METHOD FOR THE PRODUCTION OF PROTEIN AND FIBER RICH AIRY FOOD PRODUCT

Abstract

The invention relates to a baked food product comprising a protein, a dietary fiber, water, a stabilizer, and optionally a digestible carbohydrate, wherein the baked food product comprises at least 30 wt % of the protein based on a dry matter weight, wherein at least 50 wt % of the protein consist of albumin, and wherein a weight ratio of the protein to the dietary fiber is selected in the range of 0.75-4, wherein the food product is a gluten-free food product, and wherein a weight ratio of the optional digestible carbohydrate to protein is equal to or less than 0.15. Further, a process for the production of such food product and a baking composition obtainable by the process is described.

Claims

1. A baked food product comprising a protein, a dietary fiber, water, a stabilizer, and optionally a digestible carbohydrate, wherein the baked food product comprises at least 30 wt % of protein based on a dry matter weight, wherein at least 50 wt % of the protein consist of albumin, and wherein a weight ratio of the protein to the dietary fiber is selected in the range of 0.75-4, wherein the food product is a gluten-free food product, and wherein a weight ratio of the optional digestible carbohydrate to the protein is equal to or less than 0.15.

2. The baked food product according to claim 1, wherein, if the digestible carbohydrate is available, a weight ratio of the digestible carbohydrate to the protein is equal to or less than 0.05.

3. The baked food product according to claim 1, comprising at maximum 60 wt % protein based on the dry matter weight.

4. The baked food product according to claim 1, wherein the dietary fiber comprises one or more of a vegetable fiber and a fruit fiber.

5. The baked food product according to claim 1, wherein the dietary fiber comprises one or more of citrus fiber and inulin.

6. The baked food product according to claim 1, wherein the dietary fiber is available in an amount of 15-25 wt % based on a dry matter weight of the baked food product.

7. The baked food product according to claim 1, wherein the stabilizer comprises one or more stabilizers selected from the group consisting of a hydrocolloid, lecithin (E322), glycerol (E422), mono- and di-glycerides of fatty acids (E471), acetic acid esters of mono- and diglycerides (E472a), lactic acid esters of mono- and diglycerides (E472b), citric acid esters of mono- and diglycerides (E472c), tartaric acid esters of mono- and diglycerides (E472d), diacetyltartaric acid esters of mono- and diglycerides (E472e), and mixed esters of mono- and diglycerides (E472f), sodium or calcium stearoyl lactate (E481, E482), and sorbitan mono stearate (E491).

8. The baked food product according to claim 7, wherein the stabilizer comprises one or more stabilizers selected from the group consisting of mono- and di-glycerides of fatty acids (E471) and diacetyltartaric acid esters of mono- and diglycerides (E472e).

9. The baked food product according to claim 1, wherein the stabilizer is available in an amount of 0.5-7.5 wt %, on a dry matter weight of the baked food product.

10. The baked food product according to claim 1, claims, further comprising flax seed.

11. The baked food product according to claim 1, claims, further comprising oil or fat selected in the range of 0-7.5 wt % based on the dry matter weight of the baked food product.

12. The baked food product according to claim 11, wherein the oil and/or fat are available in an amount of 0.2-7.5 wt % based on the dry matter weight of the baked food product.

13. The baked food product according to claim 11, wherein the oil or fat comprise one or more of butter, palm oil, coconut oil, and rape oil.

14. The baked food product according to claim 1, comprising a bread-like food product, wherein a total area of gas cells relative to a total slice area of a slice of the food product as determined with a C-Cell analysis is selected from the range of 45-55% and wherein the baked food product comprises water in an amount selected in the range of 40-60 wt % relative to a total weight of the baked food product.

15. The baked food product according to claim 1, comprising a food product selected from the group consisting of a bun, a cookie, a cake, and a cracker.

