Patent Application
20080044524
A plurality of different embodiments of the invention are shown in the Figures of the application. Similar features are shown in the various embodiments of the invention. Similar features have been numbered with a common reference numeral and have been differentiated by an alphabetic suffix. Also, to enhance consistency, features in any particular drawing share the same alphabetic suffix even if the feature is shown in less than all embodiments. Similar features are structured similarly, operate similarly, and/or have the same function unless otherwise indicated by the drawings or this specification. Furthermore, particular features of one embodiment can replace corresponding features in another embodiment unless otherwise indicated by the drawings or this specification.
The invention relates to processes for producing food products with omega-3 fatty acids, apparatus' for carrying out the processes, and the edible food products that result from practice of the processes and apparatus'. Two embodiments of the invention are set forth below. Generally, each of the embodiments provide a process for incorporating omega-3 fatty acids that contemplates “gentle” handling of the omega-3 fatty acids to reduce the likelihood that the omega-3 fatty acids will oxidize. From one perspective, control over the temperature of the handling/manufacturing process is enhanced in the exemplary embodiments. For example, a maximum desirable temperature limit of 120° F. is established. From a second perspective, control over the mechanical stress experienced by the omega-3 fatty acids is enhanced. For example, gravity is used in part to move an omega-3 fatty acids containing coating to reduce the need to exert excess pressure on the coating to induce movement through the handling/manufacturing system. From a third perspective, control over exposure of the omega-3 fatty acids to oxygen is enhanced. For example, a flow or stream of inert gas can be directed at any point along the system to flush oxygen away from the omega-3 fatty acids, the coating, or the combined omega-3 fatty acids and coating. Individually and cumulatively, these perspectives increase the shelf-life of the coating, whether the coating is applied directly onto another food product such as a bar, or whether the coating is mixed as discrete pieces with other discrete food pieces such as ready-to-eat (RTE) cereal. The invention provides the benefit of increasing the shelf-life of the omega-3 fatty acids containing coating, the shelf-life defined by the time period lasting until the coating exhibits an appreciable fishy odor or taste.
As discussed above marine animals and marine plants are the main sources of EPA and DHA omega-3 fatty acids. The use of fish oils as a source of EPA and DHA is well known. Recently, a number of manufactures have developed processes for growing marine micro algae with high efficiency. These micro algae are a great source of EPA and DHA at very high yields in a completely renewable process. Such micro algae derived EPA and DHA are available from a number of sources. One source of micro algae derived EPA and DHA is Martek Biosciences Corporation, Columbia, Md., USA. A second source of micro algae derived EPA and DHA is Nutrinova Nutrition Specialties and Food Ingredients, DE. The omega-3 fatty acids can be provided as a free flowing powder for the present invention or as a liquid oil, usually including an additional carrier oil. To make the powdered form, typically, the fatty acids are plated onto bulking agents such as corn syrup solids, mannitol, calcium carbonate, whey protein isolate, gluten, pregelatinized starches, cellulose fiber, carbohydrates, gelatin, flour, grain, bran, freeze dried whole fruits and fruit powders. The plated powders are then spray dried to form a free flowing powder. The omega-3 fatty acids can be provided as the free fatty acid or in the form of triglycerides, generally the triglyceride form is more stable. In the present specification and claims unless specifically noted there will be no distinction made between the free form or the triglyceride form of the omega-3 fatty acids or whether the omega-3 fatty acids are used as a powdered form or in the form of a liquid oil.
Referring now to
The omega-3 fatty acid is an ingredient of a coating applied to the food product, a coating such as chocolate or a compound coating. Chocolate and compound coating are not necessarily mutually exclusive; a compound coating can include cocoa powder and be chocolate flavored. Generally, a compound coating is a confectionary product based on vegetable fat. For example, the fat can be provided to the compound coating by cocoa butter, palm kernel oil, coconut oil, partially hydrogenated forms of palm kernel oil or coconut oil or soybean oil as some examples. In addition to vegetable fat the confectionary or compound coatings typically contain sugar and may optionally contain flavorings such as cocoa solids, peanut solids, other natural or artificial flavors, emulsifiers, coloring agents, salt, and milk solids.
In the first exemplary embodiment of the invention, a compound coating 14 in the form of solid discrete pieces is liquefied and applied to the snack bar 12. The apparatus 10 is operable to convert the coating 14 in substantially solid form to substantially liquid form for application to a food product or for creation of a discrete piece of omega-3 fatty acid containing coating.
