Methods Of Fortifying Foods With Vitamin D And Food Products Thereof

Abstract
Methods are provided for making nutrient fortified foods, and particularly methods of fortifying cheeses and the resulting cheese products. These methods maximize nutrient retention in the final packaged product by fortifying desired portions of the food product and minimize fortification in other portions of the food product. Moreover the fortification methods described herein allow significant amounts of nutrient supplements to be delivered per serving of food product without adversely affecting functionality or product quality. Foods fortified by the disclosed methods retain their desired textures, mouthfeel, flavor, and other organoleptic properties.
Description

BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 is a process flow chart of methods for the fortification of a food product, such as cheese products, in accordance with embodiments of the present invention;



FIG. 2 is a schematic diagram of a method for topically fortifying a cheese brick with a solution containing a nutrient at the point of packaging in accordance with one embodiment of the present invention;



FIG. 3 is a schematic diagram of another method for topically fortifying a cheese stick with a solution containing a nutrient at the point of packaging;



FIG. 4 is a schematic diagram of a method for topically fortifying a cheese slice with a coated interleaf paper bearing a nutrient-containing coating at the point of packaging in accordance with an embodiment of the present invention; and



FIG. 5 is a schematic diagram of a method for topically fortifying cheese strings with a coated paper bearing a nutrient-containing coating at the point of packaging in accordance with an embodiment of the present invention.





DETAILED DESCRIPTION

Referring to FIG. 1, exemplary methods of fortification are illustrated using topical fortification systems that provides the nutrient(s) to the food product at the point-of-packaging. Fortifying at the point-of-packaging maximizes nutrient retention in the final product and minimizes nutrient losses in undesired food product portions.


In one form, a food product is fortified during its manufacture at the point-of-packaging by topically applying a nutritional supplement to an individual food product unit just prior to the final packaging of the individual unit. As used herein, point-of-packaging refers to either during or just prior to the actual packaging step in a manufacturing process. Preferably, the nutritional supplement is applied “in-line” as the food product is transferred to the packaging station. Fortification in this manner—just prior to final packaging and to individual food product units rather than large quantities of bulk food product upstream (e.g., prior to product portioning into individual units)—permits more efficient fortification and minimizes or substantially eliminates the loss of fortifying nutrients) in waste streams.


In a preferred embodiment, the selected nutritional supplement is topically applied to an outer surface of a cheese product via a method of the present invention at a coating or application rate (e.g., up to about 0.4 ml/serving—however this rate is widely variant depending on the nutrient and cheese product) effective to deliver at least about 10% DV of the supplement per serving of the food product. For instance, the nutritional supplement is applied to an outer surface of a cheese, such as cheddar cheese, Colby cheese, Monterey jack, havarti cheese, Muenster cheese, brick cheese, Gouda cheese, and mixtures thereof, or applied to the outer surface of a processed cheese.


Preferably the nutritional supplement is vitamin D (e.g., vitamin D3 and vitamin D2); however, the nutritional supplement may also contain other vitamins, minerals, antioxidants, probiotics, botanicals, and mixtures thereof. For example, the nutritional supplement may contain vitamin A, vitamin C, vitamin E, vitamin B1, vitamin B2, vitamin B3, vitamin B6, vitamin B12, vitamin K, niacin, folate, folic acid, biotin, calcium, magnesium, copper, iron, zinc, chromium, iodine, phosphorus, pantothenic acid, potassium, sodium, manganese, phosphate salt, sulfate salt, chloride salt, propyl gallate, octyl gallate, dodecyl gallate, butylated hydroxyanisole, butylated hydroxytoluene, Acidophilus Bifidobacterium, Lactobacillus Johnsonii, ginseng, ginkgo biloba, Echinacea, and mixtures thereof.


Optionally, the nutritional supplement may also include other functional ingredients. For instance, the solution may contain anticaking agents, antimycotic agents, other antioxidants, preservatives, colors, flavors, or mixtures thereof. The nutritional supplement may also include a visible component to indicate the presence of the supplement on the food product surface. The visible component may be, for example, an amount of beta-carotene or annatto to impart a predetermined color to the nutritional supplement, and consequently, a predetermined color to the food product having the supplement thereon. Alternatively, the supplement may include invisible ink, which would render the supplement visible under an ultra-violet light or other separate viewing aid, or a component that develops color when a developer is added (e.g., starch developed with iodine, sodium chloride developed with silver nitrate). The use of an invisible component that can become visible would be advantageous because the supplement would not be visible under normal viewing circumstances and give the food substantially the same appearance as an unfortified food product, yet it could easily be verified that the food product contains the supplement through use of the separate viewing aid such as a UV light inspection station or developing station.


Again referring to the flowchart in FIG. 1, the nutritional supplement is applied to the outer surface of individual food product units through a facilitating or other carrier agent that transports the desired nutrient(s) to the food product surface. In one form, the facilitating agent may be a powder or liquid premix containing the desired nutrients) therein that is applied to an outer surface of each individual food product to be packaged. In another form, the facilitating agent may be a carrier element or sheet containing the desired nutrient(s) that is applied to or wrapped around each individual food product unit to be packaged. With such methods, any product trim, waste, or rework would not be fortified because the nutrients) is applied after such waste streams are removed from the process.


