STRUCTURED OIL-IN-WATER EMULSION AND FOOD PRODUCT COMPRISING THE SAME

Abstract

The present invention relates to a structured oil-in-water emulsion for use in a food product, a food product, such as a bakery product, comprising the same, and a method of preparing the food product and the emulsion itself. In one aspect the present invention provides an oil-in-water structured emulsion for use in a food product; said structured emulsion comprising: i) from 1 to 8 wt. % emulsifier; ii) from 8 to 55 wt. % of sugar and/or sugar alcohol; iii) from 12 to 40 wt. % water; and iv) from 25 to 70 wt. % oil.

Claims

1-35. (canceled)

36. An oil-in-water emulsion comprising: i) from 1 to 8 wt. % emulsifier; ii) from 8 to 55 wt. % of sugar and/or sugar alcohol; iii) from 12 to 40 wt. % water; and iv) from 25 to 70 wt. % oil; wherein the emulsion is structured.

37. An emulsion according to claim 36, wherein the emulsifier is present in an amount of from 2 to 7 wt. %.

38. An emulsion according to claim 36, wherein the oil to water weight ratio is from 1.0 to 5.0.

39. An emulsion according to claim 36, wherein the sugar and/or sugar alcohol is present in an amount from 10 to 40 wt. %.

40. An emulsion according to claim 36, wherein the emulsion comprises sugar and is preferably free of sugar alcohol.

41. An emulsion according to claim 36, wherein the emulsifier comprises a non-ionic emulsifier selected from monoglycerides, propylene glycol fatty acid esters, polyglycerol fatty acid esters, and combinations thereof.

42. An emulsion according to claim 36, wherein the emulsifier comprises at least one monoglyceride.

43. An emulsion according to claim 36, wherein the emulsifier comprises an ionic emulsifier selected from acid esters of mono- and diglycerides, fatty acids and metal salts thereof, anionic lactylated fatty acid salts, and combinations thereof.

44. An emulsion according to claim 43, wherein the ionic emulsifier is selected from stearic acid, sodium stearate, sodium palmitate, palmitic acid, sodium stearoyl lactylate, a diacetyl tartaric acid ester of a monoglyceride, and combinations thereof.

45. An emulsion according to claim 36, wherein the emulsifier comprises a non-ionic emulsifier.

46. An emulsion according to claim 36, wherein the emulsifier comprises a non-ionic emulsifier and an ionic emulsifier.

47. An emulsion according to claim 46, wherein the weight ratio of the nonionic emulsifier to ionic emulsifier is from 70:30 to 99:1.

48. An emulsion according to claim 36, wherein the emulsifier comprises an ionic emulsifier selected from stearic acid, sodium stearate and sodium stearoyl lactylate and a non-ionic emulsifier comprising a monoglyceride.

49. An emulsion according to claim 36, wherein the sugar is a monosaccharide selected from glucose, fructose, xylose, ribose, galactose, mannose, arabinose, allulose, tagatose; a disaccharide selected from sucrose, maltose, trehalose, lactose, lactulose, isomaltulose, kojibiose, nigerose, cellobiose, gentiobiose, sophorose; an oligosaccharide selected from oligofructose, galacto oligosaccharides, raffinose, or a combination thereof.

50. An emulsion according to claim 36, wherein the sugar alcohol is selected from ethylene glycol, glycerol, erythritol, sorbitol, xylitol, maltitol, mannitol, lactitol, and combinations thereof.

51. An emulsion according to claim 36, wherein the emulsion has a water activity of 0.90 or lower.

52. An emulsion according to claim 36, wherein the emulsion retains a water activity of 0.90 or below after storage for 28 days or 55 days at a temperature of less than 30° C.

53. An emulsion according to claim 36, wherein the emulsion comprises oil droplets having an equivalent surface area mean diameter of from 0.1 to 3.0 μm, as measured by dynamic light scattering (DLS).

54. An emulsion according to claim 36, wherein the oil is selected from a vegetable oil, a marine oil, an animal oil, and combinations thereof.

55. An emulsion according to claim 36, wherein the oil comprises a vegetable oil, wherein the vegetable oil is selected from the group consisting of aεai oil, almond oil, beech oil, cashew oil, coconut oil, colza oil, corn oil, cottonseed oil, flaxseed oil, grapefruit seed oil, grape seed oil, hazelnut oil, hemp oil, lemon oil, macadamia oil, mustard oil, olive oil, orange oil, peanut oil, palm oil, palm kernel oil, pecan oil, pine nut oil, pistachio oil, poppyseed oil, rapeseed oil, rice bran oil, safflower oil, sesame oil, shea butter and its fractions, soybean oil, sunflower oil, walnut oil, and wheat germ oil.

56. An emulsion according to claim 36, wherein the emulsion is free of palm oil and/or palm kernel oil.

57. A cooked or part-cooked food product prepared using the emulsion according to claim 36.

58. A cooked or part-cooked food product according to claim 57, wherein the food product is a bakery product selected from biscuits, cookies, crackers, hardtack, pretzels, cut bread, wafers, sable, Langue du chat, macaroons, butter cakes, sponge cakes, cream puffed confectionery, fermentation pastry, western style fresh confectionery, sweet buns, French bread, stollen, panettone, brioche, donuts, Danish pastry and croissants.

59. A dough for preparing a bakery product, the dough comprising: i) an emulsion according to claim 36; ii) flour; and iii) a chemical leavening agent; wherein the bakery product is a biscuit or cookie.