The omega-3 fatty acid is pre-mixed with the other ingredients of the compound coating 14 in the first exemplary embodiment of the invention. However, in alternative embodiments of the invention, the omega-3 fatty acid can be combined with the coating by the apparatus carrying out a process according to the invention, as shown in the second exemplary embodiment of the invention set forth below. In the invention, the omega-3 fatty acid is mixed with the coating at some point prior to the dispensing of the coating from the apparatus.
The first exemplary apparatus 10 includes an auger assembly 16 to convert the coating 14 from substantially solid form to substantially liquid form. In alternative embodiments of the invention, an apparatus for practicing the invention may include structures other than an auger/screw design. Separate components, one for melting/liquefying the coating and one for mixing the omega-3 fatty acid, can be cooperatively engaged to practice the invention. An advantage of a screw/auger arrangement is that the process can be a “first-in, first-out” process whereby the compound coating need not be maintained in liquid form in a vat for extended periods of time. In other words, the apparatus of the first exemplary embodiment of the invention is non-recirculating. However, if this not deemed an advantage in certain operating environments, the invention can be practiced in other ways to achieve different advantages. An apparatus for practicing the invention “starts” when the temperature of the coating is 120° F. or less.
The apparatus 10 also includes a distribution manifold 18, a plurality of metering pumps 20, and a plurality of application heads 22. The auger assembly 16 includes a hopper 24 for receiving a mass of the compound coating 14, a tube-like auger housing 26, a screw or auger 28, a drive motor 30, and heating bands 32, 34. The hopper 24 communicates the mass of compound coating 14 to auger housing 26. The auger 28 is disposed in the auger housing 26 for rotation. The motor 30 drives the auger 28 in rotation. In operation, the rotation of the auger 28 draws the compound coating from the hopper 24, through the auger housing 26, and toward the manifold 18.
As best shown in
It can be desirable to heat the compound coating slightly to promote passage of the compound coating through the auger assembly 16. Heating changes the compound coating 14 to a molten state and reduces the viscosity of the compound coating 14 and enhances the flow of the compound coating 14. The heating bands 32, 34 are arranged downstream of the hopper 24 along the auger housing 26 to gradually heat the compound coating 14 to about 105° F. Heating of the compound coating 14 occurs in the enclosed auger housing 26 portion of the auger assembly 16 and not the open hopper 24.
Maintenance of a desired temperature at any position along the auger assembly 16 can be controlled or enhanced by application of a water bath at the desired temperature.
The compound coating 14 moves from the auger assembly 16 to the distribution manifold 18. Although not shown in the drawings, the manifold 18 can be heated as desired to raise the temperature of the compound coating 14. Alternatively, the temperature of the compound coating 14 can be maintained between 100° F. and 110° F. throughout the apparatus 10 from the auger housing 26 to the application heads 24.
The compound coating 14 moves through the distribution manifold 18 to the plurality of metering pumps 20. The pumps 20 enhance the precision of and control over the flow of compound coating 14 through the application heads 22. The compound coating 14 is dispensed onto the snack bars 12 from the application heads 22. The dispensing heads 22 dispenses the compound coating 14 in the form of line, but alternative embodiments of the invention can include dispensing heads that dispense the omega-3 fatty acid mixture in spray form. In still other embodiments, the omega-3 fatty acid mixture may be dispensed separately from the food item and added
As best shown in
Referring now to
The apparatus 10a includes a cooling band 38a proximate to the hopper 24a. The cooling band 38a can be sleeve-like, surrounding the auger housing 26a, and channeling a flow of cooling fluid such as water around the auger housing 26a. The auger assembly 16a can be cooled at the location of the hopper 24a to reduce the likelihood that the temperature of the hopper 24a will increase and thereby induce melting of the chocolate prior to entry into the auger housing 26a. In the second exemplary embodiment of the invention, the stream of coolant can be substantially maintained at a temperature of 50° F.