Fortification Powder. One method of fortification at the point-of-packaging includes topically applying a fortified flowable, solid particulate premix, such as a fortified powder, to an outer surface of each individual food product unit just prior to the food product being packaged. Preferably, the fortified powder is applied to an outer surface of individual cheese units, such as an individual slice, stick, slab, cube, brick, block, shred, crumb, string, loaf, or other shape of cheese just before packaging. For purposes herein, such individual cheese units generally have a product weight ranging from about 0.4 grams (e.g., a cheese crumb) to about 3500 grams (e.g., a cheese loaf).


The fortified flowable, solid particulate premix preferably is a blend of a powdered carrier agent, such as a farinaceous powder, and the desired nutrients) to be applied to the food. In one form, the farinaceous powder includes a starch powder and other, optional functional ingredients. For example, the premix may also include anticaking agents (e.g., starches, cellulose, and the like) or antimycotic agents (e.g., Natamycin), flavors, or other desirable components. In this manner, the surface treatment not only fortifies the food product, but may also minimize or reduce product sticking and/or undesired fungi growth.


In order to maintain the desired product quality (e.g., appearance, texture, mouthfeel, etc.), it is preferred that about 0.25 to about 0.75 percent, and most preferably, about 0.5 percent of the fortification powder be applied to the outer surface of a cheese through electrostatic spraying, controlled nozzle spraying, or a metered delivery of the powder. Levels above this range generally result in a visible powder on the surface of the food product, which is undesirable to the consumer. Levels below this range generally do not adequately cover the outer surfaces of the product, which may result in less than desired fortification.


The carrier for the fortification powder preferably includes about 70 to about 100% starches (e.g., potato starches), 0 to about 20% cellulose, 0 to about 10% calcium (e.g., calcium sulfate) to which an amount of powdered vitamin D is added. It is preferred that vitamin D be added to the fortification powder in an amount to provide about 10% DV to each individual cheese unit that the fortification powder is applied thereon (e.g., about 40 IU per individual unit).


Fortification Liquid. Another method of food product fortification at the point-of-packaging involves topically applying a fortified liquid premix, such as a fortified solution, emulsion, suspension or oil, to an outer surface of the food product just prior to the food product being packaged. Similar to the fortified powder, it is preferred to apply the fortified solution to an outer surface of individual cheese units, such as an individual slice, slab, stick, shred, cube, brick, block, crumb, string, loaf, or other shape of cheese, having a unit weight ranging from about 0.4 grams to about 3500 grams. Preferably, the individual cheese unit may be a cheese slice of about 10 to about 40 grams. Using this fortification method, it has been discovered that about 35% to about 100% of the fortification in the fortified liquid premix can be transferred to the food product unit.


Referring to FIG. 2, one method of topically applying a fortified liquid solution to a food product outer surface is illustrated schematically using a brick of cheese 10 as an example. In this method, the cheese brick 10 is transported to a fortification station 12 via a conveyor 14 or other suitable transport. Prior to the fortification station 12, the cheese 10a is unfortified. The fortification station 12 includes a reservoir or other tank 16 to contain the fortification solution 17 and an applicator 18 to apply the solution onto an outer surface 10b of each individual cheese unit 10 by spraying, dispersing, roller coating, brushing, casting, combinations thereof, or other suitable methods to apply a solution to the surface 10b. After the fortification station 12 the cheese is now a fortified cheese 10c having the fortification solution 17 topically applied to the cheese outer surface 10b. As shown, the solution 17 is coated in a strip on the cheese surface 10b, but the surface coating may completely cover or only partially cover the surface 10b or applied in other configurations.


Referring to FIG. 3, another method of topically applying the fortified liquid solution to a food product outer surface is illustrated schematically using a single serving stick of cheese 110 as an example. In this method, the fortified solution is first injected into a cheese package 20 after which the cheese stick 110 is then inserted. Here, an empty cheese package 20a is transported via the conveyer 14 to the applicator station 12. The applicator 18 provides one or more drops 22 of the fortified solution 17 into the empty cheese package 20a. After depositing a quantity of the fortified solution 17 into the package 20, the untreated cheese 110a is then placed into the package 20 so that a cheese surface 110b contacts the solution 17 in the package to form a fortified cheese 110c. Optionally, to seal the package a lid 24 or other suitable sealant may also be applied to the package 20.


The fortified liquid premix includes a liquid carrier agent and an amount of the desired nutrient(s) blended therein. The carrier agent may be an aqueous solution, an emulsion, an aqueous dispersion, an oil dispersion, or a slurry. Preferably, the liquid carrier agent is an aqueous solution. Evaporation or absorption of the liquid carrier permits the food product surface to substantially retain its original appearance. The nutrient is preferably vitamin D in a predetermined amount such that about 10% DV is applied to each individual food product unit that is coated with the premix. For example, the fortified liquid premix is an aqueous solution of vitamin D containing about 10 to about 10,000 IU per mil of vitamin D. Most preferably, the aqueous solution contains about 100 to about 400 IU per ml of vitamin D.


