Patent Application
20220295804
The present invention relates to an ovenable pre-baked crumb-coated snack comprising:
The ovenable snack according to the present invention can be heated in an oven to prepare a ready-to-eat snack without the occurrence of cracks or so-called ‘blow outs’, i.e. leakage of filling through the barrier layer and crumb layer as a result of pressure build-up within the filling.
The invention further relates to a process of manufacturing an ovenable crumb-coated snack and to a method of preparing a ready-to-eat snack, said method comprising heating the ovenable snack of the present invention in an oven.
Fried battered and breaded (crumb-coated) snacks with a filling of fish, seafood, poultry, red meat, vegetables, ragout, cheese, etc. are popular for their crispy texture and golden brown appearance. Such crumb-coated snacks generally comprise a food substrate to which a variety of combinations of coating materials is applied. The coating materials typically include predust, adhesion batters, and breading crumbs.
Industrially produced crumb-coated snacks that only need to be fried to produce a ready-to-eat snack are commercially available. These fryable snacks typically are prepared by coating a filling with a layer of batter; applying crumbs onto the batter coated filling; and freezing the crumb-coated portion. During frying, the filling and the batter become fully cooked and the snack develops crispy texture and golden brown appearance. The crispy texture of the fried snack is provided by the combination of batter and crumb. During frying, the starch in the batter gelatinizes and water is removed from both the batter and crumb particles. Together, these changes contribute to the formation of a crunchy outer layer that is characteristic of fried crumb-coated snacks.
However, if the aforementioned fryable snacks are heated in an oven instead of a deep fryer, the oven heated product lacks the desirable crispy texture. This is because the heat transfer rate during baking is much lower than during deep frying.
Crumb-coated snacks that are meant to be prepared in an oven instead of fryer, so called ‘ovenable’ snacks, are known in the art.
U.S. Pat. No. 4,943,438 describes a method of preparing food products which produces in said food products, when reheated by microwave or conventional baking, a flavour, texture, and appearance produced by frying said food products, said method comprising the steps of:
The preferred batter contains water, wheat flour and carboxymethyl cellulose.
U.S. Pat. No. 4,460,837 describes a food coating composition for imparting a crisp, golden-brown surface to foodstuff cooked in a microwave appliance comprising:
U.S. Pat. No. 6,562,384 describes batter mixes comprising 35-75% adhesion component, 2-11% viscosity component, and 5-50% crispness component. Tapioca dextrin, maltodextrin, adhesion starch (e.g., BATTER BIND from National Starch & Chemical), and corn syrup solids, used alone or in combination, are said to be particularly suitable for use as the adhesion component.
WO 96/28051 describes a batter composition comprising:
This batter can be used to enrobe a food core, followed by the application of crumb. The crumb coated product can be frozen without pre-frying.
CN 101263913 describes a batter composition that can be used in the preparation of microwaveable frozen pre-fried crumb-coated food products. The dry components of the batter comprises 70-100 parts by weight flour; 2.5-7.5 parts by weight soy protein; 0.8-2.3 parts by weight of soybean phospholipid; 2.3-6.8 parts by weight of maltodextrin; 0.1-0.5 parts by weight of guar gum.
U.S. Pat. No. 4,260,637 describes a dry, self-sticking bread crumb composition comprising:
US 2016/165930 describes a stabilizer composition comprising, calculated by weight of dry matter:
U.S. Pat. No. 3,852,501 describes a process for imparting the taste, texture, and appearance of fat frying to foodstuffs which are baked, comprising,
The inventors have developed a pre-baked crumb-coated snack that can be heated in an oven to prepare a ready-to-eat snack without the occurrence of blow outs and cracks. The inventors have discovered that blow outs and the occurrence of cracks during oven baking of pre-baked crumb-coated snack can be minimized effectively by employing a special coating that contains at least 15 wt. % of oligosaccharides. More particularly, the present invention relates to an ovenable pre-baked crumb-coated snack comprising:
During the pre-baking of the ovenable snack, the combination of oligosaccharides and protein in the barrier layer contributes to the rapid formation of a cohesive dehydrated barrier layer that effectively prevents against blow outs and formation of cracks. After pre-baking, the dehydrated barrier layer acts as an effective moisture barrier between filling and crumb during frozen or chilled storage of the ovenable snack, thereby allowing the pre-baked snack to be baked to produce ready-to-eat snack with a crispy outer coating. Finally, during bake-off of the ovenable snack, the dehydrated barrier layer once more effectively prevents against the occurrence of blow outs and cracks.
