until lightly browned. The exact baking time is recorded below.

[0052] Some experiments employed quantities of standard unbleached all-purpose wheat flour in addition to the starch. Those experiments, and the quantities of flour used, are indicated in the Flour Quantity column. All material units are in grams and times are in minutes.

[0053] Base Ingredients:

TABLE-US-00003 Starch (see below) (see below for quantity) Crisco 2.5 Sugar 5 Corn Syrup 5.5 Condensed Milk 5 Vanilla (McCormick) 1 Salt 0.1 Whole Egg 4 Gluten 4 Baking Powder 0.3 Xanthan Gum 0.1

TABLE-US-00004 Experiment Starch Starch Flour Water Bake Number Type Quantity Quantity Quantity Time Notes 1 Unmodified 27 8 8, 12 Good, slightly tougher Corn Starch texture 2 Unmodified 30 2.5 8 Good Potato Starch 3 FiberSym 70 25 2.5 8 Good (RS-IV) 4 FiberSym 80 25 2.5 8 Good (RS-IV) 5 Novelose 260 25 12 8, 14 (High moisture) (RS-II) Starchy initially, turned wet and mushy the next day 6 Novelose 260 25 5 8, 12 (Low moisture) (RS-II) Starchy, chalky 7 Novelose 260 25 2.5 NA Unable to form dough (RS-II) 8 Novelose 260 12.5 12.5 3 8 A bit moist, maybe some (RS-II) starchiness, but nominally acceptable 9 Novelose 330 25 14 8, Dense, chewy, nearly (RS-III) 12, inedible; too chalky, 14 awful 10 Novelose 330 25 2.5 NA Unable to form dough (RS-III) 11 Novelose 330 12.5 12.5 8.5 8, 10 Also moist, slight degree (RS-III) of graininess and starchiness, but edible; not as light as the type IV cookies Baked some for another 2 minutes, which helped reduce moistness 12 ActiStar 25 2.5 8 Awful, grainy, sticks to 11700 teeth (RS-III) 13 GemStar R70 25 2.5 8 Slightly starchy (RS-IV) A bit dense, odd odor, but nominally acceptable

[0054] Summary: Using the FiberSym 80 product, which contains the highest percentage of resistant starch, and provides a very acceptable product, the final product provides 2.66 calories per gram on a dry weight basis, well within the range of 1 to 3.25 calories per gram of the present invention.

[0055] II. Chocolate Cake

[0056] These experiments were conducted by combining and blending the dry ingredients thoroughly, in the order given below. The wet ingredients were then combined in the order given below and added to the dry ingredients. Water was added until it formed an acceptable batter. The amount of water is variable, and is recorded below. The batter was then poured into a greased loaf pan, and baked at 350 degrees Fahrenheit for at least 15 minutes.

[0057] Base Ingredients:

TABLE-US-00005 Starch (see below) 26 Sugar 10 Ghirardelli chocolate 5 Baking Powder 0.7 Nutrasweet 0.5 Xanthan Gum 0.3 Baking Soda 0.2 Condensed Milk 5 Vanilla Extract 1 Whole Eggs 20

TABLE-US-00006 Experiment Number Water Starch Type Notes 1 20 FiberSym 80 Batter was runny (RS-IV) Final product was good and cake-like 2 20 FiberSym 70 Batter was runny (RS-IV) OK, but not as good as the FS-80 3 20 Novelose 260 (Low moisture) (RS-II) Batter was sticky Final product was wet and gummy after 15, so put half back in for another 10 minutes Neither version (baked for 15 or 25) was very good 4 35 Novelose 260 (High moisture) (RS-II) Batter was runny Baked for 25 minutes total, in attempt to dry it out to an acceptable texture Final product was gummish, brownie-like 5 35 Novelose 330 Batter was too dry with 20 g water, so upped to (RS-III) 35. Batter at that point was sticky, similar to the Novelose 260. Was wet and gummy after 15, so put back in for another 10 minutes Bad, grainy, starchy, nearly inedible; worse than the Novelose 260, even. 6 20 Unmodified Good, perhaps a bit tough Corn Starch 7 20 Unmodified Too rubbery, elastic Potato Starch

[0058] Summary: Using the FiberSym 80 product, which contains the highest percentage of resistant starch, and provides a very acceptable product, the final product provides 2.39 calories per gram on a dry weight basis, within the range of 1 to 3.25 calories per gram of the present invention.

[0059] III. Crisps 1

[0060] These experiments were conducted by combining the starch and salt with 3 g of Vital Wheat Gluten and 15 g of water. Additional gluten and water were added in 1 g and 2 g increments (respectively) until the dough attained an appropriate machineable consistency. The dough was then rolled through a hand-operated double roller to achieve a uniform thickness, cut into strips, baked for 12 minutes at 375 degrees Fahrenheit, and fried in Olean for 1 minute at 375 Fahrenheit.

