Process for making a bouillon tablet or bouillon cube

Abstract

The invention relates to a manufacturing process for the production of a bouillon tablet or bouillon cube. In particularly the invention relates to a process for the production of a bouillon tablet or bouillon cube wherein the hygroscopic amorphous ingredients are encapsulated with fat and wherein the encapsulated hygroscopic amorphous ingredients have a fat content of between 22 to 80%.

Claims

1. A process for preparing a bouillon product, comprising: 5 to 40% of fiber (by weight of the composition), characterized by having a rate of hydration between 15 to 500 cP/min; 5 to 20% of fat (by weight of the composition), characterized by having a slip melting point in a range of 42-69° C. and at a temperature of 30° C. a solid fat content of 35-75%; 30 to 80% of crystalline ingredients (by weight of the composition); and 5 to 35% of hygroscopic amorphous ingredients (by weight of the composition); comprising the steps of: a) encapsulating fiber with fat to generate a fiber-fat powder; wherein the fiber has a fat content of between 22 to 80% (by weight of the fiber); b) mixing the fiber-fat powder with the crystalline ingredients and the non-hygroscopic amorphous ingredients to make a bouillon product in the form of: powder, tablet or cube; and c) packaging the bouillon product.

2. The process according to claim 1, wherein the fiber has a Tg in the range of −5° C.<Tg<60° C. at 0.1<aw<0.6.

3. The process according to claim 1, wherein the hygroscopic amorphous ingredients are selected from the group consisting of yeast extract, vegetable powder, animal extract, bacterial extract, vegetable extract, meat powder, reaction flavor or hydrolysed plant protein and combinations thereof.

4. The process according to claim 1, wherein the fiber has a Tg of at least 60° C. at 0.1<aw<0.6.

5. The process according to claim 1, wherein the fiber comprises: maltodextrin, starch, flour, or combinations thereof.

6. The process according to claim 1, wherein the crystalline ingredient is selected from the group consisting of salt, monosodium glutamate, sugar or citric acid anhydrous and combinations thereof.

7. The process according to claim 1, wherein the encapsulated hygroscopic amorphous ingredients have a fat content of between 30 to 60%.

8. The process according to claim 1, wherein the bouillon product further comprises 0.1 to 30% garnishes, herbs or spices or a combination thereof (by weight of the composition).

9. The process according to claim 1, wherein the encapsulation of the fiber is done by using a core-shell technology.

10. The process according to claim 1, wherein the encapsulation of the fiber is done by using fluidized bed technology.

11. The process according to claim 1, wherein the encapsulated fiber is not in granular form.

12. The process according to claim 1, wherein the encapsulated fiber does not comprise starch.

Description

EXAMPLES

(1) The invention is further described with reference to the following examples. It is to be appreciated that the examples do not in any way limit the invention.

Description of Methods

(2) The process of sample preparation can be subdivided in the three basic processing steps; encapsulating of hygroscopic amorphous ingredients, mixing of bouillon masses and pressing of bouillon tablets.

(3) Prior processing, it has to be decided, which materials will be encapsulated.

Selection of Core Materials

(4) Which materials of a bouillon recipes will be encapsulated is decided based on their hygroscopicity. Ingredients are classified as hygroscopic, if they possess a Tg in the range of −5° C.<Tg<60° C. at aw0.1<aw<0.6.

(5) Furthermore, the amount of available fat in the recipe and the total quantity of hygroscopic amorphous ingredients determine kind and quantity of ingredients that can be encapsulated. If the total fat content is too low to encapsulate all materials, classified as above, materials in the Tg range of 10° C.<Tg<45° C. at aw0.2<aw<0.5 are preferably chosen as core material over those with higher Tg. If not all ingredients with this classification can be encapsulated, ingredients with Tg 10° C.<Tg<40° C. at aw 0.2<aw<0.4 are preferably chosen.