Optionally, the fortified liquid premix may also include other functional ingredients in addition to the carrier agent and nutrients). For instance, the solution may contain anticaking agents (e.g., starches, cellulose, and the like), antimycotic agents (e.g., sorbic acid, natamycin), antioxidants (e.g., vitamin C, vitamin E), minerals (e.g., magnesium), preservatives, colors, flavors, or mixtures thereof. For instance, the fortified liquid premix may include a visible marker to indicate the presence of the solution on the food product surface.


Furthermore, oxidation of sensitive nutrients, such as vitamin A, vitamin C, or B vitamins can also be stabilized with added antioxidants like tocopherols or stabilized with traditional encapsulation or in liposomes or in a liposome-like encapsulation.


Drying of Premix Liquid. After applying the fortified liquid premix onto the surface of the individual food product unit, it is preferred to maximize adherence of the nutrient(s) to the food product surface through a subsequent surface treatment. Maximizing surface adherence helps to ensure that the nutrients) is maintained on the food product surface rather than removed in the packaging step or by contact with other food items during transport. Preferably, adherence of the nutrient(s) is improved by drying the premix solution onto the food product surface. While not wishing to be limited by theory, it is believed that the drying step increases the adherence of the nutrient(s) to the food product surface because, after drying, any oil and/or solid in the premix remain on the cheese surface forming a bond therebetween.


Possible drying techniques that may be employed include limited heat treatments, gas drying, air drying, evaporative aids, and the like. It is less preferred to dry the fortified solution through heat treatment because elevated temperatures may affect the shape, consistency, or quality of the individual cheese unit. It is most preferred, therefore, to use gas or air drying because such drying methods generally will not affect the quality of the cheese.


Gas Drying. One method to dry the premix is to direct a gas under positive pressure over the premix solution. For instance, a cheese product having the fortified liquid premix thereon is subjected to a low pressure gas stream, such as air, nitrogen, carbon dioxide, and the like, in order to evaporate liquids from the fortification solution via convection.


Evaporative Aid Drying. Another method to dry the fortified premix is to employ evaporation aids, such as including an amount of edible alcohol in the liquid premix. For instance, the fortification solution may also include about 0.1 to about 1 percent of edible alcohol as a drying aid. The edible alcohol may comprise, e.g., food grade ethanol, and the like. The addition of such levels of alcohol permit increased evaporation of liquids or permit a shorter or lower pressure gas stream to dry the premix. Alternatively, with sufficient edible alcohol in the premix, the solution may also dry itself as it is conveyed between fortification application and the final packaging station.


Fortification via Transfer Carrier Element. Referring to FIGS. 4 and 5, another method of a food product fortification at the point-of-packaging includes the use of a fortified carrier element, such as a sheet-form element, that is applied to the outer surface of individual food product units just prior to packaging. The carrier element includes the desired nutrients) coated thereon, or impregnated or inter-mingled therein. Over time, the nutrients) migrate from the carrier element to the food product to provide the desired fortification to the food.


Similar to the previous methods, the fortified carrier element may be applied to an outer surface of individual cheese units, such as an individual slice, slab, cube, stick, brick, block, crumb, shred, string, or other shape of cheese, having a unit weight of about 0.4 grams to about 3500 grams. During the typical product supply chain from a manufacturing facility to a grocery store display shelf, for example, sufficient time (e.g., about 1 to about 14 days) passes such that the nutrient migrates from the carrier element to the cheese in order to provide the desired fortification in the cheese. Using this method of fortification, it is expected that between about 30% and about 100% of the fortification in the carrier elements may be transferred to the food product.


For example, a cheese may be fortified just prior to packaging with vitamin D by contacting an outer surface of an individual cheese unit with an interleaf paper, a treated cellulose paper, or other solid matrix (e.g., filter paper, standard cellulose paper, and the like) having an amount of vitamin D coated thereon or impregnated therein. As illustrated schematically in FIG. 4, an interleaf 30 is used as the carrier sheet to fortify a slice of cheese 32. Here the applicator 18 is configured to form a spray 17a of the fortified solution 17 onto an untreated interleaf 30a to form a treated interleaf 30b having the desired nutrients coated on, impregnated therein, or intermingled with a surface of the interleaf 30. As further described below, the fortification station 12 may be in-line with the packaging station or off-line. The treated interleaf 30b is then placed in contact with an outer surface 32a of the cheese 32 to form a fortified slice of cheese assembly 32c, which over time will fortify the cheese slice as the nutrients migrate from the interleaf to the cheese. A plurality of fortified cheese slice assemblies 32c are prepared in a similar manner and packaged together with the treated interleaf sheets 30b interposed between adjacent cheese slices 32. The collection of cheese slice assemblies 32 may then be packaged in a known manner.