16. A process for the production of a baked food product, the process comprising: heating a baking composition comprising a fiber, a protein, water, an optional leavening agent, a stabilizer, and optionally further ingredients, to provide the food product; wherein the baking composition comprises a water amount selected in the range of 50-72.5 wt %, a protein amount selected in the range of 12-20 wt %, a fiber amount selected in the range of 5-16 wt %, a leavening agent amount selected in the range of 0-10 wt %, and a stabilizer amount selected in the range of 0.01-3 wt %, relative to a total weight of the baking composition.

17. The process according to claim 16, wherein the process comprises a mixing stage and a baking stage, wherein the mixing stage comprises mixing the fiber, the protein, water, the stabilizer, and optionally the optional leavening agent and the optional further ingredients to provide the baking composition; and the baking stage comprises heating the baking composition.

18. The process according to claim 17, wherein the mixing stage comprises: mixing dry ingredients to provide a dry mixture, wherein the dry ingredients are the ingredients selected from the group comprising the fiber, the protein, the stabilizer, the optional leavening agent, and the optional further ingredients, wherein the ingredient comprises at least 90 wt % dry matter relative to a total weight of the ingredient; mixing wet ingredients in the dry mixture into a smooth batter, wherein the wet ingredients are the ingredients selected from the group comprising water, the fiber, the protein, the stabilizer, the optional leavening agent, and the optional further ingredients, wherein the ingredient comprises less than 90 wt % dry matter relative to the total weight of the ingredient.

19. The process according to claim 16, wherein the optional further ingredients comprise fat.

20. The process according to claim 19, wherein an amount of fat in the baking composition is selected from the range of 1-10 wt % relative to a total weight of the baking composition.

21. The process according to claim 16, wherein the fiber comprises one or more of a citrus fiber and inulin.

22. The process according to claim 16, wherein the fiber comprises a combination of a cold-swelling fiber and a texturizing fiber, wherein a ratio of the cold-swelling fiber to the texturizing fiber is selected from the range of 40:60-60:40.

23. The process according to claim 16, wherein an amount of the fiber in the baking composition is selected in the range 5-17.5 wt % relative to a total weight of the baking composition.

24. The process according to claim 16, wherein the stabilizer comprises one or more stabilizers selected from the group consisting of mono- and di-glycerides of fatty acids (E471) and diacetyltartaric acid esters of mono- and diglycerides (E472e).

25. The process according to claim 16, further comprising a proofing stage, wherein the baking composition to be baked is proofed during a proofing period, wherein the proofing stage is configured before heating the baking composition.

26. The process according to claim 16, wherein the optional further ingredients further comprise flax seed.

27. The process according to claim 16, wherein the baking composition comprises the optional leavening agent, wherein the leavening agent comprises a leavening agent selected from the group of yeast, baking powder, and baking soda.

28. The process according to claim 27, wherein the leavening agent comprises yeast.

29. The process according to claim 16, wherein the protein comprises albumin.

30. The process according to claim 16, wherein the stabilizer comprises a hydrocolloid.

31. The process according to claim 16, wherein the baking stage comprises heating the baking composition at a temperature selected in the range of 120-290 C. during a baking period selected in the range of 5 min-120 min.

32. The process according to claim 16, wherein the baking stage after heating the baking composition during the baking period further comprises: providing a vacuum to the baked baking composition, wherein the vacuum is configured for cooling a core of the baking composition to a core temperature selected from the range of 35-40 C.