Preparation of Fat Encapsulated Ingredients

(6) Encapsulating has to be performed in a way that hygroscopic amorphous ingredients are preferably fully and homogeneously covered with fat

(7) A homogeneous encapsulation can e.g. be produced via core-shell technologies like fluidized bed encapsulation technology or to produce fat flakes with incorporation of hygroscopic ingredients

Fluidized Bed Encapsulation

(8) A batch fluidized bed encapsulator (GPCG 15, Glatt GmbH, Germany) was used to encapsulate hygroscopic amorphous substances. The experiments were carried out using the top-spray method. The process needs to be executed in a way that a fine, flow-able powder is generated. Hygroscopic amorphous ingredients act as core materials and are homogenously encapsulated with the fat.
Prior to the actual encasulation process, the desired amount of selected hygroscopic amorphous ingredients was filled in the bottom part of the encapsulation-chamber. Encapsulation was performed by fluidizing this material at the lower part of the chamber and spraying the melted fat from the top on the particles (top-spray method). Droplet formation, contact, spreading, coalescence and solidification are proceeding almost simultaneously.
All operating parameters have to be chosen in a way that fat homogeneously spreads around the fluidized particles and forms a thin layer on the surface of each fluidized particle.
The droplet size, received during spraying of encapsulating material, is crucial for the encapsulating quality. The molten fat needs to be atomized into small droplets. Larger droplets might lead to undesired agglomeration phenomena. It should be emphasized that it is desired to encapsulate every particle and thus to separate the particles. At the same time, it has to be avoided that particles stick together.
Fat was heated (70° C.) outside the encapsulation-chamber on a heating plate and pumped via heat-able tubes (70° C.) to the nozzle. The flow rate of the encapsulated material can be controlled by a pump and was set to 78-128 g/min.
The nozzle was heated by spraying air to a temperature between 50-75° C. in order to inhibit premature crystallisation of fat. The spraying air was also used to preheat the encapsulation-chamber. Prior to the actual encapsulation-experiments, the hot air (50-75° C.) was circulating for 30 min in the chamber. The pressure of the spraying air influences the spraying pattern and the droplet size. A pressure of 1.5-2 bar was chosen in order to generate small droplets of fat, which spread over the fluidized particles and form a homogeneous encapsulation layer. It is thereby of importance that the produced droplets (less than 100 μm) are smaller than the fluidized particles. The fluidized bed was built up by the fluidizing air stream, which flows through an inlet pipe at the bottom of the chamber. Before entering the system, the fluidizing air was preheated to a desired temperature (30° C.). The product temperature measured during spraying varied between 17-25° C.
The volumetric flow of the fluidizing air is an important parameter, as it is used to control the height of the fluidized bed. The core material should be fluidized in a way that the tip of the nozzle is immersed in the fluidized bed. Furthermore, the volumetric flow of the fluidizing air should be high enough to prevent that particles stick together.
In order to implement this during the whole process, the volumetric flow was adjusted while the fluidized bed encapsulator was running. A low volumetric flow (350 m.sup.3/h) was applied in the beginning of the process. Throughout the process the volumetric flow of the fluidizing air had to be adapted. This is due to the increasing weight of the fluidized bed, caused by the addition of fat. The volumetric flow had to be increased (up to 800 m.sup.3/h) during the process in order to maintain an appropriate fluidization of the powder.
Once the complete amount of palm fat was atomized, a cooling step was executed. During this, the product was continuously fluidized for 10 min. At the same time, the fluidizing air temperature was reduced to 10° C., resulting in a final average product temperature of 12° C.

Fat Flake Production

(9) In a first step, hygroscopic amorphous ingredients were dispersed in molten fat (65° C.) in a bionaz tank (N° B 20 0000) with double jacket (Bionaz, France). This tank is equipped with a stirring device and a dispersion disc. The operating parameters were chosen in a way that a homogeneous dispersion of the particles in the fat was achieved.
In a second step, fat flakes were produced with a cooling drum (K6, 5/6) (Sulzer-Escher Wyss AG, Switzerland). The produced dispersion was pumped in a feed basin and distributed with an applicator roll as a thin layer on the rotating cooling drum (Rotation: 10.3 rpm; Temperature: Cold side: −15 to −14.5° C.; Warm side: −11.2 to −9.3° C.). A scraper (clearance: 0.25 mm) removes the material from the drum and forms fat flakes.

