Patent Application
20070298079
In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
The invention relates to a food product fortified with omega-3 fatty acids. In one embodiment, the food product comprises a liquid beverage. The liquid beverage, in one embodiment, comprises orange juice. The orange juice, for example, is a not-from-concentrate (NFC) orange juice. Food products comprising other types of beverages or juices, such as citrus, non-citrus, from concentrate, and not from concentrate, or others are also contemplated and within the scope of the invention. The food product could be in liquid form or non-liquid form. For example, the food product could be provided as a ready-to-drink beverage or in dry form for reconstituting with a liquid, such as water, for drinking. Additionally, the food product could be yogurt, oatmeal, cereal, cheese, pudding, rice cakes, snack bars, or other types of hand-held, non-refrigerated food products.
In one embodiment, the omega-3 fatty acids comprise the long-chain omega-3 fatty acids eicosapentaenoic acid (EPA) and docosahexaenoic acid (DHA). The long-chain omega-3 fatty acids are derived from, for example, marine or fish oils. Such oils can be extracted from various types of fish or marine animals, such as anchovies, capelin, cod, herring, mackerel, menhaden, salmon, sardines, shark and tuna, or from marine vegetation, such as micro-algae, or a combination thereof. Other sources of omega-3 fatty acids include liver and brain tissue and eggs.
The ratio of EPA to DHA in the orange juice or other food product may vary depending on the source of the omega-3 fatty acids (e.g., fish oils), the manner in which the omega-3 fatty acids are mixed, and the beverage/food product to be produced. The EPA:DHA ratio will vary to suit a particular application and can include, for example, 0:100, 100:0, 2:1, or 3:2. In a particular application the EPA:DHA ratio is 60:40; however, other ratios are contemplated and within the scope of the invention.
In one embodiment, the omega-3 fatty acids are added to the product (e.g., orange juice) in a powdered form and/or as a free oil in a liquid form. Additionally, the omega-3 fatty acid could be supplied in a gel form or as part of an emulsion with other types of carriers. Various types of powdered omega-3 fatty acids can be used. In one embodiment, the powdered form includes powdered omega-3 fatty acids prepared by spray-drying the fish oils into an encapsulation matrix comprising, for example, a protein and a carbohydrate. The matrix encapsulates the fish oils, forming microcapsules in the range of about 1-500 microns. In one embodiment, the encapsulate size range is about 5-100 microns. Additional ranges include about 0.5 to 20 microns. The particle size will be vary as necessary to suit a particular application and may be selected based on desired mouthfeel, visual appearance (hazy, cloudy, or opaque), oxidation stability, and suspension stability within the product. Encapsulated and multi-encapsulated fish oils include, for example, Meg-3® from Ocean Nutrition Canada. Encapsulated fish oils are advantageous, since the microcapsules can effectively protect the omega-3 fatty acids from stresses encountered due to oxidation of fatty acids during processing, such as, shear mixing, high temperature processing, and during subsequent storage.
A desired amount of omega-3 fatty acids is provided to the beverage/food product. The amount may vary depending on the application and nutritional content desired. In one embodiment, the orange juice comprises about 5-5000 mg of omega-3 fatty acids per 8 fluid ounces (0.24 liters)(serving size). The amount to be added will vary to suit a particular application and can be based, at least in part, on nutritional value, taste, shelf-life, efficacy levels approved, qualified health claims, and combinations thereof. Other amounts are also contemplated and within the scope of the invention. For example, it may be desired to provide at least 32 mg of omega-3 fatty acids (combined EPA and DHA) per serving of the beverage/food product to meet the United States Food and Drug Administration (FDA) excellent source nutrient content claim requirements, or 16 mg to meet the FDA good source nutrient content claim requirements. The omega-3 fatty acids are sufficiently mixed in the food product to provide a relatively uniform distribution; however, mixing is not limited to dissolving the omega-3 fatty acids in a liquid. For example, the omega-3 fatty acids may be mixed in powder form with a powdered drink mix (e.g., Gatorade® from Stokely-Van Camp, Inc.) to form a substantially evenly blended powdered product.
The beverage/food product may include other nutritional ingredients. For example, short-chain omega-3 fatty acids such as alpha-linolenic acid (ALA), which are derived from micro-algae or other sources, omega-6 fatty acids, vitamins, minerals, or a combinations thereof may also be added to the product. Ingredients such as sweeteners, flavorings, colorings, thickeners, emulsifiers, acidulants, electrolytes, proteins, carbohydrates, and preservatives can also be added to the product, as desired.
The finished food product with the omega-3 fatty acids may have a shelf-life of about 2-12 months and possibly up to 24 months under ambient conditions, depending on the level of processing the product undergoes, the type of packaging, and the materials used for packaging the product. In another embodiment (e.g., a more lightly processed product), the finished product with the omega-3 fatty acids may have a shelf-life of about 12 weeks under refrigerated conditions. Additional factors that may affect the shelf-life of the product include, for example, the nature of the base formula (e.g., a beverage sweetened with sugar has a longer shelf-life than a beverage sweetened with aspartame) and environmental conditions (e.g., exposure to high temperatures and sunlight is deleterious to ready to drink (RTD) beverages).
In one embodiment, the pre-processing forms an intermediate food product just prior to pasteurization. Providing an intermediate food product at other stages of processing is also contemplated and within the scope of the invention. For example, the pre-processing can form an intermediate food product that requires additional processing prior to pasteurization. Various conventional techniques can be employed to form the intermediate food product. The pre-processing may vary depending on the application. In the case of NFC orange juice, this includes, for example, the addition of fortification or other additives and the lowering of the acidity levels of the juice, as disclosed in U.S. Pat. Nos. 6,565,898, 6,682,767, and 6,761,915, the entire disclosures of which are hereby incorporated herein by reference.