The invention also relates to a process of manufacturing an ovenable pre-baked crumb-coated snack, said process comprising:
The invention also provides a method of preparing a ready-to-eat snack, said method comprising heating the ovenable snack of the present invention in an oven to a core temperature of at least 60° C.
Accordingly, a first aspect of the invention relates to an ovenable crumb-coated snack comprising:
The words ‘comprising’ and ‘containing’ as used herein should not be interpreted restrictively as meaning ‘consisting of’. In other words, besides the features listed after these words, non-listed features may be present.
The term “oligosaccharides” as used herein refers to saccharide polymers containing 4 to 20 monosaccharide residues, i.e. having a degree of polymerisation in the range of 4 to 20. Examples of oligosaccharides include oligofructose (e.g. hydrolysed starch), oligofructose (e.g. inulin) and oligogalactose.
The term “protein” as used herein refers to linear polymers of at least 100 amino acid residues that are bonded together by peptide bonds.
The term “heat setting protein” as used herein refers to a protein that is capable of forming a aqueous gel when the non-denatured protein is denatured by heating. Here, “non-denatured protein” refers to protein that still has the secondary structure which is present when that protein is in its native state.
The term “starch” as used herein refers to a polysaccharide consisting of amylose and/or amylopectin and containing at least 100 monosaccharide residues.
The term “oil” as used herein refers to lipids selected from triglycerides, diglycerides, monoglycerides, free fatty acids and phospholipids.
The term “baking” as used herein refers to cooking by exposure to dry heat, as opposed to e.g. boiling or frying. Besides oven heating, which may involve steam injection, the term “baking” also encompasses, for instance, contacting with superheated steam, exposure to hot air impingement and exposure to infrared radiation.
The term “dry matter” as used herein refers to the matter that remains after water and other volatile components have been removed by evaporation using a forced-air oven (3 hours at 105° C., or longer if not all moisture has been removed).
Whenever reference is made herein to the particle size distribution of a particulate material, the particle size (or diameter) distribution is determined using a set of sieves having different mesh sizes.
The ovenable snack of the present invention preferably has a weight of 8 to 150 grams, more preferably of 10 to 130 grams and most preferably of 15 to 120 grams.
Examples of ovenable snacks according to the present invention include chicken nuggets, cheese bites, fish fingers, croquettes and “bitterballen” (crumb coated ragout balls).
The ovenable snack of the present invention preferably is regularly shaped in that the volume of the snack equals at least 50% of the volume of the smallest enclosing sphere or ellipsoid that fully encompasses the snack.
According to a particularly preferred embodiment, the ovenable snack of the present invention has been pre-baked.
According to another preferred embodiment, the ovenable snack of the present invention is a frozen ovenable snack.
The ovenable snack preferably comprises 40-95 wt. % of filling, more preferably 42-92 wt. % of filling and most preferably 45-90 wt. % of filling.
The benefits of the present invention are particularly appreciated in case the filling contains at least 35 wt. % water. More preferably, the filling contains 40-85 wt. % water. Most preferably, the filling has a water content of 50-80 wt. %.
Preferably, the filling contains at least about 50 wt. %, more preferably at least about 60 wt. % and most preferably at least about 80 wt. % of edible ingredients selected from fish, meat, poultry, shellfish, shrimps, cheese, ragout, vegetables, fungi and combinations thereof.
The filling, especially if it is composed of chopped or comminuted pieces, is preferably impregnated with a stabiliser composition, for example by soaking, permeation or injection (for example vacuum pulse injection), prior to the forming into portions. Examples of suitable stabiliser compositions can be found in WO 97/03572.
During the pre-baking of the present crumb-coated snack, protein in the barrier layer is at least partly denatured and starch, if present, is at least partly gelatinised.
