Patent Application
20200337355
The invention relates to a manufacturing process for the production of a bouillon tablet. In particularly the invention relates to a process for the production of a bouillon tablet comprising a lipid-fiber powder.
Fats and oils are often added in foods to provide nutrition, taste/aroma, texture, specific processing role, and/or to drive consumers liking. Current trends are toward healthier fats; usually reflected in lower SFA, TFA, and minimally processed (e.g. non-hydrogenated, non-interesterified) fats or oils. Replacing hard fats e.g. with healthier oils is however not trivial. Issues in processing or consumer-related complains may arise. Practical examples in bouillon production, direct replacement of hard fat with oil is detrimental to powder flow-ability leading to manufacturing issues. Furthermore, one may expect severe oil staining that are detested by consumers.
A conventional way of manufacturing bouillon tablets comprises mixing powdered bouillon components with fat and no or only little amounts of oil, and pressing the mix into tablet form.
The most common used fat is palm fat as it provides good technical properties having a good flow-ability of the bouillon powder. In addition palm fat delivers good binding properties to a bouillon itself resulting in a good hardness of the tablet but still easy to crumble. Consumers are increasingly becoming sensitive to palm fat concerns. Many of them perceive palm fat as not healthy and many others perceive it as not environmentally sustainable as a lot of news mention that the rain forest is destroyed to grow palm trees. In addition nowadays there is a nutritional trend to avoid or at least reduce consumption of fats rich in trans-fatty acids and saturated fatty acids and to preferably consume healthy oils rich in monounsaturated fatty acids and/or polyunsaturated fatty acids such as sunflower, safflower, rapeseed and/or olive oil, for example.
Particular oil and fats are also relevant for product formulations from taste and aroma perspective. For example, chicken fats added in chicken bouillon recipes may eliminate the use of expensive and/or artificial flavors to deliver chicken taste/aroma. Challenges is that a small amount of chicken fat has been detrimental to flow-ability of bouillon powder.
An even dispersion of the lipid with the other ingredients is essential to achieve a homogeneous product avoiding the formation of lumps, which can be cumbersome as lipid is introduced in liquid form. A good flow-ability of the bouillon powder or dehydrated soup is needed. The bouillon powder can be filled directly as a free flow-able powder into a packaging container or the bouillon powder can be pressed into tablet or cube form (bouillon tablet/cube). In addition the used lipid in a bouillon powder/bouillon tablet should not stain the packaging material.
Hence, it was the object of the present invention to provide the art with a manufacturing process for the production of a bouillon tablet.
The object of the present invention is to improve the state of the art or at least provide an alternative for a bouillon tablet:
The object of the present invention is achieved by the subject matter of the independent claims. The dependent claims further develop the idea of the present invention.
Accordingly, the present invention provides in a first aspect a process for the production of a bouillon tablet comprising the steps of:
In a second aspect of the invention, there is provided a product obtainable by process for the production of a bouillon tablet comprising the steps of:
A third aspect of the invention relates to a food product prepared by making use of the bouillon tablet of the invention.
It has been surprisingly found by the inventors that by the process of the invention a bouillon tablet comprising a lipid-fiber powder comprising 40 to 78 wt % (by weight of the lipid-fiber) of a lipid composition having a solid fat content (SFC) at 20° C. below 12 wt %, and 22 to 60 wt % (by weight of the lipid-fiber) of a fiber characterized by having a rate of hydration between 15 to 500 cP/min, can be obtained which can now solve the requirement to achieve the necessary attributes:
The present invention pertains to a process for the production of a bouillon tablet comprising the steps of:
“Lipid-fiber powder” according to this invention has particle size distribution with a median diameter Dv50 in the range of 15 to 5000 μm, preferably in the range of 20 to 5000 μm, preferably in the range of 30 to 3000 μm, preferably in the range of 30 to 1500 μm, preferably in the range of 40 to 1500 μm, preferably in the range of 40 to 1000 μm, preferably in the range of 50 to 1000 μm, preferably in the range of 80 to 1000 μm, preferably in the range of 80 to 700 μm, preferably in the range of 100 to 700 μm, preferably in the range of 150 to 700 μm, preferably in the range of 150 to 500 μm. In a further embodiment “lipid-fiber powder” according to this invention has a water activity below 0.50, preferably below 0.40, preferably below 0.35, more preferably below 0.30, more preferably below 0.25, more preferably below 0.20. The bouillon tablet comprises 4 to 30 wt % of the lipid-fiber powder (by weight of the bouillon tablet), preferably 7 to 30 wt %, preferably 10 to 30 wt %, preferably 12 to 30 wt %, preferably 12 to 27 wt %, preferably 15 to 27 wt % (by weight of the bouillon tablet).
The particle size Dv50 is used in the conventional sense as the median of the particle size distribution. Median values are defined as the value where half of the population resides above this point, and half resides below this point. The Dv50 is the size in microns that splits the distribution with half above and half below this diameter. The particle size distribution may be measured by laser light scattering, microscopy or microscopy combined with image analysis. For example, the particle size distribution may be measured by laser light scattering. Since the primary result from laser diffraction is a volume distribution, the Dv50 cited is the volume median.