In another example, referring to FIG. 5, a string cheese 40 is fortified in a similar manner using a strip of material 42. An untreated strip 42a is treated using the nutrient spray 17a as described above to form a treated strip 42b. In this method, instead of applying the treated strip 42b to the string cheese 40, the treated strip 42b is first inserted into a string cheese over wrap 44. Subsequently, the string cheese 40 is inserted into the over wrap 44 and then an outer surface 40a of the string cheese 40 is contacted by the treated strip 42b when the over wrap 44 is sealed.


The fortified carrier element may replace a common, non-fortified interleaf paper that separates individual units of a food product in a package. While it is preferred that the fortified carrier element be used between slices of natural or processed cheese, the fortified nutrient carrier elements may also be used around string cheeses, blocks or loafs of cheese, cubes of cheese, between slices of processed meats, and the like to fortify such food items in a similar manner.


In this form of the fortification method, the nutrient carrier element is first coated or impregnated with a solution containing nutrients) and other optional functional ingredients. Preferably, the fortification solution is an aqueous solution of a nutrient(s) (e.g., vitamin D, beta carotene, etc.) in water to provide between about 100 and about 400 IU per ml of the nutrients). However, as one skilled in the art will appreciate, the amount of nutrients) provided in the solution will vary based on the final product usage and amount of fortification desired in the food product.


The carrier element is fortified either as a separate processing step prior to product packaging or concurrently as the product is being packaged. For example, standard interleaf paper may be fortified by applying a metered amount of the nutrient solution to one or both sides of the interleaf paper by spraying, marking, painting, coating, or other suitable application method. The fortification of the interleaf paper may occur in-line or just prior to the application of the interleaf to the cheese surface. In this manner, the coated interleaf paper is portioned into appropriately sized sheets and immediately inserted onto a slice of cheese as they are cut. With such in-line processing, the interleaf paper may be wet or moist from the nutrient solution, which may aid in the adhesion of the interleaf to the food product surface. Optionally, the fortified interleaf may be dried prior to contacting the cheese surface by heating, a gas stream, through evaporative aids (e.g., alcohol and the like), or other drying methods.


Alternatively, the interleaf may be fortified separately off-line during its manufacture and processed into a roll, which is unwound at the point of packaging. In this situation, the interleaf paper is preferably dry when it contacts the food product surface. In this method, standard paper processing techniques may be employed to fortify the interleaf paper during its manufacture. For instance, the nutrients) may be added to the pulp or other raw materials that are formed into the bulk interleaf sheet, or the nutrient solution may be coated or applied to one or both sides of an already formed interleaf sheet by the manufacturer via suitable methods, such as spraying, coating, marking, extruding, or other known paper coating methods.


The carrier element preferably does not utilize adhesive or other securing aids to attach it to the food product surface. The interleaf is typically held in contact to the food product surface by the sealing of the food product with an over wrap (i.e., vacuum packing, shrink wrapping, or other suitable packaging methods) or by being sandwiched between food product units. Depending on the food product, however, different packaging methods or even the use of an adhesive or a securing agent may be employed to hold the carrier element to the food product surface. While the carrier element is preferably a fortified interleaf paper, the carrier element may also be any material that retains its integrity during coating/impregnation of the nutrients), during packaging with the food product, and during removal (e.g., peeling) from the food product that also permits a nutrient coated thereon or impregnated therein to migrate from the carrier element to the food product.


The carrier element may also be the product packaging that is used to wrap or otherwise package the food product. For instance, the carrier element may be a plastic over wrap film or a rigid plastic container having the nutrient coated on or impregnated therein. When the food product is packaged with such fortified packaging materials, the nutrient contained within or coated on the packaging material is transferred to the food product over time due to the packaging material's contact with the food product.


Edible or Dissolvable Carrier Sheet. Yet another method of a food product fortification at the point of packaging includes the use of a dissolvable or edible fortified carrier element that is applied to the outer surface of individual food product units just prior to packaging. The dissolvable or edible carrier is preferably a sheet, film, strip, or other form of material that includes or incorporates an effective amount of the desired nutrients) coated thereon, impregnated therein, or inter-mingled therewith as a film ingredient per se. The dissolvable or edible carrier may be applied directly to the food product surface or may be applied to the food product packaging. Over time, the nutrients) migrate from the carrier to the food product surface, the carrier may dissolve to deposit the nutrients onto the food product surface, or the carrier may remain on the food and be consumed when the product is eaten. Using this method of fortification, it is expected that between about 30% and about 100% of the fortification in the carrier element is transferred to the food product.


Preferably, the edible or dissolvable carrier element comprises an edible, water-soluble, film-forming hydrocolloid. In one form, the film forming hydrocolloid is an edible, film-forming polysaccharide, such as a modified polydextrose, modified cellulose, or modified starches. The hydrocolloid material may form a matrix-like material in which the nutrient supplement is dispersed and contained. Preferably, the edible or dissolvable film is formed from a solution containing mixtures of water, hydrocolloids, nutrients), vegetable oil (e.g., high oleic canola oil), glycerin, and/or polysorobate 60.