The barrier layer that surrounds the filling preferably contains, calculated by weight of dry matter, 18-70 wt. %, more preferably 20-65 wt. % and most preferably 22-60 wt. % of oligosaccharides having a DP in the range of 4-20.
According to another preferred embodiment, the barrier layer contains, calculated by weight of dry matter, at least 12 wt. %, more preferably at least 15 wt. % and most preferably at least 18 wt. % of oligosaccharides having a DP in the range of 4-10.
The oligosaccharides that are contained in the barrier layer of the ovenable snack are preferably selected from gluco-oligosaccharides, fructo-oligosaccharides, galacto-oligosaccharides and combinations thereof. Most preferably, the oligosaccharides are gluco-oligosaccharides.
Preferably, the barrier layer contains, calculated by weight of dry matter, at least 15 wt. %, more preferably at least 18 wt. % and most preferably at least 20 wt. % of gluco-oligosaccharides having a DP in the range of 4-20.
According to a particularly preferred embodiment, the barrier layer contains, calculated by weight of dry matter, at least 12 wt. %, more preferably at least 15 wt. % and most preferably at least 18 wt. % of gluco-oligosaccharides having a DP in the range of 4-10.
Preferably, the barrier layer contains, calculated by weight of dry matter, at least 2 wt. % of protein selected from soy protein, egg protein, whey protein, legume protein, gluten and combinations thereof.
In one advantageous embodiment of the invention the barrier layer contains, calculated by weight of dry matter, 10-45 wt. %, more preferably 12-40 wt. % of heat setting protein selected from soy protein, egg protein, legume protein and combinations thereof. Even more the barrier layer contains, calculated by weight of dry matter, 10-45 wt. %, more preferably 12-40 wt. % of heat setting protein selected from soy protein, pea protein, lupin protein and combinations thereof. Most preferably, the barrier layer contains, calculated by weight of dry matter, 10-45 wt. %, more preferably 12-40 wt. % of soy protein.
The combination of the heat setting protein and the oligosaccharides preferably constitutes at least 35 wt. % of the dry matter of the barrier layer, more preferably at least 45 wt. % of the dry matter of the barrier layer and most preferably at least 50 wt. % of the dry matter of the barrier layer. In accordance with this embodiment, starch preferably constitutes less than 30 wt. %, more preferably less than 20 wt. % and most preferably less than 10 wt. % of the dry matter that is contained in the barrier layer.
According to another advantageous embodiment, the barrier layer contains, calculated by weight of dry matter, 2-15 wt. %, more preferably 3-12 wt. % and most preferably 4-10 wt. % gluten.
The combination of gluten and starch preferably constitutes at least 30 wt. % of the dry matter of the barrier layer, more preferably at least 40 wt. % of the dry matter of the barrier layer and most preferably at least 50 wt. % of the dry matter of the barrier layer.
The barrier layer that is present in the ovenable crumb-coated snack preferably has a fat content, calculated by weight of dry matter, of 0-10 wt. %, more preferably of 0-5 wt. % and most preferably of 0-3 wt. %.
In order to improve adhesion characteristics and stability of the barrier layer it can be advantageous to include a thickening agent. Preferably, calculated by weight of dry matter, the barrier layer contains 0.03-1 wt. %, more preferably 0.05-0.6 wt. % of a thickening agent selected from guar gum, xanthan gum, cellulose derivative and combinations thereof.
The barrier layer that surround the filling of the ovenable snack may suitably contain, calculated by weight of dry matter, 0-22 wt. %, more preferably 2-20 wt. % and most preferably 5-18 wt. % of sugars selected from monosaccharides, disaccharides, trisaccharides and combinations thereof.
A combination of oligosaccharides and sugars may suitably be provided by a hydrolysed starch (e.g. glucose syrup). Preferably, the barrier layer contains, calculated by weight of dry matter, 0-22 wt. %, more preferably 2-20 wt. % and most preferably 5-18 wt. % of sugars selected from glucose, maltose, maltotriose and combinations thereof.
