Biscuit filling

Abstract

The present disclosure relates to a method for producing a composite biscuit product, the method comprising: forming a filling comprising a yoghurt powder and from 10 to 30 wt % of dry starch, based on the total weight of the filling, wherein the filling has an Aw of from 0.05 to 0.25 and contains live lactic cultures having a cell count of at least 10.sup.7 cfu/g; contacting the filling with one or more biscuit parts to form a composite biscuit product.

Claims

1. A method for producing a composite biscuit product, the method comprising: forming a filling comprising a yoghurt powder and from 10 to 30 wt % of dry starch, based on the total weight of the filling, wherein the filling has an Aw of from 0.05 to 0.25 and contains live lactic cultures having a cell count of at least 10.sup.7 cfu/g; contacting the filling with one or more biscuit parts to form a composite biscuit product, wherein the dry starch has a water content of less than 8 wt %, and wherein the filling comprises the yoghurt powder in an amount of from 3 to 15 wt %, based on the total weight of the filling.

2. The method according to claim 1, wherein the filling has an Aw of from 0.08 and 0.2.

3. The method according to claim 1, wherein the Aw of the composite biscuit product is less than 0.2.

4. The method of forming a filling comprising yoghurt powder and from 10 to 30 wt % of dry starch, based on the total weight of the filling, where the filling has an Aw of from 0.05 to 0.25 and contains live lactic cultures having a cell count of at least 10.sup.7 cfu/g; contacting the filling with one or more biscuit parts to form a composite biscuit product, wherein the dry starch has a water content of less 8 wt %, and wherein the filling comprises the yoghurt powder in an amount of from 3 to 15 wt %, based on the total weight of the filling, wherein the filling comprises less than 30 wt % fat and/or less than 50 wt % sugars.

5. The method of claim 1, wherein the filling comprises from 15 to 25 wt % of dry starch, based on the total weight of the filling.

6. The method of claim 1, wherein the starch has a moisture content of less than 6wt %.

7. The method of claim 1, wherein the live lactic cultures comprise Lactobacillus bulgaricus and Streptococcus thermophilus.

8. The method of claim 1, wherein the live lactic cultures have a cell count of at least 10.sup.8 cfu/g.

9. The method of claim 1, wherein the composite biscuit product has a shelf stability when stored at 20 C. of at least 6 months.

10. The method of claim 1, wherein the composite biscuit product is a sandwich biscuit comprising two biscuit parts and the filling therebetween.

11. The method of claim 1, wherein the composite biscuit product further comprises a separate water-based filling.

12. The method of claim 1, wherein the filling is formed at a temperature of from 37 C. to 46 C.

13. A composite biscuit product made by the method of claim 1.

14. A composite biscuit product comprising a biscuit part and a filling, wherein the filling comprises a powder containing live lactic cultures having a cell count of at least 10.sup.7 cfu/g, and from 10 to 30 wt % of dry starch based on the total weight of the filling, wherein the filling has an Aw of from 0.05 to 0.25, and the dry starch has a water content of less than 8 wt %, and the filling comprises the yoghurt powder in an amount of from 3 to 15 wt %, based on the total weight of the filling.

15. The composite biscuit product according to claim 14 having a shelf stability when stored at 20 C. of at least 6 months.

16. The composite biscuit product according to claim 14, wherein carbohydrates provide at least 60% of a calorific value of the product.

17. The composite biscuit product according to claim 14, wherein the filling contains at least 5g of slowly digestible starch per 100 g of filling.

18. The method according to claim 1, wherein the Aw of the composite biscuit product is less than 0.1.

19. The method of claim 1, wherein the starch has a moisture content of from 3 to 5 wt %.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The present disclosure will be described in relation to the following non-limiting figures, in which:

(2) FIG. 1 is a flowchart illustrating the different steps of one embodiment of the method for producing a food product as described here above.

(3) FIG. 2 schematically shows one embodiment of a composite biscuit product 1 as described above in a sandwich biscuit form comprising a biscuit part and a filling part. The biscuit part comprises two biscuits 21, 22 between which lies the filling part 31.

EXAMPLES

(4) The present disclosure will now be described in relation to the following non-limiting examples.