33. (canceled)

Description

EXPERIMENTAL

Initial Set of Experiments

[0091] Bread-like products have been prepared and evaluated. The ingredients are given in the following table:

TABLE-US-00002 Ingredient description Water tap water Egg white powder Spray dried albumin (about 81% protein) Fruit fiber natural citrus fiber (sugars and oils are removed) Inulin 1 inulin syrup, soluble dietary fiber, in water (about 8% sugars) Inulin2 Inulin powder, long chain Salt NaCl Baking powder baking soda with an acid, and filler Xanthan gum stabilizing agent/thickener Ground flax seed ground seeds comprising dietary fibers and fatty acids
Using the process conditions given below:
1. Solving inulin1 in warm water; mixing for 2 minutes (setting 2/3) (.fwdarw.clear solution)
2. Pre-mixing dry ingredients (Citrus fiber, salt, xanthan, flax seed) (.fwdarw.homogeneous mixture)
3. Mixer at setting 1, within 1 min. adding the dry mixture to the water with dissolved inulin1 (.fwdarw.no aggregations formed).
4. Mixer at setting 2 and mixing for 1.5 min. (.fwdarw.homogeneous mixture).
5. Mixer at setting 3 and mixing for 3.5 min. (.fwdarw.viscous mixture).
6. Remove (scrape) dry ingredients from side of the bowl (.fwdarw.left over powder removed from bowl).
7. Mixer at setting 2 and add protein powder within 1.5 min. (.fwdarw.no dust formation).
8. Mixing for 2 minutes with mixer at setting 3 (.fwdarw.batter).
9. Scrape dry ingredients from sides of bowl (.fwdarw.left over powder removed form side of the bowl).
10. Mixing for 1.5 minutes at setting 2 (.fwdarw.incorporation scrapings)
11. Mixing for 2 min. at setting 3 (.fwdarw.airy and sticky batter)
12. Gradually add baking powder during 30 sec. with mixer at op setting 1 (.fwdarw.no dust).
13. Mixing for 30 sec. at setting 2 (.fwdarw.no dust).
14. Mixing for 20 sec at setting 3 (.fwdarw.homogeneous distribution).
15. Coat the baking tin with a fat based release agent (.fwdarw.no sticking).
16. Fill the tin to about 2 centimeters below the rim (.fwdarw.prevent overflow).
17. Put the tin in the oven.
18. Preferably pre-steam (.fwdarw.may improve rising process)
19. Bake at 175 C. during 45 minutes (use other condition for yeast) (.fwdarw.leavened bread)
20. Remove bread immediately after baking from tin (.fwdarw.no sticking).

Compositions of the Baking Composition (to be Baked)

[0092]

TABLE-US-00003 Trial Trial Trial Trial Trial Trial Trial Ingredients 11.1 11.2 11.3 11.4 12.1 12.2 12.3 Water 68% 68% 68% 60% 65.5% 70.5% 65.5% Egg white 7.5% 17.5% 12.5% 35% 17.5% 15% 17.5% powder Citrus fiber 15% 5% 10% 5% 7.5% 5% 5% Inulin1 7.5% 7.5% 7.5% 0 7.5% 7.5% 7.5% Salt 0.4% 0.4% 0.4% 0 0.4% 0.4% 0.4% Baking 1.2% 1.2% 1.2% 0 1.2% 1.2% 1.2% powder Xanthan 0.4% 0.4% 0.4% 0 0.4% 0.4% 0.4% gum Flax seed 2.5% Total 100 100 100 100 100 100 100 Trial Trial Trial Ingredients 13.1 13.2 13.3 Water 65.5% 65.7% 65.7% Egg white 17.5% 17.7% 17.7% powder Citrus fiber 5% 5% 5% Inulin1 7.5% 7.5% Inulin2 7.5% Salt 0.4% 0.4% 0.4% Baking powder 1.2% 1.2% 1.2% Xanthan gum 0.4% 0 0.8% Flax seed 2.5% 2.5% 2.5% Total 100 100 100
Quality parameters [0093] Stretchability, rupture of crumb, a crispy crust: Texture analyzer [0094] Leavened volume and shape, resilience: Volscan (volume), C-cell, Texture analyzer [0095] Size and wall thickness of crumb (cells): C-Cell [0096] Doneness, moisture loss, moisture: Weighing, measuring core temperature, sensory evaluation [0097] Crispness of the crust, browning of the crust: Sensory evaluation, LAB color measurement, Texture analyzer