Preparation of Bouillon Powder

(10) The preparation of the model recipes was performed with a Lödige ploughshare batch mixer (FM 130 D) (Gebrüder Lödige Maschinenbau GmbH, Germany). This mixer is composed of a horizontal, cylindrical drum with rotating ploughshare shovels. The ploughshare shovels are used as mixing elements and are organized systematically in the drum. The mixer is equipped with a chopper.
Mixing was performed in four steps. During the first step crystalline ingredients were mixed for 30 s at 200 rpm (without chopper). In the second step fat powder was added and mixed at 200 rpm for 60 s. During this mixing step, sunflower oil was sprayed in the mixer. To avoid the formation of lumps, the chopper was used during this mixing step. In case the complete amount of fat in a recipe was incorporated via encapsulated material, only sunflower oil and crystalline ingredients were mixed in this step. In the third step, all remaining materials, except garnishes, were added and mixed for 60 s at 200 rpm. The chopper was turned on for 15 s. During the last mixing step, garnishes were added and mixing was performed at 200 rpm for 30 s (without chopper).
It is also possible to use a different mixing procedure. For example, melted fat can be used instead of powdered fat. When fat is introduced in melted form, fat is completely melted at 80° C. (clear and transparent in appearance) and sprayed in the mixer during the first mixing step. Mixing time can then be increased.
One batch mixing was carried out for 50 kg bouillon powder. The resulting powder was then stored in closed plastic bags for at least 24 h at room temperature prior to pressing.

Pressing of Bouillon Cube

(11) Pressing of bouillon cube was carried out with Flexitab Tablet Pressing equipment (Röltgen GmbH, Germany). Bouillon powder was automatically fed to a tableting mold. Filling depth was adjusted in a way to receive cubes with an average weight of 4 g and height of 14 mm.

Hardness Measurement of Bouillon Tablet

(12) Hardness measurement was carried out using Texture Analyser TA-HDplus (Stable Micro System, UK) equipped with 250 kg load cell and P/75 compression platen. Texture Analyser test mode was set to “Compression” with pre-test speed of 1 mm/s, test speed of 0.5 mm/s, post-test speed of 10 mm/s, target mode of “Distance”, distance of 5 mm, halt time was set to “No”, way back of 10 mm, trigger type to “Auto(Force), and trigger force of 50 gram. Bouillon tablet was placed centrally in vertical-landscape orientation. Hardness measurement was carried out in 10 replication.

Evaluation of Post-Hardening of Bouillon Tablets

(13) For each sample, hardness was measured directly after pressing, with the described method. Additionally, prior to hardness measurement, cubes of each sample were stored unpacked at specified conditions to evoke post hardening phenomena. A memmert ICH 100 L climate chamber (Memmert GmbH+Co. KG, Germany) was used for storage of samples.
In order to provoke and evaluate post hardening, cubes were stored at varying relative humidity. In a first step, cubes should absorb moisture and were thus stored at higher relative humidity. During a second storage step, relative humidity was reduced in order to cause drying of cubes. Two different storage conditions have been used to investigate post hardening of cubes (see table 1).

(14) TABLE-US-00001 TABLE 1 Storage conditions applied for investigation of post hardening. Relative Temperature Time Condition Step humidity [%] [° C.] [d] A 1 55 25 3 2 15 25 3 B 1 60 25 4 2 30 25 3
Post hardening of samples, containing encapsulated hygroscopic amorphous ingredients was compared with hardness of samples containing pure hygroscopic amorphous ingredients (reference). Therefore the hardness of the hard bouillon cube has been measured as described above.

Examples 1-3

(15) Hygroscopic amorphous ingredients in the recipe were identified based on their Tg-curves including celery root powder, onion powder, chicken extract, bacterial extract and yeast extract (11.9% of the recipe). Encapsulation of the hygroscopic amorphous ingredients was done with the available palm fat of the recipe (9.9%). No additional palm fat was used compared to the example with non-encapsulated hygroscopic amorphous ingredients. An encapsulation-ratio of 40% fat and 60% hygroscopic amorphous ingredients was applied. Thus a total quantity of 19.83% encapsulated material was used in the sample, whereas the reference contains the pure hygroscopic amorphous ingredients. In addition only 3% of the hygroscopic amorphous ingredients has been encapsulated and an encapsulation-ratio of 40% fat and 60% hygroscopic amorphous ingredients was applied. Thus a total quantity of 5% encapsulated material was used in the sample.

(16) TABLE-US-00002 Comp. Comp. Ingredients example 1 Example 2 example 3 NaCl 55 55 55 Sugar 7 7 7 Palmfat Powder 9.9 1.97 7.9 Chicken fat 2.4 2.4 2.4 Starch Corn Native 6% 5.5 5.5 5.5 Hygroscopic amorphous 11.9 — 8.9 ingredients (not encapsulated) Garnishes, herbs and spices 8.3 8.3 8.3 Hygroscopic amorphous — 19.83 5 ingredients (encapsulated) Average hardness after 99 90 94 pressing [N] Average post hardening [N] 782 158 761 Storage: 1. Step: 55% r.h., 25° C., 3d 2. Step: 15% r.h., 25° C., 3d
The encapsulation of hygroscopic amorphous ingredients (example 2) causes less post-hardening of the bouillon cube as observed in comparison example 1. The bouillon cube of example 2 has still a very good crumbliness wherein the bouillon cube from comparison example 1 is too hard to be crumbled by a consumer. In addition as can be shown with comparison example 3 that encapsulation of only 3% of hygroscopic amorphous ingredients (by weight of the composition) does not result in a reduced post-hardening effect.