The crumb particles that are deposited onto the barrier layer preferably contain at least 50 wt. % starch. More preferably, the crumb particles have a starch content of 55-85 wt. %, most preferably of 65-80 wt. %.
The flour content of the crumb particles preferably exceeds 80% by weight of dry matter, more preferably the flour content exceeds 90% by weight of dry matter.
Gluten content of the crumb particles preferably is in the range of 5-20 wt. %, more preferably in the range of 5-12 wt. % and most preferably in the range of 7-11 wt. %.
Preferably, the starch in the crumb particles is essentially completely gelatinized as demonstrated by the absence of birefringence that is associated with the presence of starch granules. Starch granules show birefringence or a typical “maltese cross” when viewed in polarised light. The property of birefringence is brought about because the starch molecules are radially oriented within the granule. When starch is heated in water, birefringence is lost.
The crumb particles employed in accordance with the present invention preferably have been obtained by a process that comprises extruding a mixture comprising flour and water, wherein the mixture of flour and water is heated to a temperature in excess of 90° C., more preferably in excess of 105° C. during extrusion. The crumb particles are preferably obtained by milling the extrudate so obtained.
According to a particularly preferred embodiment, the crumb particles of the present invention consist of milled extrusion-baked dough. These extruded crumb particles preferably contain 0.05-2 wt. %, more preferably 0.1-1 wt. % and most preferably 0.12-0.4 wt. % of biopolymer selected from natural gums, modified gums, gelatin, pectin, alginate, arabinogalactan, agar, carrageenan, furcellaran, xanthan and combinations thereof. Preferably, the biopolymer is selected from natural gums and combinations thereof. Examples of natural gums that may suitably be employed include guar gum, xanthan gum, locust bean gum, gum Arabic, tragacanth, gum karaya, gum ghatti, xanthan gum and combinations thereof. Most preferably, the biopolymer is selected from guar gum, locust bean gum, xanthan gum and combinations thereof.
The crumb particles preferably have a volume weighted average diameter of 0.5 to 3 mm, more preferably a volume weighted average diameter of 0.7 to 2.8 mm, and most preferably a volume weighted average diameter of 0.8 to 2.5 mm.
The inventors have found that it may be advantageous to prepare an ovenable snack according to the present invention by alternatingly applying two or more barrier and crumb layers. Accordingly, in a preferred embodiment, the layer of crumb particles that is deposited on the barrier layer that surrounds the filling is coated with a second barrier layer and a second layer of crumb particles is deposited onto the second barrier layer.
Preferably, both the first and the second barrier layer are barrier layers as described herein before. Preferably, the dry composition of the second barrier layer is identical to the dry composition of the first barrier layer that surrounds the filling.
Likewise, the crumb that is employed in the second layer of crumb particles preferably is a crumb as described herein before.
According to another preferred embodiment, the layer of crumb particles on the outside of the ovenable snack is coated with oil. The application of an oil coating offers the advantage that after oven heating the ready-to-eat snack closely resembles a deep fried snack. Preferably, the oil contains at least 80 wt. % triglycerides.
In accordance with a particularly preferred embodiment, the ovenable snack of the present invention is packaged in a packaging material that carries instructions to heat the food product in an oven, preferably at a temperature in the range of 160-220° C.
Another aspect of the present invention relates to a process of manufacturing an ovenable pre-baked crumb-coated snack, said process comprising:
Preferably, step (d) of the aforementioned manufacturing process yields an ovenable pre-baked crumb-coated snack as described herein before.
The filling composition that is employed in the process preferably is a filling as described herein before. Likewise, also the crumb particles employed preferably are crumb particles as described herein before.
The dry composition of the coating composition employed in the process preferably is identical to that of the barrier coating layer as described herein before. The ingredients of the coating composition that is applied in the present process are also preferably as described herein before.
The coating composition preferably has a water content of 48-88 wt. %, more preferably a water content of 50-87 wt. % and most preferably a water content of 52-86 wt. %.
Before coating the portion of filling composition with uncooked coating composition, the portion may suitably be coated with predust. The application of predust facilitates the adhesion of the coating composition onto the surface of meat, fish, poultry and vegetables.