First Results

[0098] 11.1: Rejection. Too compact, not airy. Lower limit protein/Upper limit fiber.
11.2: Good. Airy, resilient, good crust color, looks like white bread.
11.3: Rejection. Too compact, not airy. Lower limit protein/Upper limit fiber.
11.4: Rejection: Plastic appearance, off flavor, upper limit protein.
12.1: Acceptable. Less leavening volume. Upper limit fiber.
12.2: Rejection. Bread collapses during baking, compact, moist. Lower limit protein/Upper limit water.
12.3: Good. Like 11.2, but with a visual effect of flaxseed.
13.1 Good. No sugar, dry fiber replaces fiber syrup. Brown color disappears.
13.2: Rejection. Poorly raised, less airy bread, less volume. Lower limit xanthan
13.3: Good. Improved texture, more cells, more volume, less spongy, more bread-like.

[0099] Based on these results new trials have been performed with ingredient concentrations varied (relative to the total weight of the baking composition), see following table:

TABLE-US-00004 Trial Trial Trial Trial Trial Trial 4.1 4.2 4.3 4.5 4.6 4.10 Ingredients [wt %] [wt %] [wt %] [wt %] [wt %] [wt %] Water 63 63 65.2 67.5 69.5 63 Egg white powder 20 22.5 17 18 18.5 17.5 Citrus fiber 5 2.5 5 2.5 0 4 Inulinl 7.5 7.5 7.5 7.5 7.5 4 Salt 0.4 0.4 0.4 0.4 0.4 0.3 Baking powder 1.2 1.2 1.2 1.2 1.2 10 Xanthan gum 0.4 0.4 1.2 0.4 0.4 1.2 Flax seed 2.5 2.5 2.5 2.5 2.5 0 Total 100 100 100 100 100 100

Results

[0100] 4.1: Good. More compact and crumb is firmer, smaller bubbles/cells
4.2: Rejection. Deformed and crust shines like plastic. Upper limit protein
4.3: Rejection. Deformed, undercooked, disproportional (strongly) leavened. Upper limit xanthan (solo)
4.5: Rejection. Deformed, plastic shine, too large cells, not uniformly cooked. Lower limit (citrus) fiber
4.6: Rejection. Like 4.5 but enhanced effects. Below lower limit (citrus) fiber
4:10: Good. Nice crumb, large bubbles, elastic like bread. Improved texture compared to 12.3.
4:10: Rejection. Salty, metallic taste, baking powder ingredient too high, porous crust, but very good airy texture

[0101] Based on the experiments the following preliminary technical limits can be deduced. Note: Not all possible combinations can be tested, see e.g. the outcome of trial 4.3 vs. 4.4 (both increase Xanthan, but the end result changes because of other relationships). The wt percentages are depicted relative to the total weight of the baking composition.

TABLE-US-00005 Ingredient wt % Water 60-70.5 Egg white powder 15-22.5 Citrus fiber 2.5-10 Inulin 1 4-7.5 Salt 0.3-0.4 Baking powder 1.2-10 Xanthan gum 0.4-1.2 Ground flax seed 0-2.5

[0102] Remark: In this mixture, especially, the water, the egg protein, the fiber ingredient(s), the leavening agent and the stabilizer seem most relevant. Inulin1 is a dietary fiber syrup (oligosaccharides) and can be exchanged with long chain inulin powder or a different dry dietary fiber. The total minimal amount of fiber (citrus+Inulin1+Inulin2 inulin) required and the maximum that still works are estimates. Total fiber is expected to be somewhere between 7.5 and 17.5 wt %. The data are based on the values of recipes that did not produce good result, and as such provide functional limits.