60. A dough according to claim 59, wherein the dough further comprises one or more of eggs, water, liquid emulsifier, liquid sugar and syrups, milk, liquid flavours, alcohols, humectants, honey, liquid preservatives, liquid sweeteners, liquid oxidising agents, liquid reducing agents, liquid anti-oxidants, liquid acidity regulators, liquid enzymes, milk powder, yeast, sugar substitutes, protein, powdered emulsifiers, starch, salt, spices, flavour components, colourants, cocoa, thickening and gelling agents, egg powder, enzymes, gluten, preservatives, sweeteners, oxidising agents, reducing agents, anti-oxidants, and acidity regulators.

61. A process for preparing a dough as defined in claim 59, the process comprising the steps of: a) preparing a wet phase comprising the emulsion as defined in claim 36 and any wet ingredients; b) preparing a dry phase comprising flour, a leavening agent, and additional dry ingredients; and c) blending the wet phase and dry phase until a dough is formed.

62. A process for preparing a cooked or part-cooked bakery product, the process comprising preparing a dough by the process of claim 61 and cooking the dough to form a cooked or part-cooked bakery product.

63. A process according to claim 62, wherein cooking includes baking, frying and/or microwaving.

64. An emulsion according to claim 36, wherein the emulsion is employed as a shortening substitute.

65. An emulsion according to claim 36, wherein the emulsion is employed to reduce fat blooming when used in a bakery product.

66. A process for making a product as defined in claim 36, comprising: i) preparing an oil phase by combining oil with the emulsifier, and heating the oil phase; ii) preparing an aqueous phase by combining water with a sugar component, and heating the aqueous phase; iii) combining the aqueous phase and the oil phase and mixing to form an emulsion; and iv) cooling the emulsion by means of a tubular cooler to form a solid comprising surfactant-encapsulated oil layers in a continuous aqueous phase.

67. A process according to claim 66, wherein the oil phase and/or aqueous phase is heated to a temperature of 40° C. to 90° C.

68. A process according to claim 66, wherein the oil phase and the aqueous phase are heated to the same temperature.

69. A process according to claim 66, wherein the emulsion is cooled to a temperature below 40° C.

70. A process according to claim 66, wherein the emulsion is cooled to a temperature in the range of 0 to 35° C.

71. A food product comprising the emulsion of claim 36.

Description

[0105] The present invention will now be described by way of reference to the Figures and Examples, in which:

[0106] FIGS. 1a and 1b are optical microscope images of a structured emulsion according to the invention (FIG. 1a) and not in accordance with the invention (FIG. 1b);

[0107] FIG. 2 is a graph showing of the change in the concentration of sub-alpha gel phase in inventive and comparative structured emulsions based on melting enthalpy (7-13° C.) stored for up to 55 days;

[0108] FIGS. 3a and 3b are optical microscope images of a structured emulsion not according to the invention (FIG. 3a) and in accordance with the invention (FIG. 3b), where each structured emulsion comprises a different proportion of a sugar component;

[0109] FIGS. 4a and 4b show images of cookies prepared using doughs comprising a structured emulsion according to the invention (FIG. 4a) and not in accordance with the invention (FIG. 4b);

[0110] FIGS. 5a to 5i show optical microscope images (×10 objective lens) of different samples of structured emulsion at different stages in a heat treatment experiment;

[0111] FIGS. 6a to 6i show optical microscope images (×40 objective lens) of different samples at different stages in a heat treatment experiment;

[0112] FIG. 7 shows X-ray scattering patterns of structured emulsions both in accordance with and not in accordance with the invention taken at day 1 and over an 8-week period of storage;

[0113] FIG. 8 shows a graph of oil droplet size distribution for a structured emulsion of the invention;

[0114] FIG. 9 shows a graph of storage modulus, G′, and loss modulus, G″, determined for a structured emulsion of the invention;

[0115] FIG. 10 is a graph showing the results of DSC melting enthalpy assessments of structured emulsions according to the present invention after 35 days of storage at 20° C.,

[0116] FIGS. 11a to 11h show optical microscope images (×10 and ×40 objective lens) of different samples of structured emulsions according to the present invention;

[0117] FIGS. 12a to 12d show pictures of cookies containing structured emulsions according to the present invention;

[0118] FIG. 13 is a diagrammatic view of the tubular cooler used in Example 9; and

[0119] FIGS. 14a to 14d show optical microscope images (×40 objective lens) of different samples of structured emulsions according to the present invention.

GENERAL METHOD FOR PREPARING THE STRUCTURED EMULSIONS

[0120] An oil phase was prepared by combining oil with the emulsifier component and an aqueous phase was prepared by combining de-ionized water with a sugar component (if present). Oil and aqueous phases were both separately heated to 75° C. The oil phase was slowly added to the aqueous phase over the course of two minutes with simultaneous mixing using a Dynamic MD95 hand mixer to give a batch of 2 kg combined weight. The mixture was then allowed to cool naturally to room temperature (20° C.).

Example 1

[0121] A first structured emulsion (Emulsion A) in accordance with the present invention was prepared using the above general method. The composition of the structured emulsion is as follows: [0122] 48.75 wt. % rapeseed oil [0123] 3.75 wt. % emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0124] 22.5 wt. % de-ionized water [0125] 25 wt. % refined sucrose (EC category 1) [0126] Oil to water weight ratio: 2.17

[0127] The water activity of Emulsion A was determined to be 0.88 using an Aqualab 4TE benchtop water activity meter. The pH of the aqueous continuous phase of the emulsion was also measured and found to be 8.6 using a pH probe (Sartorius PB-11) inserted directly into the emulsion.