(5) Cell Count Measurement

(6) The cell count of the two cultures typically found in yoghurt (S. thermophilus and L. bulgaricus, see CODEX ALIMENTARIUS) was measured according to the official standard method for enumerating lactic bacteria (ISO 7889, Yoghurt: Enumeration of characteristic micro-organisms. A colony-count technique at 37 C.). Cell count was measured at different times during shelf-life (several months at room temperature) and the decay rate was measured according to Equation 1:

(7) $\begin{array}{cc}\mathrm{Decay}\mathrm{rate}=\frac{{\log }_{10}\left(C_0\right)-{\log }_{10}\left(C_f\right)}{\mathrm{Storage}\mathrm{time}},& \left(\mathrm{Eq}.1\right)\end{array}$

(8) Where log.sub.10(C.sub.0) is the initial log.sub.10 cell count and log.sub.10(C.sub.f) the final log.sub.10 cell count. Storage time is expressed in month, so that decay rate is expressed in log.sub.10(CFU).month.sup.1.

(9) In practice, log.sub.10(c) is plotted vs time for each culture and the decay rate is the slope of the linear regression.

(10) Viscosity Measurement of the Filling

(11) The rheological behaviour of the filling was measured using a high performance rheometer MCR300 (Anton Paar Physica) interfaced with a PC. Viscosity was measured using coaxial cylinders geometry (TEZ 150PC and CC27) at different temperatures and at a shear rate of 2 s.sup.1.

Example 1

(12) Improvement of the Survival Rates at Room Temperature During Shelf-Life with Dry Starch (Vs Standard Wheat Starch)

(13) Example 1 shows how the replacement of native wheat starch with 12% moisture by a dry starch with 5% moisture allows a significant increase in live cultures survival over the shelf-life at room temperature.

(14) A yoghurt cream was produced with the ingredients of table 1. Fat is first melted and incorporated in the mixer at a temperature of about 50-55 C. Then, all powders except yoghurt powder are dispersed under high shear in the melted fat. When added to the melted fat, the powders are at room temperature, so that their incorporation into the melted fat drops the temperature down to between 38 C. and 45 C. The resulting mixture is then further mixed during 5 to 10 minutes at high speed for obtaining a homogeneous mixture with a relatively fluid consistency. Yoghurt powder is then added to this mixture under shear and the whole is mixed for 2 to 5 minutes resulting in a yoghurt filling (cream) with a viscosity of about 14 Pa.Math.s. The yoghurt filling is then transferred from the mixer into a double jacketed buffer tank kept at 400.5 C. with mild stirring.

(15) TABLE-US-00001 TABLE 1 Ingredients Filling 1 Filling 2 Fat 27.5 27.5 Sugars 36.0 36.0 Starch 12% moisture 20.0 Starch 5% moisture 20.0 Yoghurt powder 11.0 11.0 Sweet whey powder 5.0 5.0 Others (texturing agents, flavours, 0.5 0.5 etc.) TOTAL 100.0 100.0

(16) TABLE-US-00002 TABLE 2 Time (month) Filling 1 Filling 2 Cell count for 0.1 8.7 8.7 S. thermophilus 1.0 8.2 8.8 (logCFU .Math. month.sup.1) 1.5 7.9 8.9 1.9 8.0 8.8 3.0 7.7 8.8 4.1 7.2 8.5 Cell count for 0.1 4.2 4.2 L. bulgaricus 1.0 3.5 4.2 (logCFU .Math. month.sup.1) 1.5 3.4 3.6 1.9 3.0 3.9 3.0 1.8 3.9 4.1 1.0 3.0

(17) Table 3 shows decay rate for the 2 strains contained in yoghurt in the 2 fillings. L. bulgaricus is more sensitive to storage than S. thermophilus. The replacement of native wheat starch by dry starch allows improving very significantly the survival, as shown by the reduction in the decay rate.

