Patent Application
20080038439
These and other advantages of the present invention are best understood with reference to the drawings, in which:
The preferred embodiment of the present invention provides a rapid melt dairy based product that is solid at room temperature and is easily portionable, but that when heated or when dispensed onto hot food melts quickly into a sauce and remains in sauce form. The rapid melt dairy based product uses a gelatin, either with or without a starch as a base, to produce a dairy-based sauce that becomes firm or hard when refrigerated and cured. This rapid melt dairy based product may then be machined or processed into reduced size particles and packaged. Consumers may then easily dispense and consume the rapid melt dairy based product.
For example, a cheddar-cheese based product, which is discussed in detail below, may be formed and refrigerated, and then diced into cubes, about one-eighth inch to one-quarter inch on each side, or larger. These cubes may be placed into an individual one ounce packet, a larger eight ounce packet, a two pound container, or any other desired size package. When a consumer wishes to add a cheddar-based sauce to a broccoli, eggs, or another hot food product, the consumer may open the packaging and shake a desired quantity of the small cubes onto the hot food. In a preferred embodiment, the small cubes have a sufficiently low softening point that the cubes will melt into a sauce. In another embodiment, the consumer may take the food item with small cheese cubes placed thereupon and heat the food item and the small cubes briefly, typically in a microwave oven, to melt the small cheese cubes into a sauce that will spread evenly over the food.
In the preferred embodiment, a stabilizer system helps to form and firm the cheese or sauce product. The stabilizer system preferably uses a blend of a gelatin and a starch or other carbohydrate. If no starch or other carbohydrate is used, the stabilizer will be less firm, and a thinner, “finishing” sauce or dairy based product will be formed. The stabilizer system substantially firms or hardens the product in its bulk form so that it becomes firm or hard when it is later refrigerated and cured. The product may then be easily machined into smaller pieces, such as by slicing, dicing, shredding, crumbling, or comminuting, i.e., pulverizing, or through the use of any other suitable size-reducing forming technique.
Formulations of the dairy based sauce preferably also use one or more cheeses, dairy powders, milk, condensed milk, or dairy fats, although nondairy sauces can also be made using the teachings of the present invention. In one embodiment, one or more of the following cheeses may be added to the sauce: Asiago cheese, blue cheese, brick cheese, Swiss cheese, Edam cheese, Gouda cheese, Muenster cheese, Mozzarella cheese, Parmesan cheese, Provolone cheese, Romano cheese, American cheese, Cheddar cheese, Colby cheese, Monterey Jack cheese, wash curd cheese, stirred curd cheese, cream cheese, Neufchatel, or any other desired type of cheese.
In other embodiments, dairy powders or dairy fats may be used. For example, powdered casein products may be used, e.g., complete milk protein, e.g., CMP-GP eighty percent, an ultrafiltered natural milk protein isolate in fine powder form, from American Casein Co., of Burlington, N.J. Enzyme-modified cheese (EMC) and emulsifying salt can also be added to tailor the flavor and textural properties of the cheese product being produced. Other useful powders that may be used include nonfat skim dry milk and dairy powders. Thickeners, gelling agents, pH adjusters, preservatives, emulsifiers, flavor modifiers, seasonings, particulates, and colorants may also be added.
A variety of dairy fats also add to the texture, flavor, and consistency of the product. Preferred dairy fats are heavy whipping cream and plastic cream (plastic cream is a product formed during the separation of whole milk) Plastic cream typically has a fat content approaching eighty percent, but it remains as an oil-in-water emulsion in which the fat is still in the form of globules and the skim milk is the continuous phase of the emulsion. Other dairy fats may also be used instead.
Such other fats may also be used to produce lower-cost sauces and cheeses. For instance, vegetable fats, such as shortening, may be used instead of dairy fats. Other liquid components such as a fluid milk, condensed milk, ultra-filtered milk may also be used.
In an add gelatin and hydrate step 26, gelatin and salt and optional other dispersing agents are added to the water and blended (with slow agitation) about one minute to cause the gelatin to hydrate. Once the gelatin is hydrated, the fat, such as dairy fat or vegetable fat is blended into the mixture and heated in a blend fat and heat step 28. Optionally, the fat may be preheated in an optionally preheat fat step 29 prior to the blend fat and heat step 28. Following the addition of the fat, the additional ingredients including cheese, EMC's, flavorings, colorants, and other optional ingredients may be blended into the mixture in a blend additional ingredients step 30, and the blend may then be cooked in a cook mixture step 32.