[0128] A second structured emulsion (Emulsion B) not in accordance with the present invention was prepared using the above general method. The composition of the structured emulsion is as follows: [0129] 65 wt. % rapeseed oil [0130] 5 wt. % emulsifier (4 wt. % glycerylmonostearate (Myverol 18-08 NP) and 1 wt. % SSL) [0131] 30 wt. % de-ionized water [0132] Oil to water weight ratio: 2.17

[0133] The water activity of the Emulsion B was determined to be from 0.99 using an Aqualab 4TE benchtop water activity meter. The pH of the aqueous continuous phase of the emulsion was also measured and found to be 5.45 using a pH probe (Sartorius PB-11) inserted directly into the emulsion.

[0134] Microbial evaluations of the Emulsions A and B were made following preparation and over a 28-day storage period at different temperatures and following exposure to air (“open lid”). Results of the analyses for Emulsions A and B are provided in Tables 1 and 2 below respectively.

TABLE-US-00001 TABLE 1 Yeast* Aerobe** colony Moulds*** Days Condition (CFU/g) count 37° C. (CFU/g) (CFU/g)  0 20° C. <10 <10 <10  0 37° C. <10 <10 <10  0 20° C., <10 <10 <10 open lid 14 20° C. <10 <10 <10 14 37° C. <10 20 <10 14 20° C., <10 <10 <10 open lid 21 20° C. <10 <10 <10 21 37° C. <10 <10 <10 21 20° C., <10 <10 <10 open lid 28 20° C. <10 <10 <10 28 37° C. <10 <10 <10 28 20° C., <10 <10 <10 open lid *AFNOR 3M 01/13-07/14 **AFNOR 3M 01-1-09/89 ***3M Nordval n16

TABLE-US-00002 TABLE 2 Yeast* Aerobe** colony Moulds*** Days Condition (CFU/g) count 37° C. (CFU/g) (CFU/g)  0 20° C. <10 20 <10  0 37° C. <10 40 <10  0 20° C., <10 10 <10 open lid 14 20° C. <10 10 92000 14 37° C. 6800 410 43000 14 20° C., <10 10 64000 open lid 21 20° C. <10 <10 18000 21 37° C. 660 40 23000 21 20° C., 4900 10 4300 open lid 28 20° C. 2000 680 >15000 28 37° C. >15000 20 >15000 28 20° C., >15000 10 >15000 open lid *AFNOR 3M 01/13-07/14 **AFNOR 3M 01-1-09/89 ***3M Nordval n16

[0135] The results in Tables 1 and 2 above demonstrate that Emulsion A (invention) has far superior resistance to microbial, yeast and mould reproduction and growth over the storage period analysed in comparison to Emulsion B (comparative). There is little evidence of microbial, yeast and mould reproduction and growth over the course of the experiment in the case of Emulsion A according to the invention. This is believed to be the result of the lower water activity of the aqueous phase of Emulsion A, in comparison to comparative Emulsion B. Comparative Emulsion B has a water activity which is sufficiently high to support bacterial, mould and yeast growth and also has an aqueous phase with an acidic pH. The lower water activity associated with Emulsion A is believed to derive from the particular proportions of emulsion components, particularly the high sugar content which is substantially higher than in known structured emulsions, and also the resulting impact on the pH of the aqueous continuous phase. Such a high resistance to microbial, yeast and mould reproduction is particularly surprising for an emulsion with a continuous phase having alkaline pH, since such benefits are typically observed where acidic pH is employed together with a preservative system. Emulsion A illustrates how the present invention can obviate conventional means for extending microbial shelf-life of structured emulsions.

[0136] Emulsions A and B were also analysed by optical microscope and microscope images of Emulsion A and B are provided in FIGS. 1a and 1b respectively. As can be clearly seen, the microscope images show that Emulsion A of the invention has significantly smaller oil droplet size in comparison to Emulsion B, despite being prepared by the same general method.

Example 2

[0137] Further structured emulsions were prepared by the above general method. Emulsion C (comparative) includes the same oil phase and emulsifier components but does not include the high proportion of sugar according to the present invention (the amount of sugar in Emulsion C is instead only 5 wt. %). Emulsions D to F are in accordance with the present invention and comprise from 10 wt. % to 25 wt. % of sugar. Further details of the compositions of the Emulsions C to F are provided below in Table 3. P47619

TABLE-US-00003 TABLE 3 Component Emulsion Emulsion Component Phase C D E F Oil oil phase 57 55 48.75 48.75 distilled monoglyceride, oil phase 5 5 3.75 3.75 Dimodan HR 85 S6 De-ionized water aqueous phase 33 30 22.5 22.5 Sugar aqueous phase 5 10 25 25 lemon juice aqueous phase — — — yes pH aqueous phase (pre- — — 6.43 3.84 emulsion) pH aqueous phase (post- 8.56 8.83 9 8.15 emulsion) Water Activity Aw 0.9811 0.9706 0.89 0.89

[0138] As may be seen below, Emulsion F also contains a pH modifier (lemon juice) in the aqueous phase and shows that, although prior to emulsification the aqueous phase is acidic, emulsification still provides an aqueous continuous phase which is alkaline. This shows that the nature of the structured emulsion and the interaction of the aqueous phase with at least the emulsifier and/or sugar/sugar alcohol component induces a change to alkaline pH.

[0139] Emulsions C to F were analyzed by Differential Scanning calorimetry (DSC) over the course of a 55 day storage period at 20° C. in a sealed container. DSC was used to identify the presence of a melting peak at 7-13° C., which is characteristic of the sub-alpha gel phase and results are plotted in the graph of FIG. 2.