It can be desirable to heat the chocolate slightly to promote passage of the compound coating through the auger assembly 16a. Heating changes the chocolate to a molten state and reduces the viscosity of the chocolate, thereby enhancing the flow of the chocolate. The heating bands 32a, 34a are arranged downstream of the hopper 24a along the auger housing 26a to gradually heat the chocolate to about 105° F.-110° F. Heating of the chocolate occurs in the enclosed auger housing 26 portion of the auger assembly 16a and not the open hopper 24a. The heating bands 32a, 34a, can be sleeve-like, encircling the auger housing 26a and channeling a flow of heating fluid such as water. The bands 32a, 34a, 38a are fed coolant by the pumps and fluid lines shown in
The heating band 32a is disposed substantially immediately upstream of a second hopper 40a. The second hopper 40a communicates with the interior of the auger housing 26a and is operable to receive omega-3 fatty acid in powder form. The omega-3 fatty acid in powder form is encapsulated. Martek Biosciences Corporation of Maryland produces an encapsulated form of omega-3 fatty acid that can be used in embodiments of the invention, such as the product number KSF35D. In alternative embodiments of the invention, omega-3 fatty acid in forms other than powder may be introduced to the interior of the auger housing 26a through the hopper 40a.
In the second exemplary of the invention, the hopper 40a is disposed at a location along the auger housing 26a where the chocolate is not fully melted. The omega-3 fatty acid therefore initially contacts the chocolate at a relatively lower temperature. The combined omega-3 fatty acid and chocolate is further heated by the heat band 34a downstream. Thus, the chocolate is heated in a first stage to first temperature by the band 32a and is heated in a second stage to a second temperature by the band 34a. The first temperature can be between about 100° F.-105° F. and the second temperature can be between about 110° F.-120° F. As a result of the arrangement of the second exemplary apparatus 10a, the temperature of the omega-3 fatty acid rises gently, with the rise in temperature of the chocolate.
The amount of omega-3 fatty acid added through the hopper 40a can be any amount desired. For example, the amount of omega-3 fatty acid introduced to the auger interior can result in a mixture of omega-3 fatty acid and chocolate that is dispensed on the food product having a ratio of between about 1 milligram of omega-3 fatty acid per gram of chocolate to about 100 milligrams of omega-3 fatty acid per gram of chocolate.
The heating band 34a is disposed substantially immediately downstream of a second hopper 40a. The heating band 34a gently raised the temperature of the combined omega-3 fatty acid and chocolate to a temperature desirable for dispensing the mixture on a food product and below 120° F. The mixture of omega-3 fatty acid and chocolate exits the auger assembly 16a and is received in a reservoir 42a associated with the metering pump 20a.
Alternative embodiments of the invention can incorporate more cooling and/or heating bands.
Referring again to
The apparatus 10a can be arranged such that the combined coating (chocolate in the second exemplary embodiment of the invention) and omega-3 fatty acid travel together only through the narrowed section of the screw assembly 16a at which the thread of the screw 28a is relative short and widely spaced. In other words, it may be desirable to combine the omega-3 fatty acid with the chocolate to the housing 26a at the point immediately prior to the screw thread becoming short and widely spaced. Alternatively, it may desirable to combine the omega-3 fatty acid with the chocolate to the housing 26a at a point subsequent to the screw thread becoming short and widely spaced so that the temperature of the chocolate is more precisely controlled prior to combining with the omega-3 fatty acid.
Referring to
The combined coating produced by the first and second embodiments of the invention is substantially homogenous. The omega-3 fatty acid is generally evenly dispersed in the compound coating. As a result, the output of the system will include some quantity of omega-3 fatty acid at a surface. The output of the system can be a layer disposed on top of, below, or around another edible item. Such a layer will have some quantity of omega-3 fatty acid exposed, not covered by the coating or the other food item. The output of the system could also be a discrete piece, to be added to some other edible product or to be consumed as-is. Such an output will have some quantity of omega-3 fatty acid exposed.
The combined coating and omega-3 fatty acid can be applied to a food bar. In one embodiment, a quantity of the combined coating was applied to a food bar having a water activity of about 0.6. The bar has been subjected to an accelerated shelf life test, at 85° F. It has been observed that, currently, the coated bar has not exhibited a fishy aroma and taste after 20 weeks storage. It is believed that the coated bar may not exhibit a fishy aroma and taste after 36 weeks storage.
The present invention is directed to processes, apparatus, and food products with omega-3 fatty acid. However, the teachings herein can be applied to applying any nutriceutical sensitive to temperature, mechanical stress, and chemical reaction (oxidation or other chemical reactions analogous to oxidation) to a food product. Probiotics, anti-oxidants, and other sensitive nutriceuticals can be incorporated into a food product by the teachings set forth herein.
The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/822,408, filed on Aug. 15, 2006, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60822408 | Aug 2006 | US |