Next, the blend may be homogenized in an optional homogenize step 34, which preferably occurs in two stages (at one thousand psi for the first stage and two hundred fifty psi for the second stage), although strictly speaking homogenizing is not required. After homogenizing, a flavor modifier or other seasonings may be added in an optional add seasonings step 36. In this step, spices, herbs, or other particulates such as dried vegetables and/or fruits and nuts may optionally be added. Examples of spices and herbs that may be added include (but are not limited to) garlic, basil, cilantro, jalapenos, oregano, tomato powder, onion powder, bell peppers, cilantro, garlic, celery, parsley, salt, pepper, and sugar. Examples of other particulates that may be added include sun-dried tomatoes, garlic, basil, dehydrated tomatoes, jalapenos, hot peppers, sweet peppers, mushrooms, onions, meats, and various purees. It should be noted in passing that the addition of the flavor modifier and/or seasonings may instead take place at other points in the process (such as in the blend additional ingredients step the single-serving sealing step 30).
The dairy product may then be separated into a desired number of smaller quantities, such as two pound loaf boxes, thirty to forty pound boxes, or trays of a larger quantity, such as seventy-five pound trays, and refrigerated in a form and refrigerate step 38. After refrigeration and curing for a sufficient time (the cheese becomes firmer over time due to the stabilizer), the cheese is sufficiently firm so that it can be processed in a machine or process to desired size step 40 into slices, dice, shreds, or any other desired small size configuration. Those skilled in the art will appreciate that the cure time must be sufficiently long to allow the cheese to become sufficiently firm to render the cheese convertible, and not so long that the time required for curing substantially increases the cost of manufacturing the cheese. As an alternative method, product can be hot filled into a final form such as, for example, cubes.
Firmness of the cheese may be measured with a texture analyzer such as the TA.XT Plus device from Texture Technologies Corporation. The setup for this device includes a forty-five degree cone with a thirty kilogram load cell. The probe is set at a rate of two millimeters per second, and travels to a depth of twenty millimeters. The product temperature of four to eight degrees Celsius. Acceptable TA readings of firmness require a reading of five to fifteen kilograms of force, with a preferred minimum TA reading of eight kilograms of force. Cheese which is insufficiently firm is particularly difficult to convert, and cheese which is too firm may not possess desired melting characteristics.
Alternately, firmness of the cheese may be measured with a cone penetrometer such as the universal penetrometer available from Universal Scientific Petroleum Instruments with a needle, per ASTM D 5, 2.5 gram tapered 0.040 inch to 0.006 inch, at thirty-eight degrees Fahrenheit with a dropping assembly mass of one hundred grams, after a period of ten seconds. Acceptable readings of firmness require a penetrometer reading of less than about sixteen millimeters, with the preferred range being between six and ten millimeters.
Finally, the cheese is packaged for sale in a packaging in desired packaging step 42, following which the finished product may be refrigerated or frozen. The process then ends in a process termination step 44. As specific illustrations of portionable, rapid melt dairy products, three examples (which are illustrative of and in no way limit the present invention) are provided hereinbelow.
A first example is a cheese sauce made with Parmesan cheese, which typically tends to be a harder cheese, using the ingredients that are shown in Table 1 below.
The Parmesan sauce is prepared in the following manner. All of the dry ingredients are preblended except for the gelatin and the seasonings. Water is added to a laboratory cooker, and gelatin is then added to the cooker and allowed to hydrate with slow agitation for about one minute. Heavy cream is then added slowly to the gelatin/water mix and is allowed to blend thereinto. The dry blended ingredients are then added, and blending is continued. The plastic cream and flavor are then added and blended, and heating is begun. Hydration of the gelatin may take place in about one to five minutes depending on the gelatin used and the water temperature.
The product in the cooker is heated to one hundred eighty-four degrees Fahrenheit with steam. In production equipment, the blending will preferably be accomplished in an unheated blender and then the blend transferred to a cooker for heating. The temperature used for heating in a production cooker may vary from as low as one hundred sixty degrees Fahrenheit, to possibly as high as two hundred degrees Fahrenheit. What is important is that the gel be hydrated and that the blend be properly cooked, rather than requiring any particular temperature.
The batch is then optionally homogenized in two stages, at one thousand psi for the first stage and two hundred fifty psi for the second stage (250/1000). The seasonings are then added to the batch, which is subsequently divided into two pound loaf boxes and refrigerated to cool it and thereafter to allow it to cure. The curing process must be for a sufficiently time to allow the product to become sufficiently firm to render the product easily convertible into finely divided, portionable, segments. It will be recognized by those skilled in the art that excessively long curing times substantially increase the cost of manufacture.