[0140] The results in FIG. 2 show that there is a substantial loss of the sub-alpha phase peak associated with comparative Emulsion C over a 28 day period. There is however a significantly higher retention of the sub-alpha phase peak for inventive Emulsion D, which contains twice the amount of sugar in the emulsion compared to Emulsion C. Emulsions E and F, which contain yet higher sugar concentrations, indicate near complete retention of the alpha-phase over the same 28 day period, and a significant majority of the alpha-phase retained after even 55 days.

[0141] This example demonstrates how the proportion of the ingredients of the structured emulsion of the invention, particularly the high proportion of sugar, has been found to provide a structured emulsion which exhibits surprising stability for the sub-alpha and alpha gel phases, and therefore resistance to mesomorphic change to the beta gel phase and any unwanted oil and/or water loss.

[0142] Emulsions C and E were also analysed by optical microscope and microscope images of Emulsion C and E are provided in FIGS. 3a and 3b respectively. As can be clearly seen, the microscope images show that Emulsion E of the invention has significantly smaller oil droplet size in comparison to Emulsion C, despite being prepared by the same general method. This is considered to be a further illustration of how the particular proportion of ingredients of the emulsion of the invention gives rise to a material difference in the nature and stability of the resulting structured emulsion.

Example 3

[0143] A first structured emulsion (Emulsion G) in accordance with the present invention was prepared using the above general method. The composition of the structured emulsion is as follows: [0144] 55 wt. % rapeseed oil [0145] 5 wt. % emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0146] 30 wt. % de-ionized water [0147] 10 wt. % refined sucrose (EC category 1) [0148] Oil to water weight ratio: 1.83

[0149] The water activity of Emulsion G was determined to be from 0.97 using an Aqualab 4TE benchtop water activity meter.

[0150] A second structured emulsion (Emulsion H) not in accordance with the present invention was prepared using the above general method. The composition of the structured emulsion is as follows: [0151] 65 wt. % rapeseed oil [0152] 5 wt. % emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0153] 30 wt. % de-ionized water [0154] Oil to water weight ratio: 2.17

[0155] The water activity of the Emulsion H was determined to be from 0.99 using an Aqualab 4TE benchtop water activity meter.

[0156] Emulsions G and H were stored for 6 weeks at 20° C. in a sealed container. Afterwards, cookie doughs were prepared using the emulsions using the recipe provided in Table 4 below.

TABLE-US-00004 TABLE 4 Weight (g) Invention Comparative Creaming Emulsion G 300 phase Emulsion H 275 Sugar 45 70 Dough up Flour 385 385 phase Sugar 80 80 Baking powder 6.2 6.2 Skimmed milk 6.6 6.6 powder Salt 4.6 4.6

[0157] The creaming phase was prepared in each case by combining sugar (refined, EC category 1) and the emulsion and mixing in a Hobart Mixer apparatus with a flat beater for 1 minute at Speed 1 followed by 1 minute at Speed 2.

[0158] The dough up phase of dry ingredients were in each case blended and sieved before being added to the corresponding prepared creaming phase. The resulting mixture was then mixed with the Hobart Mixer for 1 minute at Speed 1 to form a dough.

[0159] Each prepared dough was evaluated for oil loss by forming sheets of the doughs of 2 cm thickness using a Fritsch lamination table. Round dough pieces were cut from each sheet (height 2 cm, diameter 5 cm, weight 40-42 g) and each dough piece was applied to a Whatmann #4 110 mm filter paper for 1 hour, before being removed. After, resting for a further hour, measurement of the weight of the Whatman paper was conducted to determine the amount of oil adsorption from the dough pieces. The dough quality was also assessed. The results of the oil loss experiment and the dough assessment are shown in Table 5 below.

TABLE-US-00005 TABLE 5 Difference in weight filter Dough quality paper = oil adsorbed (g) score (1 = low; 5 = best) Invention 0.004 4 (Emulsion G) Comparative 0.018 2.5 (Emulsion H)

[0160] As can be seen from the results in Table 5, the dough prepared using Emulsion G in accordance with the present invention produced substantially lower amounts of oil loss than for the comparative dough prepared using Emulsion H. This is believed to be at least partially derived from the stability of Emulsion G to mesomorphic changes over the 28-day storage period. The lower oil droplet size of Emulsion G compared to Emulsion H is also believed to contribute to the improved performance. In contrast, Emulsion G clearly suffers from some oil loss over the storage period, which is believed to be at least partially the result of a mesomorphic change in the emulsion structure. This mesomorphic change also negatively impacts the quality of the dough which is prepared from the emulsion, with the dough prepared using the inventive Emulsion G scoring far higher in the quality assessment (4 vs 2.5).

[0161] The dough was rolled out until a height/thickness of 5 mm. Round dough pieces were cut (diameter 5 cm) and baked for 20 minutes in a deck oven at 180° C. (top)/160° C. (bottom). Cookies prepared from the inventive doughs also show improved properties compared to those prepared from the comparative doughs under the same conditions. FIG. 4a shows a picture of the inventive cookie, whilst FIG. 4b shows a picture of the comparative cookie. As can be seen, there is significant cracking at the surface of the cookie prepared from the comparative dough (indicated by the arrows).

[0162] This example further illustrates the advantages of the structured emulsion of the invention, particularly the long term stability and the benefits thereof in the preparation of a food product.