[0061] Base Ingredients:

TABLE-US-00007 Starch (see below) 25 Gluten (initial) 3 Water (initial) 15 Salt 1

TABLE-US-00008 Experiment Added Added Number gluten water Starch type Notes 1 4 Unmodified Very crunchy, a Corn bit sticky on teeth Starch 2 0 Unmodified Very crunchy Potato Starch 3 10 Novelose 260 Stuck to teeth (RS-II) 4 3 22 Novelose 330 Burnt, gritty (RS-III) 5 4 FiberSym 70 Brittle, crumby, (RS-IV) a little starchy 6 4 FiberSym 80 Very crunchy, tiny bit (RS-IV) starchy, but doesn't stick to palate

[0062] IV. Crisps 2

[0063] These experiments were conducted by combining the starch and salt with 3 g of Vital Wheat Gluten and 15 g of water. Additional gluten and water were added in 1 g and 2 g increments (respectively) until the dough attained an appropriate machineable consistency. The dough was then rolled through a hand-operated double roller to achieve a uniform thickness, cut into strips, baked for 10 minutes at 375 degrees Fahrenheit, and fried in Olean for 30 seconds at 375 Fahrenheit.

[0064] Base Ingredients:

TABLE-US-00009 Starch (see below) 25 Gluten (initial) 3 Water (initial) 15 Salt 1

TABLE-US-00010 Experiment Added Added Number gluten water Starch type Notes 1 4 Unmodified Good, crunchy, but Corn Starch tough 2 0 Unmodified Excellent. Very crispy, Potato Starch a little hard 3 10 Novelose 260 Good. A little softer (RS-II) and starchier. Some aftertaste. 4 3 20 Novelose 330 Awful, inedible (RS-III) 5 4 FiberSym 70 Brittle, crumby, a (RS-IV) little starchy, silty, tough to chew 6 2 FiberSym 80 Excellent, very crispy (RS-IV)

[0065] Summary: Using the FiberSym 80 product, which contains the highest percentage of resistant starch, provides a very acceptable product, the product, prior to frying in Olean, provides 1.15 calories per gram on a dry weight basis, within the range of 1 to 3.25 calories per gram of the present invention. Since Olean contributes no calories, but some weight, the final product would provide even fewer calories. The actual number is unknown, due to the difficulties inherent in estimating Olean uptake, but it is estimated to be at least as low as 1 calorie per gram.

[0066] V. Standard Pasta

[0067] All of the ingredients were combined and kneaded for 5 minutes. The dough was then formed into a ball and allowed to rest for 5 minutes. It was then rolled through a hand-operated double roller to a uniform thickness, cut into strips, and hung to dry for 8 hours. Finally the pasta was boiled in water for 5-10 minutes, until al dente.

TABLE-US-00011 Starch (see below for starch 21 type) Gluten 6 Salt 0.3 Whey Protein Concentrate 1

TABLE-US-00012 Experiment Number Starch type Water Notes 1 Novelose 20 Refused to cook and get limp 260 Starchy, grainy; unacceptable (RS-II) 2 Novelose 30 Starchy, grainy, chewy, leaves 330 mouth kind of dry; unacceptable (RS-III) 3 FiberSym 14.5 Very good, strongly reminiscent of 70 real pasta (RS-IV) 4 FiberSym 15 Good, though slightly softer than 80 FiberSym 70 version; acceptable (RS-IV)

[0068] Several unsuccessful attempts were then made to salvage the Novelose 260 version

TABLE-US-00013 Gluten 6 Salt 0.3 Whey Protein Concentrate 1

TABLE-US-00014 Novelose Experiment 260 Wheat Guar Number (RS-II) Fiber Gum Oil Water Notes 5 19 2 20 Sticky, starchy, chewy, unacceptable 6 11 10 30 Too fibrous 7 11 10 0.3 2 23 Too fibrous, though harder 8 16 5 23 Too fibrous, though harder

[0069] VI. Egg Noodles

[0070] All of the ingredients were combined and kneaded for 5 minutes. Water was added as demanded by the consistency of the dough. The dough was then formed into a ball and allowed to rest for 5 minutes. It was then rolled through a hand-operated double roller to a uniform thickness, cut into strips, and left to dry in the air for 10 minutes. Finally the pasta was boiled in water for 5-10 minutes, until al dente.

TABLE-US-00015 Starch (see below for starch 21 type) Gluten 4 Whole Eggs 10

TABLE-US-00016 Experiment Xanthan Number Starch Type Gum Water Notes 1 FiberSym 70 5 Starchy, not enough (RS-IV) resistance to bite-through 2 FiberSym 70 0.2 5 Gummy (RS-IV) 3 FiberSym 80 5 Cooked very fast (RS-IV) Not enough resistance to bite-through or body 4 Novelose 10 Starchy, grainy 260 (RS-II) 5 Novelose 0.2 10 Starchy, grainy 260 (RS-II) 6 Novelose 0.2 7.5 Starchy, grainy 260 (RS-II) 7 Novelose 0.2 20 Starchy, grainy 330 (RS-III)

[0071] VII. Crisps 3

[0072] These experiments were conducted by combining the FiberSym 80 and salt with 3 g of Vital Wheat Gluten and 15 g of water. Additional gluten and water were added in 1 g increments until the dough attained an appropriate machineable consistency. The dough was then rolled through a hand-operated double roller to achieve a uniform thickness, cut into strips, baked for 10 minutes at 375 degrees Fahrenheit, and fried in Olean for 30 seconds at 375 Fahrenheit.