Optionally, the dissolvable or edible carrier sheet may also include other functional ingredients. For instance, the sheet may include—in addition to the desired vitamins, minerals, and other nutrients—an amount of anticaking agents (e.g., starches, cellulose, and the like), antimycotic agents (e.g., sorbic acid, natamycin), antioxidants (e.g., vitamin C, vitamin E, and the like, or mixtures thereof), flavorings, and colorants.


To form the edible or dissolvable carrier element, the ingredients are mixed and blended together to form a solution. In one method, the solution is then applied to a food grade paper (i.e., Wausau Paper, Mosinee, Wis.) using a brush or other suitable applicator to form a layer of the solution on the paper. The solution is then dried either by air drying, heating, or a gas stream to form the edible or dissolvable film. The film may be removed from the paper and applied to the food product surface or the paper and film combination may be applied directly to the food product surface using the paper as an outer backing. If applied along with the paper, after a predetermined length of time (e.g., at least about 24 hours), the paper may be removed, if desired, to leave only the film on the food surface.


Over time, the film may dissolve to provide the nutrients and other functional ingredients to the food or the film may remain on the food product surface and be consumed when the food is eaten. While not wishing to be limited by theory, it is believed that water diffusion from the food surface to the film is responsible for the film dissolving. However, the film may dissolve using other mechanisms.


A wide variety of nutritionally-fortified cheeses may be produced by this methods disclosed herein. These cheeses include, by way of non-limiting example, Cheddar cheese, Colby cheese, Monterey Jack, Havarti cheese, Muenster cheese, Brick cheese, Gouda cheese, Swiss cheese, and the like, as well as processed cheese products.


EXAMPLES

The Examples that follow are intended to illustrate, and not to limit, the invention. All percentages used herein are by weight, unless otherwise indicated.


Example 1

An evaluation was performed to determine the effect of varying the level of a powdered carrier agent to an outer cheese surface. In this example, the amount of product clumping and visual appearance of a cubed cheese having different levels of a topically applied powdered carrier agent was studied.


Mild cheddar cheese was cubed. Each cube is about ⅝×⅝×¼ inches and had an average weight of about 1.9 grams. A powdered anti-caking agent containing about 60% potato starch, about 30% cellulose, and about 10% calcium sulfate was applied to an outer surface of the cheese cubes using a metered feed screw to deposit the powder on the cheese cubes as it moved by the feed screw on a conveyor belt. The powder was applied at levels of 0.5%, 0.75%, 1.0%, or 1.25%. The coated cheese cubes were then tumbled in a drum to distribute the anti-caking agent and packaged. The treated cheese cubes were visually evaluated for appearance and amount of clumping 15 and 30 days after packaging. Table 1 summarizes the visual observations made in this respect.












TABLE 1






Anticake




Cheese Type
Level, %
Aging
Visual Observations


















Mild Cheddar
0.5
Initial
Slight powdery look, minimal or





no clumping


Mild Cheddar
0.5
Day 15
No visible powder, no sticking of





product cubes


Mild Cheddar
0.5
Day 30
No visible powder, some sticking,





easily broken up with handling


Mild Cheddar
0.75
Initial
Cheese cubes covered in white





powder, no sticking


Mild Cheddar
1.00
Day 15
Cheese cubes covered in white





powder, no sticking


Mild Cheddar
1.25
Day 30
Cheese cubes covered in white





powder, no sticking









Example 2

A fortified cheese product was prepared by spraying individual slices of cheese with a vitamin D solution. Pre-sliced Cheddar cheese, approximately 4″×4″ square weighing approximately 23 grams each, were sprayed with a liquid fortified solution on one side of the cheese. The solution was prepared by diluting a 40,000 IU/ml stock vitamin D solution (Danisco, Copenhagen) with water to form the liquid fortified solution containing about 400 IU vitamin D/ml. Each cheese slice was sprayed using a fine mist with about 0.4 grams of the solution and either air dried in ambient conditions, dried with a stream of air under low pressure, or dried with a stream of nitrogen under low pressure.


The samples that were air dried in ambient conditions had visible solution on the surface of the cheese and did not absorb or evaporate within 30 minutes. The samples dried under a stream of air or nitrogen exhibited partial absorption or evaporation within a minute of exposure to the drying step. The samples that were dried provided preferred results because it avoids solution run-off from the samples.


Example 3

Slices of cheese as described above in Example 2 were sprayed with a slurry of potato starch and vitamin D in water. The slurry was prepared by adding about 15 grams potato starch, about 1.6 grams vitamin D (DSM, Netherlands) to about 500 ml of the solution of Example 2. The slurry was heated to about 200° F., and at this temperature about 0.4 grams of the slurry was sprayed onto each slice of cheese.