Example 4

[0163] A comparative structured emulsion (Emulsion I) was prepared using the above general method. The composition of the structured emulsion is as follows: [0164] 60 wt. % sunflower oil (approximately 80% oleic acid) [0165] 35 wt. % de-ionized water [0166] 5 wt. % emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0167] Oil to water weight ratio: 1.71

[0168] A structured emulsion according to the present invention (Emulsion J) was prepared using the above general method. The composition of the structured emulsion is as follows: [0169] 58 wt. % sunflower oil (approximately 80% oleic acid) [0170] 27.5 wt. % demineralised water [0171] 4.5 wt. % emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0172] 10 wt. % refined sucrose (EC category 1) [0173] Oil to water weight ratio: 2.11

[0174] A further structured emulsion according to the present invention (Emulsion K) was prepared using the above general method. The composition of the structured emulsion is as follows: [0175] 50 wt. % sunflower oil (approximately 80% oleic acid) [0176] 21.8 wt. % demineralised water [0177] 4.2 wt. % emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0178] 24 wt. % refined sucrose (EC category 1) [0179] Oil to water weight ratio: 2.29

[0180] 300 g each of Emulsions I to K were subjected to ambient storage or heat treatment under the following conditions: i) stored at room temperature (20° C.), ii) subjected to 1 hour in a deck oven at 140° C.; and iii) subjected to 1 hour in a deck oven at 180° C. During treatment, the temperature of the emulsions was recorded using a temperature probe.

[0181] The treated samples were subsequently analysed using a Zeiss Axiostar plus microscope (ocular magnifications of ×10 and ×40). FIGS. 5a to 5i (×10 ocular magnification) and FIGS. 6a to 6i (×40 ocular magnification) show optical microscope images of the different samples at different stages in the above treatment, in particular: 5a: Emulsion I; 5b: Emulsion J; 5c: Emulsion K; 5d: Emulsion I after 1 hour in deck oven at 140° C.; 5e: Emulsion J after 1 hour in deck oven at 140° C.; 5f: Emulsion K after 1 hour in deck oven at 140° C.; 5g: Emulsion I after 1 hour in deck oven at 180° C.; 5h: Emulsion J after 1 hour in deck oven at 180° C.; 5i: Emulsion K after 1 hour in deck oven at 180° C.; 6a: Emulsion I; 6b: Emulsion J; 6c: Emulsion K; 6d: Emulsion I after 1 hour in deck oven at 140° C.; 6e: Emulsion J after 1 hour in deck oven at 140° C.; 6f: Emulsion K after 1 hour in deck oven at 140° C.; 6g: Emulsion I after 1 hour in deck oven at 180° C.; 6h: Emulsion J after 1 hour in deck oven at 180° C.; and 6i: Emulsion K after 1 hour in deck oven at 180° C.

[0182] As can be seen from FIGS. 5a to 5i and FIGS. 6a to 6i, as sugar concentration increases over the range test in the structured Emulsions Ito K, the smaller the oil droplets become, as observed by microscope analysis. Emulsion breakdown is observed at elevated temperatures in comparative Emulsion I (particularly evident in FIGS. 5d, 5g, 6d and 6g). However, the addition of sugar, specifically over the high range in accordance with the present invention, significantly improves the emulsion stability at higher temperatures and no emulsion breakdown was observed.

Example 5

[0183] A structured emulsion according to the present invention (Emulsion L) was prepared using the above general method. The composition of the structured emulsion is as follows: [0184] 48.75% rapeseed oil [0185] 3.525% glycerol monostearate [0186] 0.225% sodium stearate [0187] 22.5% de-ionised water [0188] 25% refined sucrose (EC category 1) [0189] Oil to water weight ratio: 2.17

[0190] A comparative structured emulsion (Emulsion M) was prepared using the above general method. The composition of the structured emulsion is as follows: [0191] 60.175% rapeseed oil [0192] 4.5% glycerol monostearate [0193] 0.225% sodium stearate [0194] 35.1% de-ionised water [0195] Oil to water weight ratio: 1.71

[0196] X-ray scattering patterns of Emulsions L and M were collected in the range of 1°<2θ<8° and 16°<2θ<24°, at a rate of 0.1°/min using a Rigaku MultiFlex powder X-ray diffractometer outfitted with a copper X-ray tube (Cu—K α1, λ=1.5418 Å) operating at 40 kV and 44 mA, and are shown in FIG. 7. The apparatus was set with a 0.5° divergence slit, 0.5° scattering slit, and a 0.3 mm receiving slit. Analysis was performed by spreading the shortening on a circular-welled aluminium slide, which served as the sample holder in the XRD apparatus. For all samples, data acquisition was performed at room temperature (20° C.).

[0197] In the wide angle region (WAXS), both emulsions exhibit a single characteristic peak with an associated d-spacing of ˜4.2 Å after 1 day. Over the course of an 8-week storage at 20° C., Emulsion L maintained this same WAXS pattern, indicating no or limited change in the molecular organization of the emulsion according to the invention. In contrast, Emulsion M began to show changes in the WAXS pattern. This change manifested as a depression in the peak with a d-spacing of 4.2 Å, and appearance of several other peaks at various locations within the amorphous peak. This indicates a shift from the alpha-gel phase to the coagel (beta-gel) phase in comparative Emulsion M.