According to a particularly preferred embodiment, the crumb particles employed in the present process have a water content of less than 8 wt. %, more preferably of less than 7 wt. % and most preferably of less than 6 wt. %. Typically, the crumb particles have a water content of at least 1 wt. %.
The crumb particles employed in the present process preferably have a glass transition temperature of more than 60° C., more preferably of more than 80° C., even more preferably of more than 100° C. and most preferably of more than 110° C.
The glass transition temperature of the crumb particles can be determined by modulated DSC using the following procedure:
In the present manufacturing process preferably 100 parts by weight of filling composition are combined with 3 to 60 parts by weight of coating composition, and 3 to 60 parts by weight of crumb particles. More preferably, about 100 parts by weight of filling composition are combined with 5 to 45 parts by weight of coating composition, and 5 to 50 parts by weight of crumb particles.
According to a particularly preferred embodiment, the crumb-coated portion is pre-baked prior to packaging. Typically, the crumb-coated portion is pre-baked in an oven at an oven temperature in the range of 130-280-° C. for 1-30 minutes, more preferably at an oven temperature in the range of 140-260-° C. for 2-20 minutes.
The core temperature of the crumb-coated portion preferably reaches a temperature of at least 50° C., more preferably of at least 55° C. and most preferably of at least 58° C. during pre-baking.
According to another preferred embodiment, the crumb-coated portion is coated with oil prior to pre-baking and/or the pre-baked portion is coated with oil prior to packaging. Preferably, the oil used for coating the portions contains at least 80 wt. % triglycerides. The oil preferably has a melting point of less than 30° C. The amount of oil that is applied preferably is in the range of 10 to 50% by weight of the crumb particles, more preferably in the range of 15 to 35% by weight of the crumb particles.
According to a particularly preferred embodiment, the process comprises freezing the pre-baked portion to a core temperature of less than −12° C. before it is packaged.
In order to minimize unwanted water migration, the pre-baked portion is introduced into a freezer within 5 minutes, preferably within 2 minutes after the pre-baking step has ended.
The pre-baked portion is preferably packaged after freezing.
Yet another aspect of the invention relates to a method of preparing a ready-to-eat snack, said method comprising heating the ovenable snack of the present invention in an oven to a core temperature of at least 60° C.
The invention is further illustrated by the following non-limiting examples.
Ovenable pre-baked crumb-coated snacks, known in the Netherlands as “bitterballen”, were prepared as described below.
A ragout filling was prepared on the basis of the recipe that is shown in Table 1. The composition was cooked for 30 minutes at 95° C. and cooled over night at 4° C.
Coating compositions were prepared by combining glucose syrup, soy flour and water. The weight ratios in which glucose syrup and soy flour were applied in the different coating compositions are shown in Table 2. Also shown is the amount of water that was used to prepare the initial mix from 100 grams of dry ingredient(s).
1Spray dried glucose syrup made from wheat starch; 95 wt. % carbohydrates (3.0% glucose, 7.5% maltose, 9.5% maltotriose, 80% higher sugars), 5 wt. % moisture
2Slightly toasted, defatted soy flour (50.0% protein [N*6.25 on dry matter], 32.0% carbohydrates of which 14.0% sugars, 1.0% fat, 6.5% ash, 9.0% moisture)
The coating compositions were prepared by mixing 100 grams of dry ingredients with 100 to 514 ml water for 5 minutes at full speed using a K-beater. Next viscosity was measured using a Brookfield viscometer (spindle 62, 10 rpm) and water was added to reduce viscosity to less than 1000 mPa·s.
The ragout filling was extruded and shaped by a Rheon into balls of 17 grams. These were kept frozen until usage. At usage the ragout balls were fully thawed by keeping them over night at 4° C.
A predust (appr. 2.4% pick-up by filling portions) was applied. The composition of the predust is shown in Table 3.
The predusted filling portions were coated with the coating composition (appr. 10% pick-up).
The coated portions were breaded with fine crumb (0.8-1.5 mm, appr. 7% pick-up). Thereafter these breaded portions were coated again with the coating composition (1.5-2.5 mm, appr. 16% pick-up). These coated portions were breaded with coarse crumb (appr. 8.% pick-up).