Further Experiments

[0103] For scale up purposes, the process steps have been optimized/combined in further experiments. An average recipe used in these experiments is given in the next table:

TABLE-US-00006 Wt % Dry matter in On total On dm the ingredient Ingredient (wet) base base Wt % Water 54 0 0 Sugars 22 5.7 92 Emulsifier 0.5 1.4 99 Egg white powder 17 43.8 92 Citrus fiber 4.5 11.7 92.6 Inulin2 4.5 12.2 97 Improver (60% fat, 4.5 12.6 100 40% emulsifier) Liquid yeast 10 5.3 19 Xanthan gum 0.6 1.6 98 Ground flax seed 2.2 5.6 91 Total 100 100

[0104] Average recipe used in the further experiments.

[0105] Using 1000 grams of the recipe and the process stages listed below, breads have been baked having a final weight of about 750-780 grams; i.e. during baking 22-25% (about 23-24% on average) of the total baking composition is lost as water.

1. Add about 50% of the water to a dough kneader already comprising all mixed dry ingredients and the fat;
2. Mix the ingredients to a firm batter;
3. Add the remainder of the water together with the liquid yeast and mix into a smooth slightly elastic batter (start the mixing slow and finish faster);
4. Coat the baking tin with a fat based release agent;
5. Fill the tin with 325-350 g batter;
6. Dough proof for about 30-35 min;
7. Bake at about 180-210 C. during 30-40 minutes;
8. Optionally: vacuum cool the breads during to a core temperature of 35-40 C.

[0106] To obtain a sensory result similar to three commercially prepared types of Dutch bread, i.e. a white bread (wit brood), a wholemeal/brown bread (bruin brood), and a whole grain bread (volkorenbrood), as well as a commercial prepared gluten free bread, a light brown food product (code BL) and a darker food product (code MZ) comprising extra seeds and extra brown colored fruit extract for a darker color have been produced, using the following recipes:

TABLE-US-00007 MZ BL Ingredient wt % wt % Water 49.5 53.75 Sugars 2 2.25 Emulsifier 0.4 0.5 Roasted sesame seeds 4.5 Roasted sunflower seeds 4.5 Egg white powder 15 17 Citrus fiber 4 4.5 Inulin2 4 4.5 Fat + emulsifier 4 4.5 Liquid yeast 9 10 Xanthan gum 0.6 0.6 Concentrated fruit extract 1 0.5 Ground flax seed 1.5 1.9 Total 100 100

[0107] Recipes for the dark (MZ) and the light brown (BL) bread.

[0108] The commercial breads were prepared at the same time by the standard industrial process.

Analysis of the Products

[0109] The products were analyzed with a Texture Analyzer and a C-Cell using standard methods approved by the American Association of Cereal Chemist (AACC), respectively the AACCI 74-09 and AACCI 10-18.01 method.

[0110] Hardness (also indicated as the elastic softness) of the crumb was determined with a Texture Analyser by means of a first measurement; wherein the force required to press a probe 20 mm into a cube of crumb having a thickness of 25 mm (one slice of 25 mm or two slices of 12.5 mm on top of each other) with a speed of 2 mm/s.

[0111] The degree of relaxation (also indicated as stickness) was determined by means of a second measurement: This measurement starts as the first measurement, but at the end the measure the probe is kept at 20 mm depth for 30 sec and then the force is measured again. The ratio of the second force to the hardness is the degree of relaxation.

[0112] Using a C-Cell colour, the number of cells per cm.sup.2, cell diameter, cell wall thickness, cell elongation, cell volume, ratio cell area to total area of a slice (%), and the brightness of the slice were determined.

[0113] Next to the structural and textural aspects, the amount of digestible carbohydrates in the BL and MZ products were analyzed.

Results

Textural Aspect

[0114] The measured data including the standard deviation (std) of the texture analysis of the different types of bread are given in the next table.