The intermediate food product can include various additional ingredients, such as vitamins, minerals, flavoring agents, sweeteners, coloring agents, other functional ingredients, stabilizers and pH adjusters, as desired. Other additives, such as those described hereinabove, are also contemplated and within the scope of the invention. Generally, the ingredients can be added prior to pasteurization, prior to mixing with the omega-3 fatty acid, and/or at the same time as the omega-3 fatty acid. The ingredients can also be added post-pasteurization.
In accordance with one embodiment of the invention, a desired amount of omega-3 fatty acids is added to the intermediate food product at step 120. The amount of omega-3 fatty acids added is, for example, about 5-5000 mg per 8 fluid ounces (0.24 liters) serving. Other amounts may also be useful, for example, depending on the serving size and nutritional content. In one embodiment, the omega-3 fatty acids in encapsulated or multi-encapsulated powder form are added to the intermediate food product. In another embodiment, the omega-3 fatty acids in encapsulated, multi-encapsulated slurry form, or as a free oil in a liquid form are added to the intermediate food product.
The omega-3 fatty acids are added to the intermediate food product after or during mixing of the intermediate food product. In one embodiment, high shear mixing is performed on the intermediate food product; however, other types of mixing are contemplated and within the scope of the invention, such as, for example, low energy/low shear mixing (e.g., stirring) and high energy/high shear mixing. The mixing can also be performed manually or as part of a batch process. Various types of high shear mixers can be employed. Typically, the high shear mixer includes rotatable blades enclosed in a housing. In one embodiment, the intermediate food product is made by use of two mixers. The first is a powder mixer that allows for incorporation of the ingredients in the intermediate food product. The second is an in-line high shear mixer. Mixing should be accomplished so as not to not destroy the encapsulation matrix, which might result in oxidation taking place. The mixer(s) can be selected for a specific application based, at least in part, on the type and amount of ingredients used, amount of product to be produced, and the flow rate. Generally, a commercially available mixer, such as those available from Invensys APV of Getzville, N.Y. or Silverson Machines, Inc. of East Longmeadow, Mass., may be used.
Many methods of incorporating the ingredients into the food product are available. In one embodiment, powder addition (or mixing) and high shear mixing is used. The powder mixer consists of a mixer-housing made up of an upper and lower chamber. The upper chamber has inlet connections for liquid and powder and the lower chamber has a special mixing-impeller mounted on a stainless steel shaft. The mixer operates by adding the dry ingredients into the hopper using a butterfly valve that controls the flow of powder from the hopper and prevents air from entering into the mixer. The dry powder gets sucked into the mixer where the impeller incorporates the ingredient into the intermediate food product stream. After passing the powder mixer, the intermediate food product then enters the high shear mixer. As the product is driven through the blades, the flow is repeatedly sheared through the action of the rotating blades. The high shear mixing disperses the omega-3 fatty acids sufficiently in the intermediate food product.
At step 130, the intermediate food product with omega-3 fatty acids is typically pasteurized. In one embodiment, pasteurization comprises pasteurizing the intermediate food product. The pasteurization process may include, for example, ultra high temperature (UHT) treatment and/or high temperature-short time (HTST) treatment. The UHT treatment includes subjecting the intermediate product solution to high temperatures, such as by direct steam injection or steam infusion, or by indirect heating in a heat exchanger. Generally, after the product is pasteurized, the product is optionally cooled as required by the particular product and/or the package filling application. For example, in one embodiment, the intermediate product solution is subjected to heating to about 185° F. (85° C.) to about 250° F. (121° C.) for a short period of time, for example, about 1 to 30 seconds, then cooled quickly to about 36° F. (2.2° C.) ±10° F. (5° C.) for refrigerated products, to ambient temperature for shelf stable or refrigerated products, and to about 185° F. (85° C.) ±10° F. (5° C.) for hot-fill applications for shelf-stable products. The pasteurization process is typically conducted in a closed system, so as not to expose the food product to atmosphere or other possible sources of contamination. Other pasteurization or sterilization techniques may also be useful, such as, for example, aseptic or retort processing. In addition, multiple pasteurization processes may be carried out in series or parallel, as necessitated by the food product or ingredients.
After processing is completed, post-processing is performed at step 140; however, post-processing may include any process steps carried out after the addition of the omega-3 fatty acids to the product. Post-processing includes, for example, cooling the product solution and filling it into containers for packaging and shipping. Post-processing may also include deaeration of the food product to <4.0 ppm oxygen, preferably <2.0 ppm, and more preferably <1.0 ppm; however, deaeration and other “post-processing” tasks may be carried out prior to processing, prior to pasteurization, prior to mixing with the omega-3 fatty acid, and/or at the same time as mixing the omega-3 fatty acid. In addition, an inert gas (e.g., nitrogen) headspace may be maintained during intermediary processing of the product and final packaging. Additionally or alternatively, an oxygen barrier and/or oxygen scavengers could be used in the final packaging. It is also contemplated and within the scope of the invention to include the process step of homogenizing the food product.
As described in accordance with one embodiment of the invention, the omega-3 fatty acids are incorporated into the food product in an encapsulated or powder form and subjected to high shear mixing. When compared with conventional methods, such as, for example, incorporating such components in oil form, the present invention gives rise to several significant advantages. For example, emulsifier need not be added to stabilize the fish oils, and no homogenization step is required during processing. In addition, reduction in the number of processing steps results in less off-flavors from oxidation of the omega-3 fatty acids, producing a more palatable product with a longer shelf-life.
The invention may be embodied in other specific forms without departing form the spirit or essential characteristics thereof. The foregoing embodiments, therefore, are to be considered in all respects illustrative rather than limiting the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.