The crumb-coated portions were sprayed with oil (appr. 4% pick-up).
The crumb-coated portions so obtained were baked for 6 minutes in a preheated oven at 200° C. and 30% RH.
After the oven, the pre-baked snacks were placed into a shock freezer and kept at −34° C. for 30 minutes. Next, the frozen snacks were packaged in bags and stored in a freezer at −25° C.
After 2 days of frozen storage, the frozen snacks were prepared for consumption by baking them for approximately 14 minutes in an oven that had been preheated to 180° C. The snacks were taken from the oven as soon as a core temperature of 72° C. had been reached.
Pictures were taken of the snacks immediately after they had been removed from the oven. These pictures were used to score the amount of cracks that had been formed during bake-off.
Two minutes after removal from the oven, the snacks were evaluated by an expert panel. The panel scored the quality of the snacks, paying special attention to the appearance and the quality of the outer coating (crispiness etc.).
Both the amount of cracks and the organoleptic quality of the snacks were rated on a scale of 0 to 5:
The results of the evaluations are summarised in Table 4.
Example 1 was repeated, except that this time coating compositions were prepared using soy flour, water and different carbohydrates. The carbohydrates and soy flour were applied in a weight ratio of 1:1. The results of the evaluations are shown in Table 5.
1 Spray dried glucose syrup made from wheat starch; 95 wt. % carbohydrates (3.0% glucose, 7.5% maltose, 9.5% maltotriose, 80% higher sugars), 5 wt. % moisture
Example 1 was repeated, except that this time coating compositions were prepared on the basis of the dry compositions shown in Table 6.
1Spray dried glucose syrup made from wheat starch; 95 wt. % carbohydrates (3.0% glucose, 7.5% maltose, 9.5% maltotriose, 80% higher sugars), 5 wt. % moisture
2Wheat gluten, 75 wt.% protein, 7 wt. % carbohydrates (4% sugars, 3% starch), 6 wt. % fat, 1.5 wt. % fibers, 1.5 wt. % others, 9 wt. % moisture
The results of the evaluations are summarised in Table 7.
Example 1 was repeated, except that this time a single coating composition was prepared on the basis of the dry compositions shown in Table 8.
The snacks prepared using this coating composition received the maximum scores for the absence of cracks and organoleptic quality.
Example 1 was repeated, except that this time an aqueous coating composition as disclosed in Example 8 of US 2016/0164930 was used as a coating composition (Coating Composition A) and compared to a coating composition according to the present invention (Coating Composition 1).
The recipes of these coating compositions are shown in Tables 9a and 9b.
1 Spray dried glucose syrup made from wheat starch; 95 wt. % carbohydrates (3.0% glucose, 7.5% maltose, 9.5% maltotriose, 80% higher sugars), 5 wt. %
Frozen pre-baked snacks were prepared as in Example 1 (Snack A using Coating Composition A, Snack 1 using Coating Composition 1).
After 3 days of frozen storage, the frozen pre-baked snacks were prepared for consumption by baking them for approximately 17 minutes in an oven that had been preheated to 220° C. The snacks were taken from the oven as soon as a core temperature of 72° C. had been reached.
Pictures were taken of the snacks immediately after they had been removed from the oven. These pictures were used to score the amount of cracks that had been formed during bake-off.
Two minutes after removal from the oven, the snacks were evaluated by an expert panel. The panel scored the quality of the snacks, paying special attention to the appearance and the quality of the outer coating (crispiness etc.). The percentage cracks was determined for a set of 10 baked snacks. Appearance, hardness and crispiness were scored on a scale of 0-5 (0=unacceptable and 5=perfect).
The results of the evaluations are summarised in Table 10.
| Number | Date | Country | Kind |
|---|---|---|---|
| 19214850.0 | Dec 2019 | EP | regional |
The present application is a continuation application of PCT/EP2020/085240 filed Dec. 9, 2020, which claims priority to EP 19214850.0 filed Dec. 10, 2019 the entire contents of both which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2020/085240 | Dec 2020 | US |
| Child | 17836583 | US |