TABLE-US-00008 max load relaxation Type (gram force) std (%) std White 245.08 35.15 28.94 1.95 Brown 171.15 33.09 29.02 1.97 Whole 178.75 12.67 30.51 1.5 grain BL 401.23 26.03 37.2 0.57 MZ 312.77 20.07 39.43 0.16 Gluten 580.63 3.11 29.75 0.34 free

[0115] Hardness (compressibility) and relaxation of the samples

[0116] Normal bread (white, brown and whole grain) is softer than the BL and MZ samples. The commercial gluten free product was significantly harder than the BL and MZ samples. The relaxation percentages of the BL and MZ samples were a little higher than the commercial types of bread, indicating that the BL and MZ samples are more resilient. Above given results are for bread analyzed at the day of production.

[0117] Further analyses were also performed using a penetrometer to determine the compressibility of the samples one day after production and two days after production (results not incorporated in this patent document). These experiments showed a large increase in the hardness and significant decrease in the relaxation percentages of the commercial breads at day 2 relative to day 1 after production, whereas the MZ and BL samples kept their initial compressibility (tenderness) It is assumed that this difference is due to the starch being present in all the commercial bread. Starch containing bread becomes stale in a short period, because of retrogradation of the starch. The food product of the invention contains substantially no starch and may keep its textural quality for an extended period (relative to commercial starch containing bread).

Structural Aspects

[0118] The analyzed data obtained using the C-Cell measurements are given in the tables below:

TABLE-US-00009 Number Cel Cell wall of cells diameter thickness Cell per cm.sup.2 (mm) (mm) elongation Type mean std mean Std mean std mean std White 73.9 4.6 2.1 0.1 0.5 0.0 1.7 0.0 Brown 65.9 2.8 2.7 0.2 0.5 0.0 1.6 0.0 Whole grain 56.0 4.4 3.1 0.3 0.5 0.0 1.6 0.0 BL 95.1 3.9 1.6 0.1 0.4 0.0 1.6 0.0 MZ 91.2 4.9 1.8 0.1 0.4 0.0 1.6 0.0 GF 80.7 4.4 1.9 0.1 0.5 0.0 1.5 0.0
Results C-Cell analysis

TABLE-US-00010 Cell volume Ratio Cell Brightness of (mm.sup.3) area (%) the slice Type mean std mean std mean std White 6.4 0.4 52.6 0.4 152.7 0.2 Brown 9.9 0.7 54.3 0.3 112.6 0.4 Whole grain 11.9 1.2 55.4 0.5 95.8 0.3 BL 5.3 0.3 49.4 0.3 138.6 1.4 MZ 6.4 0.3 50.5 0.2 120.0 0.7 GF 6.7 0.2 49.1 0.2 85.3 0.2

[0119] Results C-Cell analysis, continued.

[0120] Based on these results, it is concluded that the structural parameters of the BL and MZ samples are comparable to the parameters of the commercial normal breads and the commercial gluten free (GF) bread. The measured structural parameters may fall in the ranges of the different types of commercial wheat starch and gluten free breads. The values of the structural parameters of the bread-like food product of the invention resemble the ones of the white bread the most.

Digestible Carbohydrates

[0121] The total amount of digestible carbohydrates is given below based on the amount of starch and the amount of the total of sugars analyzed. Based on the analyzed values the amount based on a dry matter is calculated.

TABLE-US-00011 Type Type Wt % Wt % product carbohydrate (tw) (dm) BL Starch 0.30 0.72 Total of sugars 0.12 0.29 Total digestible carbohydrates 0.42 1.01 MZ Starch 0.30 0.72 Total sugars 0.34 0.81 Total digestible carbohydrates 0.64 1.53
Amount of digestible carbohydrates in the products; tw: based on total weight of the product (bread), dm: based on the dry matter weight of the product.

[0122] Conclusion: Even in the recipe comprising the carbohydrate containing sunflower seeds (MZ), the amount of digestible carbohydrates in the final product is less than 1 wt % and about 1.5 wt % based on the dry matter of the final product.