(18) TABLE-US-00003 TABLE 3 Filling 1 Filling 2 Decay rate (logCFU .Math. month.sup.1) of 0.36 0.05 S. thermophilus Decay rate (logCFU .Math. month.sup.1) of 0.82 0.25 L. bulgaricus Decay rate of total cell cultures 0.36 0.05

Example 2

(19) Improvement of the Survival Rates During Processing at High Temperature with Dry Starch (Vs Standard Wheat Starch)

(20) Example 2 shows how this also leads to an improved cell count survival during processing of the fat cream at different temperatures ranging from 37 C. to 46 C.

(21) The same filling composition as Example 1 was used. This composition was kept in a Dispermat mixer operating at 1500 rpm during 10 min then 200 rpm for the rest of the processing time. The double jacket was isothermally held at different temperatures for up to 24 hours, and a small quantity of filling was regularly sampled and yoghurt cultures cell count were enumerated.

(22) Table 4 shows the decay rate for the 2 strains contained in yoghurt, in the 2 fillings and at the different temperatures.

(23) TABLE-US-00004 TABLE 4 Temperature Filling 1 Filling 2 Decay rate 37 C. 2.5 Not measured (logCFU .Math. month.sup.1) 40 C. 3.7 2.4 for S. thermophilus 43 C. 16.1 Not measured 46 C. 25.6 7.9 Decay rate 37 C. 35.0 Not measured (logCFU .Math. month.sup.1) 40 C. 62.1 36.5 for L. bulgaricus 43 C. 97.9 Not measured 46 C. 186.4 72.6

(24) As already observed at room temperature, L. bulgaricus is much sensitive than S. thermophilus.

(25) For a given strain (S. thermophilus or L. bulgaricus), the decay rate shows a strong increase with processing temperature. In average, the decay rate is increased by a factor 2.6 and 16.8 respectively for S. thermophilus and L. bulgaricus per each C. increase.

(26) By contrast, with the filling 2, the decay rate is only increased by a factor 0.9 and 6.0 for filling 2, showing that the use of dry starch instead of the native starch has a stabilizing effect on the survival of the live cultures. Comparing the decay rates vs temperatures for the 2 fillings, one can see that the same value is obtained with a temperature difference of about 3 C. for Filling 1 compared with Filling 2. For instance, a decay rate value of 2.5 log CFU.month.sup.1 is obtained for S. thermophilus with Filling 2 at 40 C. whereas it is obtained at 37 C. for Filling 1. Same situation is observed with L. bulgaricus. Since processing temperature is mainly governed by filling rheology, it follows that processing Filling 2 at 40 C. isfrom the point of view of cultures survivalequivalent to processing Filling 1 at 37 C., a temperature at which the filling would be too stiff/firm to be deposited.

Example 3

(27) Improvement of Filling Fluidity with Dry Starch (VS Standard Wheat Starch)

(28) The same filling composition as Example 1 was used. 9 different fillings were prepared according to the process given in Example 1. The only difference was the type of starch, either obtained from wheat or corn, and with moisture content ranging from 3 to 14%. The fillings were prepared according to Example 1 and their viscosity was measured at 40 C.

(29) Table 5 summarizes the information obtained on the different starches as well as the properties of the fillings.

(30) TABLE-US-00005 Starch Botanical Starch Starch Filling Filling (supplier) origin moisture (%) Aw Aw viscosity Meritena 200 Wheat 11.3 0.375 0.33 14.1 (Tereos-Syral) Dry starch 5% Wheat 5.4 0.09 0.15 11.5 (Roquette) Meritena 100 Corn 11.6 0.41 0.32 18.4 (Tereos-Syral) C* Gel LM Corn 5.8 0.12 0.18 12.3 3416 (Cargill) C* Gel LM Corn 3.1 0.05 0.09 10.7 3411 (Cargill) Merizet 118 Corn 7.3 0.17 0.19 10.5 (Tate & Lyle)

(31) Example 3 shows that using a dry starch instead of a native starch decreases the Aw of the filling. Surprisingly, it also reduced filling viscosity significantly. The reduction in viscosity between the filling containing 12% moisture starch and those containing 5% moisture starch is about 18% for wheat and 33% for corn. Such a reduction in viscosity was not expected from the prior art, since US2010136182/FR2895877, comparing starch at 13% moisture vs starch at 5% moisture in fat-based fillings, does not see any benefit in using the dry starch and recommends using standard starch.