The coated cheese slices were allowed to air dry or were immediately packaged wet. To package the slices, the cheese slices were either directly stacked on top of each other or packaged with standard, unfortified interleaf paper (Wausau Paper, Mosinee, Wis.) between each slice. The stacks of cheese were then loosely wrapped in standard packaging film and stored refrigerated for 2 months at about 40° F. The cheese slices were then evaluated for the amount of transfer of vitamin D to the cheese. The results of this evaluation are summarized in Table 2 below. A control sample with no fortification solution was also evaluated in a similar manner with and without an interleaf paper. The amount of vitamin D in the tested cheeses was analyzed using method 982.29 (modified) of the Association of Analytical Chemists (AOAC).












TABLE 2






Cheese Surface
Unfortified



Sample
During Packaging
Interleaf
Vitamin D Transfer, %


















Control 1
no solution
No
0


Control 2
no solution
Yes
0


A
Wet
No
100


B
Wet
Yes
35


C
Dry
No
100


D
Dry
Yes
100









Example 4

Slices of cheese as described above in Example 2 were sprayed on one side with a slurry containing magnesium and vitamin D. The slurry was prepared by adding 80 grams of magnesium glycerophosphate to 100 ml of the solution described in Example 2. The slurry was sprayed on the cheese heated as in Example 3. About 0.4 grams of the slurry was sprayed onto each slice of cheese.


Example 5

Slices of cheese as described above in Example 2 were sprayed on one side with three different solutions. A first solution was prepared by mixing 99% potato starch with 1% powdered vitamin D (DSM, Netherlands). A second solution was prepared by mixing 79% potato starch, 20% cellulose, and 1% vitamin D. A third solution was prepared by mixing 69% potato starch, 20% cellulose, 10% calcium sulfate, and 1% vitamin D. About 0.4 grams of each solution was sprayed onto a separate slice of cheese.


Example 6

Slices of cheese as described above in Example 2 were sprayed with a peanut oil. Amounts of peanut oil ranging from about 0.002 ml to about 1 ml were evaluated. At all levels of application, an oily layer was observed on the surface of the cheese, and therefore, was determined to not be an appropriate carrier.


Example 7

Fortified Swiss and Cheddar cheese slices were prepared by applying a fortified carrier sheet to a surface of the cheese. The fortified carrier sheet was prepared by spraying a vitamin D solution onto the surface of the sheet and then air drying. The vitamin D solution was made by mixing about 0.1 g of vitamin D (DSM, Netherlands) to about 99.9 g of water to provide a fortification solution containing about 100 IU vitamin D/ml. About 0.4 ml of the vitamin D solution was sprayed onto one side of the interleaf paper (Wausau Paper, Mosinee, Wis.), common filter paper, and common copy paper to prepare three fortified papers.


The fortified papers were allowed to air dry for about 10 minutes. Each fortified paper and a control paper (un-fortified) was used to package stacks of cheese with 1 sheet of paper between slices of cheese. Two different cheese stacks were formed using standard mild Cheddar cheese and Swiss cheese. Each cheese stack was then sealed in a typical over wrap package. The product was stored for about six weeks at about 40° F. The cheese was unpackaged and evaluated for vitamin D transfer. The results are listed below in Table 3.












TABLE 3







Vitamin D Solution
Amount of



Carrier
sprayed on Carrier
Vitamin D


Sample
Sheet
Sheet
Transfer







Control
Interleaf
None
0



paper


A
Interleaf
0.4 grams
30%*



paper


B
Filter paper
0.4 grams
0%


C
Copy paper
0.4 grams
0%





*slice had about 5% DV/slice and about 10% DV/serving






Example 8

A qualitative experiment was conducted by adding an amount of beta-carotene to the vitamin D solution of Example 7. The addition of beta-carotene gave the solution an orange-yellow color. The colored solution was applied to the papers as described in Example 7 to form colored, fortified papers that were used to stack Swiss cheese slices as also described in Example 7. After six weeks of cold storage, the cheese slices were evaluated for visible color transfer from the paper to the cheese as compared to the whitish color of the original cheese. The cheese slices exhibited an orange-yellow color. Beta-carotene was also analyzed to be present in the slices.


Example 9

An aqueous solution containing about 0.5 grams annatto (i.e., color) and about 4 grams vitamin D (DSM, Netherlands) was prepared to qualitatively test the potential of a felt-tip applicator method of applying nutrients to a food product surface. The felt-tip applicator was constructed out of a colorless felt tip inserted into a sealed glass sample vial. The vial contained the color/vitamin solution. The solution absorbed into the felt tip and was then used to “mark” the color/vitamin solution onto several different surfaces. Marks were made with gentle pressure of the felt tip to the surface usually in a line across the surface.


The following surfaces were marked with the applicator: cheese, interleaf paper, and packaging film. After the interleaf paper was marked, it was then used to stack slices of cheese as described in Example 7. After the packaging film was marked, it was then used to package cheese blocks that were vacuum sealed so that the marks were in contact with the cheese. After the cheese was marked, it was stacked, packaged, and then vacuum sealed. All samples were evaluated after about 4 weeks, and in all instances, color transfer was observed.