Alternatively, cooling of the batch may instead be accomplished using a chill roll, which is an apparatus that is commonly used in the making of process cheese slices. The batch of product may be extruded through a chill roll having two spaced-apart rollers which have low temperature coolant flowing therethrough to rapidly cool the batch of product as it flows through the chill roll. The chill roll thus acts as a heat transfer device in such an extrusion operation, with the cooled sheet of product from the chill roll then being run into a bulk container, pressed together, and allowed to cure. The product may also be converted directly to a slice utilizing both hot pack and chill roll slice equipment common to the industry.
The cheese may then be processed in several different ways, each of which is satisfactory in producing a finely divided, portionable, rapid melt dairy product. The product from may be diced into small cubes, about one-eighth inch on each side. Alternatively, the product may instead be: sliced into slices about one-half inch on a side, one and one-half inches long; shredded into shreds of Parmesan cheese about one-sixteenth inch in diameter; cut into three and one-half inch by three and one-half inch slices of various thicknesses; or diced into larger cubes about three-eighths inch on a side. All of the aforesaid machining methods worked well with this formula.
In a production environment, the product may be separated into boxes or trays, such as thirty to forty pound roughly cubic “boxes” or seventy-five pound trays. Other convenient equipment may be used such as, for example, chubs or tubes, with the understanding that with larger boxes or trays, refrigeration will take longer. Refrigeration temperature preferably ranges from about thirty-eight to about forty-five degrees Fahrenheit. Other temperatures may be used so long as the cheese does not freeze and the cheese is sufficiently firm for later processing.
A second example uses Parmesan cheese, which also tends to be a harder cheese, and cheddar cheese flavoring, with the complete list of ingredients being listed in Table 2.
The product in this second example was made in a manner similar to the first example. All dry ingredients except the gelatin, including the flavors, were blended together and placed in a laboratory cooker. Water was added to the cooker and the gelatin was added to the cooker and allowed to hydrate for one minute with slow agitation. The shortening was then added and allowed to blend. Heating was then begun and the dry ingredients were blended while heating them to one hundred eighty-four degrees Fahrenheit with steam. The batch was then separated as before, and the batch was homogenized in a two stage process at one thousand five hundred psi and five hundred psi (500/1500). The batches were then packaged separately into two pound loaf boxes and refrigerated and cured. After refrigeration and curing, the dairy product was processed, i.e., divided, using several different methods as outlined above, all of which were satisfactory.
In the second example, disodium phosphate and trisodium phosphate were added as emulsifiers, to assist in the blending of the dairy product with the gelatin and water. Other emulsifiers that may be used include, but are not limited to, monosodium phosphate, other phosphate salts, and sodium citrate. Lactic acid may be used as a pH modifier. Other pH modifiers that may be used include acetic acid, citric acid, propionic acid, and phosphoric acid, although lactic acid is preferred. In addition, adding three percent starch by weight made the cheese much harder. More starch, up to nine percent, may be added.
A third example uses Parmesan cheese and Butter Buds flavoring, with the ingredients being listed in Table 3.
The dairy product in this third example was made in a manner similar to the first and second examples. All dry ingredients, except the gelatin and the Chr. Hansen Dairy Powder 891 flavor modifier were blended together. Water was added to the cooker and the gelatin was added with slow agitation and allowed to hydrate for about one minute. The shortening was then added to the gelatin/water mixture and allowed to blend with slow agitation. Heating was then begun and the dry ingredients were then added by blending with slow agitation. The product in the cooker was heated to one hundred eighty-four degrees Fahrenheit with steam.
After heating, the batch was homogenized at one thousand psi for the first stage and two hundred fifty psi for the second stage and four-tenths of a percent by weight of Chr. Hansen Dairy Powder 891 flavor modifier was added to the batch. The batch was then packaged and refrigerated and cured. After refrigeration and curing, the product was processed, i.e., divided, using the methods as outlined above, all of which were satisfactory.
It has been found that the preferred products made according to these recipes and procedures use a high-strength gel, e.g., a gel with a Bloom rating of two hundred or greater. A Bloom rating of three hundred is preferred. It has also been found that type A collagen gelatin is preferred. This type gelatin is typically made from porcine skin, cow-hide, or bones of animals aged six months or greater. The isoelectric point of the preferred gelatin tends to be about 4.5 to about 5.5, and the pH may range from about 4.5 to about 7.5, more preferably about pH 5.2 to about 6.2.