[0073] Base Ingredients:

TABLE-US-00017 FiberSym 80 25 Gluten (initial) 3 Water (initial) 15 Salt 1

TABLE-US-00018 Experiment Added Wheat Whole Added Number Water Fiber Egg Gluten Notes 1 2 Good 2 10 3 1 Good. Crispier, tougher to chew 3 5 3 5 1 Good. Soft, broke up very easily in mouth in a positive fashion

[0074] These experiments were conducted by combining the all of the ingredients except for the Potato Flakes (when present in the experiment) and an amount of water equal to the weight of the Potato Flakes called for in the experiment (i.e., 5 g of water for 5 g of flakes, 10 g of water for 10 g of flakes). The dough was then rolled through a hand-operated double roller to achieve a uniform thickness. At this point the potato flakes were lightly combined with the corresponding amount of water and worked into the dough. Additional water was added in 0.5 g increments until the dough attained an appropriate machineable consistency. The dough was then cut into strips, baked for the specified number of minutes at 375 degrees Fahrenheit, and fried in Olean for 30 seconds at 375 Fahrenheit.

[0075] Base Ingredients:

TABLE-US-00019 Gluten 2 Salt 0.5

TABLE-US-00020 Experi- Bake ment FiberSym Potato Short- Total Time (in Number 80 Flakes ening Water minutes) Notes 4 25 0 0.5 16.5 5 Good 5 20 5 1 18 5 Better 6 15 10 1 20 4 Best

[0076] VIII Flavored Pasta

[0077] The most successful version of the STANDARD PASTA was adapted with flavoring, using the same procedures as above. All of the ingredients were combined and kneaded for 5 minutes. The dough was then formed into a ball and allowed to rest for 5 minutes. It was then rolled through a hand-operated double roller to a uniform thickness, cut into strips, and hung to dry for 8 hours. Finally the pasta was boiled in water for 5-10 minutes, until al dente.

TABLE-US-00021 Experiment Number Ingredient 1 2 3 FiberSym 70 21 23 22 Gluten 6 6.4 6.5 Salt 0.5 0.5 0.5 Whey Protein Concentrate 1 1 1.5 Tomato Paste 7 7 Spinach 8 Water 12 13 10.5 Notes Too soft Good Good

[0078] IX. Cheese Crackers

[0079] The dough in this experiment was rolled through a hand-operated double roller to achieve a uniform thickness, cut into strips, baked for 15 minutes at 325 degrees Fahrenheit, turned over, and baked for an additional 3 minutes again at 325 degrees Fahrenheit.

Experiment 1

[0080]

TABLE-US-00022 FiberSym 80 21 Gluten 4 Salt 0.2 Paprika 0.3 WCB 3.5 Crisco 1.8 EMC Cheddar 0.5 Water 10

[0081] X. Instant Noodles

[0082] All of the ingredients were combined and kneaded for 5 minutes. Water was added as demanded by the consistency of the dough. The dough was then formed into a ball and allowed to rest for 5 minutes. It was then rolled through a hand-operated double roller to a uniform thickness and cut into thin strips. At this point, the experiment was optionally boiled in water for 2.5 minutes (indicated in chart). All experiments were then deep-fried in vegetable oil at 375 Fahrenheit for 1.5 minutes. Finally, the noodles were placed in Styrofoam cup which was then filled with boiling water, covered, and allowed to sit for 5 minutes.

[0083] Base Ingredients:

TABLE-US-00023 FiberSym 70 21 Salt 0.3

TABLE-US-00024 Experiment Guar Number Gluten WPC Gum Water Boiled? Notes 1 4 1 14.5 No Bit through to easily, not much resistance, soft and quick- dissolving 2 6 1 14.5 No Bit through to easily, not much resistance, soft and quick- dissolving 3 6 1 14.5 Yes Acceptable, but a little too soft 4 6 1 0.3 15 No A little too hard 5 6 1 0.3 15 Yes Still a little too hard 6 6 1 0.15 14.5 No Acceptable 7 6 1 0.15 14.5 Yes Acceptable, but a little too soft 8 6 0.15 14.5 No Acceptable 9 6 0.15 14.5 Yes Acceptable, slightly rubbery

[0084] It is understood that the above examples are illustrative of the present invention and that changes may be made may be made in ingredients, formulations, processing and the like without departing from the scope of the present invention as defined in the following claims