Examples 4-5

(17) Hygroscopic amorphous ingredients in the recipe were identified based on their Tg-curves including celery root powder, onion powder, bacterial extract and hydrolyzed plant protein (11.9% of the recipe). Encapsulation of the hygroscopic amorphous ingredients was done with the available palm fat of the recipe (8%). No additional palm fat was used compared to the example with non-encapsulated hygroscopic amorphous ingredients. An encapsulation-ratio of 40% fat and 60% hygroscopic amorphous ingredients was applied. Thus a total quantity of 19.83% encapsulated material was used in the sample, whereas the reference contains the pure hygroscopic amorphous ingredients.

(18) TABLE-US-00003 Comp. Ingredients Example 4 Example 5 Salt NaCl 57 57 Sugar 9.5 9.5 Palmfat Powder 8.0 0.07 Oil Sunflower 0.8 0.8 Starch Potato 20% Moisture 9 9 Hygroscopic amorphous ingredients 11.9 — (not encapsulated) Garnishes, herbs and spices 3.8 3.8 Hygroscopic amorphous ingredients — 19.83 (encapsulated) Average hardness after pressing [N] 236 180 Average post hardening [N] 495 296 Storage: 1. Step: 55% r.h., 25° C., 3d 2. Step: 15% r.h., 25° C., 3d

(19) The encapsulation of hygroscopic amorphous ingredients (example 5) causes less post-hardening of the bouillon cube as observed in comparison example 4.

Examples 6-10

(20) Hygroscopic amorphous ingredients in the recipe were identified based on their Tg-curves including celery root powder, onion powder, bacterial extract, reaction flavor and hydrolyzed plant protein (12.6% of the recipe). Encapsulation of the hygroscopic amorphous ingredients was done with the available palm fat of the recipe (8%). No additional palm fat was used compared to the example with non-encapsulated hygroscopic amorphous ingredients. Encapsulation was performed via fluidized-bed technology (FB) as well as via incorporation of fat flakes. The total amount of available palm fat (8%) was used to produce fat flakes (39% fat content). The selected sensitive amorphous ingredients were furthermore encapsulated with three different encapsulation-ratios (39%/30%/20%) via fluidized-bed encapsulation.

(21) TABLE-US-00004 Comp. Example Example Example Comp. Ingredients Ex. 6 7 8 9 Ex. 10 Salt NaCl 55 55 55 55 55 Sugar 8 8 8 8 8 Palmfat Powder 8 — — 2.6 4.85 Oil Sunflower 0.8 0.8 0.8 0.8 0.8 Starch Potato 20% 8.5 8.5 8.5 8.5 8.5 Moisture Hygroscopic amorphous 12.6 — — — — ingredients (not encapsulated) Garnishes, herbs and 7.1 7.1 7.1 7.1 7.1 spices Fat flakes (39% fat — 20.6 — — — content) Hygroscopic amorphous — — 20.6 — — ingredients (39% fat content via FB) Hygroscopic amorphous — — — 18 — ingredients (30% fat content via FB) Hygroscopic amorphous — — — — 15.75 ingredients (20% fat content via FB) Average hardness after 149 110 112 126 109 pressing [N] Average post hardening 869 310 280 288 422 [N] Storage: 1. Step: 60% r.h., 25° C., 4d 2. Step: 30% r.h., 25° C., 3d
Using hygroscopic amorphous ingredients (comp. example 6) which are not encapsulated result in the highest post-hardening effect of the bouillon cube. Example 7 and 8 show that with any of the encapsulation processes a reduced post-hardening of the bouillon cube is achieved compared to the not encapsulated comparison example 6. In addition within comparison example 10 it is shown that a fat content of 20% of the encapsulated hygroscopic amorphous ingredients still reduces the post-hardening effect of the bouillon cube. However, the obtained hardness of the cube exceeded the maximum acceptable limit for crumbliness as evaluated by 10 internal experienced panelists.