Other gelatins may be used instead or in addition, such as another collagen-product gelatin, carrageenan, pectin, agar, a derivative of a collagen product, a derivative of a carrageenan, and a derivative of an agar.
It has been found that sauces and dairy products made according to the invention may also contain additional ingredients to stabilize and firm up the product. These stabilizers/thickeners may include starches or other products. Stabilizers/thickeners may also include guar gum, derivatives of guar gum, carboxymethyl cellulose and its derivative products, and other celluloses, such as hydroxymethyl cellulose and its derivatives.
Alginates, such as sodium alginates, may function as thickeners, and may be used, preferably as a thickener in dairy product and sauce embodiments of the present invention. Some products may be used as thickeners, and are useful in the dairy product embodiments. These include pectin, carrageenan, and agar, locust bean, tara, and xanthan gums, and their derivatives. These ingredients may be used as an additional stabilizer/thickener in the latter stages of blending. Some of these which form a gel, such as pectin, carrageenan, and xanthan and agar gums, may be used in minor proportions together with the gelatin in the gel-forming first step of the process.
Once the dairy product or cheese has been formed, as outlined above, and refrigerated and cured, the product is easily machined or cut into small pieces, e.g., diced, sliced, shredded, crumbled, pulverized, or otherwise suitably formed. The pieces may then be easily apportioned and packaged for an individualized or family-size portions. When desired, irregularly shaped pieces, small cubes, or shreds may later be portioned, i.e., shaken out of the packet and onto a food product, for use as a sauce or topping.
Depending on the firmness or “solidness” of the product or sauce, and the temperature of the food onto which the sauce is sprinkled or shaken, the sauce may melt and spread on its own. If the sauce is more firm, then further heating, such as in a microwave oven or conventional oven, may be required to melt and spread the sauce. Dairy products made according to the present invention preferably include a preservative in small amounts, of about 0.10 to about 0.50 percent, preferably about 0.20 to about 0.30 percent. Suitable preservatives include, but are not limited to, nisin, sorbic acid, benzoic acid, and sodium benzoate.
The pH of the resulting product is preferably in the range of about pH 5.1 to 5.8, more preferably about pH 5.1 to 5.5, and most preferably about 5.1-5.4. It may be useful to add small amounts of a pH or acidity regulator, such as lactic acid. For tart products such as products having fruit flavors, the pH may be lowered to about pH 4.5
The examples above used a strong gelatin, three hundred Bloom, and four to five percent was sufficient to achieve the properties desired in the finished dairy product. Gelatins of lesser strength may be used instead, with a correspondingly higher amount. For instance, if two hundred fifty bloom gelatin is used, the amount should probably be adjusted to about four and one-half to five and one-half percent by weight.
If two hundred Bloom gelatin is used, the amount of gelatin should probably be about five to six percent. Using weaker gelatins, with Blooms of fifty to one hundred, it is possible that an amount of up to seven percent of gelatin may be possible (or needed). Of course, with such a high quantity of gelatin, the cheese may also tolerate a higher moisture content. Thus, in some dairy based sauce embodiments, in which a looser or lower-melting portionable, rapid melt sauce is desired, moisture contents of as high as fifty or fifty-five percent may be possible. All these embodiments are meant to be included, so long as the resulting cubes, slices, shreds, or particles are easily portionable and will rapidly melt when heated or placed on hot food items.
Thus, it will be appreciated by those skilled in the art that the present invention provides a rapid melt dairy based product that is solid and easily portionable at room temperature, but that when heated or when dispensed onto hot food melts quickly into a sauce and remains in sauce form and does not congeal at room temperature. The rapid melt dairy based product uses a gelatin, either with or without a starch as a base, as a stabilizer to produce a sauce that becomes sufficiently firm to process when refrigerated. It may then be processed into reduced size segments and packaged. In use, it may be easily dispensed and will rapidly melt into a sauce when heated or when dispensed onto hot food, and once melted it will remain as a sauce at normal room temperatures.
All references, including publications, patent applications, and patents cited herein are hereby incorporated herein by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference herein and were set forth in its entirety herein. Except where specified, the steps of a method need not be performed in the precise order given in the method.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if individually recited herein.
All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Although the foregoing description of the portionable, rapid melt dairy-based food product of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
This patent application is a continuation-in-part of copending U.S. patent application Ser. No. 11/463,351, filed on Aug. 9, 2006, entitled “Portionable, Rapid Melt Dairy Based Product,” which patent application is assigned to the assignee of the present invention, and which patent application is hereby incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11463351 | Aug 2006 | US |
| Child | 11782795 | US |