Example 10

Commercially available edible film strips (Momentus Solutions, Marlton, N.J.) that contained a range of nutrients were qualitatively tested for transfer of the nutrients, color, and flavor when applied to cheese slices. The edible films were placed on the surface of a natural cheese slice and refrigerated (about 40° F.). About 24 hours later, the cheese was tasted and observed to confirm flavor, color delivery, and texture perception.


The cheese was found to contain all the nutrients originally provided in the film strip (i.e. riboflavin, thiamin, niacin, vitamin E, vitamin A, vitamin B12, vitamin B6, vitamin C, and zinc). The texture was not adversely affected. However, the cheese had color and a visible residue on the surface.


Example 11

A dissolvable or edible film was prepared to deliver nutrients and color to cheese. A solution having the composition in Table 4 below was prepared to form the film. Gum arabic was first hydrated in warm water (about 60° C.) using a medium shear overhead mixer. When completely hydrated, beta carotene was diluted in vegetable oil and then slowly added to the gum solution. Finally, glycerin was added. The mixture was mixed further at high speed to form a solution having orange-yellow color.












TABLE 4







Ingredient
wt (g)



















Water
380



Gum arabic
100



Beta carotene
2.5 g



(30%)



Vegetable oil
22.5



Glycerin
10










The solution was applied to a food paper (Wausau Paper, Mosinee, Wis.) with a brush and allowed to dry at room temperature at about 72°. The coated paper was then placed between slices of white natural cheese (provolone). After 24 hours the cheese was separated from the paper. It was observed that the film was partially dissolved and that the cheese had an orange-yellow color.


Example 12

In this example, a dissolvable or edible film was prepared to provide nutrients and color to a cheese. A solution was prepared similar to Example 11 above, but also included 0.2% pre-melted polysorbate 60. The solution was then mixed at high speed in a food processor for better emulsification. It was observed that the film was partially dissolved and that the cheese had an orange-yellow color.


Example 13

A dissolvable or edible film was prepared similar to Example 11 above, but using the formulation of Table 5 below.












TABLE 5







Ingredient
wt (g)



















Water
150



N-Lock Starch
43



High oleic canola oil
15



Beta carotene
1.5



solution



(30%) Polysorbate 60
0.5










In a beaker with an overhead mixer, starch was hydrated in water for about 5 to about 10 minutes. Beta carotene was first diluted in oil, and then slowly added to the starch solution. Polysorbate 60 was pre melted and added to the mixture. The mixture was then heated to about 50 to about 60° C. and homogenized for about 1 minute using an Ultra Turax homogenizer.


The solution was brushed on paper to form a thin film layer. The film was allowed to dry at ambient temperatures for at least 2 hours. The paper was sandwiched between two slices of cheese and refrigerated for overnight at about 40° F. The next day, the paper was peeled off to transfer most of the film onto the surface of the cheese slice. This solution proved to be better dissolving on the surface of the cheese than the solutions of Examples 11 and 12.


Example 14

Dissolvable or edible films were prepared similar to Example 11 above, but also incorporated vitamin D instead of the beta-carotene. Two different dissolvable films were prepared having compositions according to Table 6 below and cast into films using the procedures of Example 13.













TABLE 6








wt (g)
wt(g)



Ingredient
Formula 1
Formula 2




















water
150
150



N-Lock starch
43
43



Vitamin D solution
4.0
10



High oleic canola oil
11
5



Polysorbate 60
0.5
0.5










The solutions were each coated as thin film onto a separate paper (one side only) and the film was allowed to completely dry at ambient temperatures as in Example 13. The paper with the dry film was then sandwiched between two slices of cheese and refrigerated for one month. It was observed that the film was completely dissolved within about 1 week, and testing after 1 month verified that Vitamin D was present in the cheese.


Example 15

A fortified string cheese was prepared by injecting a vitamin D solution into a preformed string cheese package prior to placing the cheese product within the package. The vitamin D solution was prepared by diluting a 40,000 IU/ml stock vitamin D solution (Danisco) with sterile water to form a liquid fortified solution containing about 400 IU/ml of vitamin D. In each empty cheese package, about 0.1 ml of the fortified solution was added. The string cheese stick was then placed in the package, and then the package was sealed.


Upon analysis, about 50% of the vitamin D in the solution was transferred to the cheese. However, it is believed that the dilution of the fortified solution can be adjusted to obtain either more or less fortification of the cheese stick as desired.


It will be understood that various changes in the details, materials, and arrangements of formulations and ingredients, which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.