(32) Such viscosity reduction potentially allows depositing the filling at a lower temperature, while keeping the same fluidity. The survival of live cultures is ultimately enhanced by 2 different mechanisms: the fact that filling can be deposited at a lower temperature (Example 3) and the fact that at any temperature, survival is enhanced with dry starch vs standard starch (Example 2).

Example 4

(33) Improvement of the Survival Rates at Room Temperature During Shelf-Life with Dry Starch (Vs Standard Wheat Starch) in the Composite Product

(34) Example 4 shows how the replacement of native wheat starch with 12% moisture by a dry starch with 5% moisture allows a significant increase in live cultures survival over the shelf-life at room temperature in the final composite product.

(35) A composite product is obtained by assembling two biscuits with a yoghurt filling. For a sandwich biscuit of 25.3 g, the weights of the different components are 18.3 g for the biscuit part and 7 g for the yoghurt filling. The different components are produced according to the following manner.

(36) Biscuit

(37) The biscuit is produced as described in European Patent application n. 11290279.6, Healthy layered cookie, of the same applicant with the ingredients of Table 6.

(38) TABLE-US-00006 TABLE 6 biscuit Ingredients Quantity (wt. %) Flour blend 47.9 Oat flakes 14.1 Sugar blend 15.7 Vegetable fat 10.2 Others (baking powders, salt, etc.) 12.1 TOTAL 100.0

(39) The yoghurt filling are produced according to Example 1. Filling 1 contains starch at 12% moisture while filling 2 contains starch at 5% moisture.

(40) Assembling

(41) After baking, biscuits are cooled to a temperature of 303 C. The yoghurt filling at 40 C. is then deposited onto a first biscuit. A second biscuit at 303 C. is deposited onto the top of the filling part, this second biscuit and the first biscuit forming the biscuit part. The obtained sandwich biscuit is conveyed into a cooling tunnel. At the exit of the cooling tunnel, the sandwich biscuit is at a temperature of 212 C. and is immediately packaged into a sachet of aluminium foil, the sachet is then sealed.

(42) Storage

(43) The composite products were stored in their sealed sachet at a temperature of 20 C. After 2 months, the packs were open and the filling was separated from the biscuit and live cultures content was enumerated using the official method. The results in log.sub.10 cfu/g of yoghurt filling are shown in Table 7 below.

(44) TABLE-US-00007 TABLE 7 Cell count evolution Filling of Filling of composite composite Storage time product 1 product 2 Yoghurt strain (months) (logCFU/g) (logCFU/g) S. thermophilus 0 8.6 8.6 2 8.2 8.4 L. bulgaricus 0 4.1 4.1 2 3.1 3.8

(45) The Aw of the composite products was also measured. The composite product 1 had a Aw of 0.140.01 and the composite product 2 had a Aw of 0.080.01.

(46) Surprisingly, the survival is higher in the composite product 2 than in the composite product 1. This observation goes against prior art. Indeed, the studies on the impact of Aw on the survival of yoghurt cultures have shown that the cultures survive best in a Aw range between 0.11 and 0.23. This was shown on L. bulgaricus by Castro et al. who concluded that the survival rate was not linearly related to Aw and that environments at Aw of 0.11 and 0.23 gave the greatest survival rates (Teixeira, P. C. Castro, M. H., Malcata, F. X. and Kirby, R. M., 1995, Survival of Lactobacillus delbrueckii ssp. Bulgaricus following spray-drying, J Dairy Sci, 78, 1025-1031). Below 0.1, the survival decreases, i.e. cultures are less stable. The reason for the accelerated rate of decay at very low Aw could be explained by the damage caused upon the removal of structural water from important cell molecules (Castro, H. P., Teixeira, P. M and Kirby, R., 1995, Storage of Lyophilized Cultures of Lactobacillus bulgaricus under different relative humidities and atmospheres, Appl Microbiol Biotechnol, 44, 172-176).

(47) The foregoing detailed description has been provided by way of explanation and illustration, and is not intended to limit the scope of the appended claims. Many variations in the presently preferred embodiments illustrated herein will be apparent to one of ordinary skill in the art, and remain within the scope of the appended claims and their equivalents.