Example 6

[0198] A pilot trial (100 kg) was conducted using two vessels equipped with an anchor and a high shear mixer (plate turbine). A structured emulsion according to the present invention was prepared having a composition as follows: [0199] 50% sunflower oil (approximately 80% oleic acid) [0200] 4.2% emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0201] 24% refined sucrose (EC category 1) [0202] 21.8% de-ionised water [0203] Oil to water weight ratio: 2.29

[0204] The oil phase (sunflower oil and Dimodan HR 85 S6) and water phase (water and sucrose) were separately heated in two vessels to 75° C. The oil phase was subsequently incrementally added to the water phase under continuous mixing (anchor: 80 rpm; plate turbine: 3050 rpm) for 60 minutes. The mixing was stopped and samples of the final emulsion were taken and stored in separate containers with some samples undergoing intermediate cooling prior to being transferred to their containers. In particular, one sample was transferred without cooling (i.e. at 75° C.) to a container (“hot-filled”), after which the filled container was allowed to cool naturally by the prevailing environmental conditions to 20° C. (Emulsion N). Other samples were taken and instead initially cooled using a plate heat exchanger (supplied by GEA group) to the following temperatures: 50° C. (Emulsion O), 35° C. (Emulsion P) and 25° C. (Emulsion Q), before being transferred to individual containers where further cooling took place by the prevailing environmental conditions to 20° C. in each case. Each of the samples was then maintained at a temperature of 20° C. for a storage time of up to 9 weeks.

[0205] The emulsions were analyzed by Differential Scanning calorimetry (DSC) over the course of the storage period to identify the presence of a melting peak at 7-13° C., which is characteristic of the sub-alpha gel phase. The melting enthalpy (J/g) and peak temperature (° C.) for the peak between 7 and 13° C. over time are shown in Table 6 below.

TABLE-US-00006 TABLE 6 Melting Enthalpy (J/g); peak temperature (° C.) Emulsion N Emulsion O Emulsion P Emulsion Q 5 weeks 0.0485 J/g; 0.0861 J/g; 0.252 J/g; 0.253 J/g; 10.1° C.  104° C. 11.1° C. 10.9° C. 7 weeks 0.0449 J/g;  0.148 J/g; 0.216 J/g; 0.198 J/g; 9.98° C. 11.4° C. 10.1° C. 10.1° C. 9 weeks na na 0.209 J/g; 0.200 J/g; 10.1° C. 10.4° C.

[0206] The higher melting enthalpy for the peak between 7 and 13° C. of the emulsions initially cooled to 25-35° C. (Emulsions O to Q) indicate a longer presence of the sub-alpha and alpha phase for the samples. Cooling is therefore advantageous for prolonging retention of the alpha gel phase during storage.

[0207] Baking trials were also performed with samples of the Emulsions N to Q after 1 week of storage. Cookie doughs were prepared following the recipe and procedure used in Example 3 above for Emulsion G. No significant differences between the cookie doughs were observed.

[0208] Properties of each prepared dough were evaluated for oil loss, as well as dough quality, as described in Example 3 above. The results of the oil loss experiment and the dough assessment are shown in Table 7 below.

TABLE-US-00007 TABLE 7 Difference in weight Dough quality filter paper = oil score (1 = adsorbed (g) low; 5 = best) Emulsion N 0.003 5 Emulsion O 0.002 5 (cooled to 50° C.) Emulsion P 0.001 5 (cooled to 35° C.) Emulsion Q 0.002 5 (cooled to 25° C.)

[0209] As can be seen from the results in Table 7, the doughs prepared in each case exhibited low oil loss and scored highly in the dough quality assessment.

Example 7

[0210] A pilot trial (200 kg) was conducted using two vessels equipped with an anchor and a high shear mixer (plate turbine). A structured emulsion (Emulsion R) according to the present invention was prepared having a composition as follows: [0211] 60% sunflower oil (approximately 80% oleic acid) [0212] 5% emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0213] 27.3% aqueous sucrose solution (67% sucrose, Raftisweet S100/67/10) [0214] 7.7% drinking (tap) water [0215] Oil to water weight ratio: 3.59

[0216] The oil phase (sunflower oil and Dimodan HR 85 S6 emulsifier) and water phase (water and sucrose solution) were separately heated in two vessels to 75° C. The oil phase was subsequently incrementally added to the water phase under continuous mixing (anchor: 80 rpm; plate turbine: 3050 rpm) for 150 minutes. The mixing was stopped and the final emulsion was cooled using a plate heat exchanger (GEA group) to 25° C.

[0217] The oil droplet size distribution of Emulsion R was determined using a Horiba LA 960 instrument (conditions: dilution 10% emulsion/90% milli-q water; drop-wise addition to a transmittance of 94% (red laser), 84% (blue laser); circulation speed 6), the results of which are shown below in Table 8 and represented graphically in FIG. 8.

TABLE-US-00008 TABLE 8 Emulsion R Mean Size, D (3.2) (nm) 652 D10 (nm) 206 D50 (nm) 647 D90 (nm) 1083

[0218] The storage modulus, G′, and the loss modulus, G″, of Emulsion R were determined using an Anton Paar MCR300 rheometer (conditions: 2.5 ml to plate cone geometry; stress sweep at a controlled shear strain at 0.5%), the results of which are shown in FIG. 9.

[0219] Emulsion R has a storage modulus, G′, which is greater than its loss modulus, G″.

[0220] Emulsion R was evaluated after 1 and 2 weeks in a baking trial. Cookie doughs were prepared and baked following the procedure used in Example 3 above for Emulsion G, except using the recipe according to Table 9 below.

TABLE-US-00009 TABLE 9 Weight (g) Creaming Emulsion R 250 phase Water 24 Sugar 26 Dough up Flour 385 phase Sugar 70 Baking powder 6.2 Skimmed milk 6.6 powder Salt 4.6

[0221] Oil loss and dough quality assessments were also carried out for each batch as in Example 3 above and properties of the baked cookies were also determined and the results are shown in Table 10 below.