Claims
  • 1. A method of making a nutritionally-fortified cheese product, comprising: providing cheese comprising one or more discrete cheese units each having an outer surface, wherein each of said discrete cheese units has a mass between about 0.4 grams and about 3500 grams;contacting the outer surface of at least one of said discrete cheese units with a nutritional supplement in the absence of mixing with another cheese unit to provide one or more nutritionally-fortified discrete cheese units acquiring the nutritional supplement in an amount providing at least about 10% DV of said nutritional supplement per serving of said cheese; andimmediately packaging the nutritionally-fortified discrete cheese units.
  • 2. The method of claim 1, wherein the nutritionally-fortified discrete cheese units each comprise a self-supporting shape selected from the group consisting of slice, cube, stick, brick, slab, shred, crumb, string, and loaf.
  • 3. The method of claim 2, wherein the nutritional supplement comprises vitamin D.
  • 4. The method of claim 3, wherein the contacting of the outer surface of the cheese unit comprises applying a flowable premix material comprising the nutritional supplement to the outer surface of at least one the cheese units.
  • 5. The method of claim 4, wherein the contacting of the outer surface of the cheese unit comprises the steps of: applying a flowable premix material comprising a fluid medium and the nutritional supplement to the outer surface of the cheese unit; anddrying the applied premix material.
  • 6. The method of claim 5, wherein the drying comprises directing gas under positive pressure upon the applied premix material.
  • 7. The method of claim 6, wherein flowable premix material is selected from the group consisting of an aqueous solution, an emulsion, an aqueous dispersion, an oil dispersion, and a slurry.
  • 8. The method of claim 4, wherein the contacting of the outer surface of the cheese unit comprises injecting a flowable premix material into a preformed package prior to inserting the cheese unit into the package.
  • 9. The method of claim 4, wherein the flowable premix material comprises ingredients selected from the group consisting of an anti-caking agent, an antimycotic agent, colors, and flavors.
  • 10. The method of claim 4, wherein the flowable premix material comprises an evaporative aid to improve drying of the material on the discrete cheese unit outer surface.
  • 11. The method of claim 10, wherein the evaporative aid is an alcohol.
  • 12. The method of claim 3, wherein the contacting of the outer surface of the cheese unit comprises applying a flowable, solid particulate premix material comprising farinaceous powder and the nutritional supplement, to the outer surface of the cheese unit.
  • 13. The method of claim 12, wherein the farinaceous powder comprises starch powder.
  • 14. The method of claim 13, wherein the solid particulate premix material further comprises cellulose powder and calcium sulfate powder.
  • 15. The method of claim 14, wherein the applying of the solid particulate premix comprises depositing the premix material onto the cheese unit in amount sufficient to deliver at least about 10% DV of the nutritional supplement per cheese serving.
  • 16. The method of claim 3, wherein the contacting of the outer surface of the cheese unit comprises contacting the outer surface with a nutrient carrier element comprising a nutritional supplement transferably carried by the nutrient carrier element.
  • 17. The method of claim 16, wherein the nutrient carrier element comprises a dissolvable or edible layer containing the nutritional supplement.
  • 18. The method of claim 17, wherein the dissolvable or edible layer comprises an edible, water-soluble film-forming polysaccharide.
  • 19. The method of claim 16, wherein the nutrient carrier element comprises: a carrier sheet with a coating applied thereon, the carrier sheet separable from the outer surface of the cheese unit, andwherein the coating comprises the nutritional supplement, which is contacted with the outer surface of the cheese unit for a length of time sufficient for the nutritional supplement to migrate from the carrier sheet to the outer surface of the cheese unit.
  • 20. The method of claim 19, wherein the carrier sheet comprises interleaf paper.
  • 21. The method of claim 20, further comprising applying a solution containing the nutritional supplement to the interleaf paper to form the coating thereon prior to packaging, and contacting the outer surface of the cheese unit with the coated interleaf paper sheet such that the coating is moist when contacting the outer surface of the cheese unit.
  • 22. The method of claim 20, further comprising applying a solution containing the nutritional supplement to the interleaf paper to form the coating thereon prior to packaging, and contacting the outer surface of the cheese unit with the coated interleaf paper sheet such that the coating is substantially dry when contacting the outer surface of the cheese unit.
  • 23. The method of claim 16, wherein the nutrient carrier element is a packaging component in contact with the discrete cheese unit.
  • 24. A nutritionally-fortified cheese product comprising a serving of a cheese comprising one or more discrete cheese units having an outer surface in contact with a nutrient carrier element comprising a nutritional supplement transferably carried by the nutrient carrier element.
  • 25. The nutritionally-fortified cheese product of claim 24, wherein the nutritional supplement comprises vitamin D.
  • 26. The nutritionally-fortified cheese product of claim 25, wherein the nutrient carrier element comprises a dissolvable or edible layer.
  • 27. The nutritionally-fortified cheese product of claim 26, wherein the dissolvable or edible layer comprises an edible, water-soluble film-forming polysaccharide.
  • 28. The nutritionally-fortified cheese product of claim 25, wherein the nutrient carrier element comprises: a carrier sheet which is separable from the cheese unit, anda coating comprising the nutritional supplement, in contact with the outer surface of each of the cheese units.
  • 29. The nutritionally-fortified cheese product of claim 28, wherein the carrier sheet comprises a fluid-absorbable sheet material.
  • 30. The nutritionally-fortified cheese product of claim 28, wherein the carrier sheet comprises interleaf paper.
  • 31. The nutritionally-fortified cheese product of claim 28, wherein the coating comprises a dissolvable or edible layer supported on a face of the carrier sheet.