TABLE-US-00010 TABLE 10 Week 1 Week 2 Specific volume after creaming phase (ml/g) 1.52 1.47 Dough quality score (1 = low; 5 = best) 4.5 4.5 Difference in weight filter paper = oil 0.007 0.004 adsorbed (g) Thickness per cookie/baked weight (mm/g) 0.81 0.77 Diameter per cookie/baked weight (mm/g) 5.04 5.01 Specific volume cookie (ml/g) 1.62 1.58 Regularity in baking score (1 = low; 5 = best) 5 5

[0222] The results show that very good and consistent results are obtained in the baking trials using doughs prepared from Emulsion R stored for both 1- and 2-week periods.

Example 8

[0223] Four structured emulsions in accordance with the present invention were prepared using the above general method (Emulsions S to V). The composition of the structured emulsions is shown in Table 11 below.

TABLE-US-00011 TABLE 11 Emulsion S Emulsion T Emulsion U Emulsion V Rapeseed oil (wt. %) 50 50 50 50 Deionized water (wt. %) 21.8 21.8 21.8 21.8 Emulsifier* (wt. %) 4.2 4.2 4.2 4.2 Refined sucrose** (wt. %) 24 0 0 0 Dextrose (wt. %) 0 24 0 0 Sorbitol (wt. %) 0 0 24 0 Maltitol (wt. %) 0 0 0 24 *Emulsifier: distilled monoglyceride, Dimodan HR 85 S6, comprising 6 wt. % of the emulsifier of sodium stearate **EC category 1

[0224] The water activities of Emulsions S, T, U and V were determined to be 0.92, 0.89, 0.88 and 0.92, respectively, using an Aqualab 4TE benchtop water activity meter. The emulsions were then stored for a period of 35 days period at 20° C. in a sealed container, over which time the emulsions were analyzed by Differential Scanning calorimetry (DSC). DSC was used to identify the presence of a melting peak at 7-13° C., which is characteristic of the sub-alpha gel phase. The results are represented graphically in FIG. 10 which shows that after 35 days, the sub-alpha gel phase is present in all samples.

[0225] Emulsions S to V were also analyzed by optical microscopy at the end of the 35 day storage period using a Zeiss Axiostar plus microscope (ocular magnifications of ×10 and ×40) and the corresponding microscope images are provided in FIGS. 11a) to 11h) (FIGS. 11a) and 11b): Emulsion S at ocular magnifications of ×10 and ×40, respectively; FIGS. 11c) and 11d): Emulsion T at ocular magnifications of ×10 and ×40, respectively; FIGS. 11e) and 11f): Emulsion U at ocular magnifications of ×10 and ×40, respectively; FIGS. 11g) and 11h): Emulsion T at ocular magnifications of ×10 and ×40, respectively). The images show that Emulsions S to V all have a similar oil droplet size. Together with the DSC result, this shows that emulsions prepared with different sugars or sugar alcohols all have an equally good stability over 35 days of storage time.

[0226] Following storage of Emulsions S, T, U and V for 35 days at 20° C. in the sealed container, the emulsions were evaluated. Cookie doughs were prepared following the procedure used in Example 3 above for Emulsion G, except using the recipe according to Table 12 below.

TABLE-US-00012 TABLE 12 Creaming Emulsion 300 phase Dough up Flour 385 phase Sugar 70 Baking powder 6.0 Skimmed milk 6.2 powder Salt 4.5

[0227] Oil loss and dough quality assessments were carried out for each batch as in Example 3 above and the results are shown in Table 13 below.

TABLE-US-00013 TABLE 13 Difference in weight filter Dough quality paper = oil score (1 = low; adsorbed (g) 5 = best) Emulsion S 0.008 4.5 Emulsion T 0.019 3.5 Emulsion U 0.013 4.5 Emulsion V 0.010 4

[0228] As can be seen from the above Table 13, the resistance to oil loss is similar for doughs containing emulsions made with different types of sugar or sugar alcohols used. Oil loss was slightly higher with the cookie dough containing Emulsion T, which was also reflected in the overall dough quality score as doughs containing Emulsions T or U felt more oily then those containing Emulsions S or V.

[0229] The doughs were further sheeted until 5 mm thickness, round dough pieces with a diameter of 50 mm were cut out and put on a baking tray. Finally, cookies were baked in a deck oven at top/bottom temperature of 180/160° C. for 20 minutes. FIGS. 12a) to 12d) show pictures of cookies respectively containing Emulsions S to V. Although the stability of the mesomorphic phase was similar for each of the four Emulsions S to V, the cookie properties differed in terms of surface smoothness, colour and spread. From the four different cookie recipes prepared with Emulsions S to V, cookies containing Emulsion V had the smoothest surface and most appealing colour.

[0230] This example shows that by varying the sugar or sugar alcohol type, emulsions with similar stability are obtained. Furthermore, this can result in a further reduction of water activity (Emulsions T, U) or improved cookie quality (Emulsion V).

Example 9

[0231] A pilot trial (200 kg) was conducted using two vessels equipped with an anchor and a high shear mixer (plate turbine). Two structured emulsions (W and X) according to the present invention were prepared having a composition as follows: [0232] 60% sunflower oil (approximately 80% oleic acid) [0233] 5% emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0234] 27.3% aqueous sucrose solution (67% sucrose, Raftisweet S100/67/10) [0235] 7.7% drinking (tap) water [0236] Oil to water weight ratio: 3.59

[0237] The oil phase (sunflower oil and Dimodan HR 85 S6 emulsifier) and water phase (water and sucrose solution) were separately heated in two vessels to 75° C. The oil phase was subsequently incrementally added to the water phase under continuous mixing (anchor: 80 rpm; plate turbine: 3050 rpm) for 150 minutes. The mixing was stopped and the emulsions were cooled in two different ways: [0238] Emulsion W was cooled using a scraped surface heat exchanger (Terlotherm DT100: scraper 30 rpm, cooling water 10° C.) to 29° C. [0239] Emulsion X was cooled using a tubular cooler (two HRS DTA 25/18 3.0 304/316 L S in parallel, cooling water 14° C.—see FIG. 13) to 29° C. This tubular cooler has the following characteristics: [0240] 2 units of about 2.7 m in series (total length about 5.4 m), connected by elbow (U-form) and clamps [0241] Total shell volume (water): 1.07 L [0242] Total tube volume (product): 1.18 L [0243] Design pressure: 10 bar; test pressure: 15 bar; ΔP (during production of emulsion X): 5.5 bar [0244] Flow cooling water: countercurrent

[0245] Emulsions W and X were analysed using a Zeiss Axiostar plus microscope (ocular magnifications ×40) and Horiba LA 960 20 instrument (conditions: dilution 10% emulsion/90% milli-q water; drop-wise addition to a transmittance of 94% (red laser), 84% (blue laser); circulation speed 6) for oil droplet distribution, and the corresponding microscope images are provided in FIGS. 14a to d, where it can be seen that oil droplets of Emulsion X were smaller in nature.

[0246] Both emulsions have very small oil droplets, but there is a preference for emulsion X because less emulsion breakdown is seen (visually under microscope as well as a smaller increase in mean diameter of the oil droplets after cooling). Emulsion W (see FIGS. 14a and 14c) showed a volume mean diameter D[4,3] (μm) increase of 46% (0.94 to 1.37), whereas Emulsion X (see FIGS. 14b and 14d) showed a volume mean diameter D[4,3] (μm) increase of only 31% (0.83 to 1.09)

[0247] The quality of the emulsions was also followed up for more than 2 months. Cookies were made according to the recipe in Table 9 above and the evaluation is shown below in Table 14:

TABLE-US-00014 TABLE 14 Days 4 11 25 30 39 48 57 67 Texture of emulsion (g)* Emulsion 133 133 — — 153 — — — W Emulsion 151 170 174 — 174 — — 197 X Cookie dough quality (score 1 = low-5 = best) Emulsion — 4.5 — 4.5 3.5 — 2 — W Emulsion — 5 5 — 5 5 — 5 X Cookie surface smoothness (score 1 = low-5 = best)** Emulsion — 5 — 4 4 — 1 — W Emulsion — 5 5 — 5 5 — 5 X Oiling out of dough (difference in weight filter paper = g oil absorbed Emulsion — 0.015 — 0.034 0.008 — 0.411 — W Emulsion — 0.011 0.008 — 0.011 0.008 — 0.004 X *Texture analyser probe P25 **cookie smoothness: from score 1 (very uneven, large bubbles or cracks) to score 5 (smooth surface, no cracks or bubbles)

[0248] Emulsion W is functional for 30 to 40 days, after which the emulsion starts to suffer form excess oiling out of the cookie dough, low dough quality and too many cracks in the cookie surface. In contrast, Emulsion X is functional for more than 67 days.

Example 10

[0249] A structured emulsion (Emulsion Y) in accordance with the present invention was prepared using the above general method. The composition of the structured emulsion was as follows: [0250] 50 wt. % high oleic sunflower oil [0251] 4.2 wt. % emulsifier (distilled monoglyceride, Dimodan HR 85 S6, comprising 6% by weight of the emulsifier of sodium stearate) [0252] 21.8 wt. % de-ionized water [0253] 24 wt. % sugar

[0254] Palm oil was pre-crystallised (votated) by means of scraped surface heat exchangers.

[0255] Cocoa cookie doughs were prepared using the recipe provided in Table 15 below.

TABLE-US-00015 TABLE 15 Weight (g) Comparative Invention CREAMING Emulsion Y 0 381 PHASE Palm oil (votated) 181 0 Water 98 0 Sugar 206 0 DOUGH UP Flour 465 465 PHASE Dark cocoa powder 25 25 Sugar 0 125 Salt 6.1 6.1 Skimmed milk powder 8.4 8.4 Baking powder 8.2 8.2

[0256] The creaming phase for the comparative example followed different steps: [0257] Combine sugar (refined, EC category 1) and palm oil and mix in a Hobart Mixer apparatus with a flat beater for 1 minute at Speed 1; and [0258] Add water and mix further for 1 min at speed 1 and another 3 minutes at speed 2.

[0259] The creaming phase in case of the invention was prepared by mixing in a Hobart Mixer with a flat beater for 1 minute at Speed 1 followed by 1 minute at Speed 2.

[0260] The dough up phase of dry ingredients were in each case blended and sieved before being added to the corresponding prepared creaming phase. The resulting mixture was then mixed with the Hobart Mixer for 1 minute at Speed 1 to form a dough.

[0261] The dough was rolled out until a height/thickness of 5 mm. Round dough pieces were cut (diameter 5 cm) and baked for 20 minutes in a deck oven at 180° C. (top)/160° C. (bottom).

[0262] The lightness (L*) of the cookies was followed up over time using a Byk colorimeter (Table 16).

TABLE-US-00016 TABLE 16 Time L*-values (days) Palm oil Emulsion Y  0 26.4 27.6  1 26.7 27.7  9 27.6 27.1 16 28.4 27.6 24 28.4 27.4 31 28.9 27.7 36 29.8 27.7 50 29.6 27.4 64 30.2 27.7

[0263] The cookies made with palm oil have a higher L* value over time (lighter), due to the formation of visible fat crystals on the surface of the cookies, often referred to as ‘fat blooming’.

[0264] The cookies made with the Emulsion Y have a very stable color over time. There is no fat blooming over time on the surface of the cookies.