“Lipid” of the present invention has a solid fat content (SFC) at 20° C. below 12 wt %, preferably has a solid fat content (SFC) at 20° C. between 0 to 12 wt %, preferably has a solid fat content (SFC) at 20° C. between 0 to 10 wt %, preferably has a solid fat content (SFC) at 20° C. between 0 to 8 wt %, preferably has a solid fat content (SFC) at 20° C. between 0 to 6 wt %. The lipid of the present invention has a solid fat content (SFC) at 20° C. below 6 wt %. Lipid according to this invention is an oil or a fat or a combination thereof. Oil is liquid at a temperature of 25° C., preferably at a room temperature of 20° C. Sunflower oil has a solid fat content (SFC) at 20° C. of 0. Olive oil has a solid fat content (SFC) at 20° C. of 0. Chicken fat has a solid fat content (SFC) at 20° C. of 3.7. Palm fat has a solid fat content (SFC) at 20° C. between 20 to 65. The solid fat content shows that according to the invention palm fat is excluded as it is solid at a temperature of 25° C., preferably at room temperature of 20° C.
In a preferred embodiment the lipid is selected from the group consisting of sunflower oil, rapeseed oil, cotton seed oil, peanut oil, soy oil, olive oil, chicken fat, duck fat, goose fat, insect fat, algal oil, safflower oil, corn oil, rice bran oil, sesame oil, hazelnut oil, avocado oil, almond oil, walnut oil or a combination thereof; more preferably sunflower oil, rapeseed oil, or chicken fat. In a further embodiment, the lipid-fiber powder comprises lipid in an amount in the range of 40 to 78% (by weight of the lipid-fiber powder), preferably between 45 to 78%, preferably between 50 to 78%, preferably 55 to 78%, preferably 60 to 78% (by weight of the lipid-fiber powder).
“Fiber” according to this invention has a rate of hydration between 15 to 500 cP/min, preferably 25 to 400 cP/min, preferably 50 to 350 cP/min. The cP/min can be recalculated to cP/sec and 1 cP=10−3 Pa·s. In a preferred embodiment fiber having a rate of hydration between 0.250 to 8.333 cP/sec, preferably 0.417 to 6.666 cP/sec, preferably 0.833 to 5.833 cP/sec.
“Rate of hydration” according to this invention is defined as the time required for the fiber to interact with water and swell resulting an increase in viscosity.
In a preferred embodiment fiber is a water insoluble dietary fiber, preferably a water insoluble vegetable dietary fiber. It is selected from at least one of carrot, beetroot, pumpkin or combinations thereof.
Fiber has particle size with median diameter Dv50 in the range of 5 to 400 μm, preferably in the range of 10 to 400 μm, preferably in the range of 15 to 400 μm, preferably in the range of 20 to 400 μm, preferably 25 to 375 μm, preferably 30 to 350 μm; preferably 35 to 300 μm.
In a further embodiment, the lipid-fiber powder comprises fiber in an amount in the range of 22 to 60% (by weight of the lipid-fiber powder), preferably between 22 to 55%, preferably between 22 to 50%, preferably 22 to 45%, preferably 22 to 40% (by weight of the lipid-fiber powder). In a further embodiment, the mixture of process step a) comprises fiber in an amount in the range of 22 to 60% (by weight of the lipid-fiber powder), preferably between 22 to 55%, preferably between 22 to 50%, preferably 22 to 45%, preferably 22 to 40% (by weight of the lipid-fiber powder).
In an embodiment water is added at a weight ratio of fiber to water between 1:2.5 and 1:35, preferably between 1:3 and 1:30, preferably between 1:3.5 and 1:30, preferably between 1:3.5 and 1:25, preferably between 1:3.5 and 1:20.
“Dietary fiber” consists of the remnants of the edible plant cell, polysaccharides, lignin, and associated substances resistant to digestion (hydrolysis) by human alimentary enzymes.
In a preferred embodiment, the lipid-fiber powder and therefore the mixture of process step a) of the present invention does not include any emulsifier, added proteins or combinations thereof. The term “emulsifier” is selected from the group consisting of egg yolk, lecithin, mustard, soy lecithin, sodium phospates, sodium stearoyl lactylate, diacetyl tartaric ester of monoglyceride (DATEM), polyglycerol-polyricinoleate (PGPR), monoglyceride and mono-diglyceride or a combination thereof. The term “protein” is selected from the group consisting of milk and/or whey proteins, soy proteins, pea proteins, caseinate, egg albumen, lyzozyme, gluten, rice protein, corn protein, potato protein, pea protein, skimmed milk proteins or any kind of globular and random coil proteins as well as combinations thereof.
The drying step can be carried out by any commonly known drying technique such as air drying, oven drying, ventilation, spray drying, vacuum drying, bed drying, microwave-vacuum drying, inferred radiation drying or combinations thereof. The drying temperature is between 50 to 120° C., preferably between 50 to 110° C., preferably between 60 to 100° C., preferably between 60 to 90° C.
Milling according to this invention is a process that breaks solid materials into smaller pieces by grinding, crushing, or cutting. Milling can be carried out by any commonly known milling techniques such as roll mill, hammer mill, chopper mill, ball mill, SAG mil, rod mil or combinations thereof.
As it is shown within the experimental part independently of the mixing sequence of the fiber, lipid, and water a powdered lipid can be obtained after drying. In case fiber and water is mixed first the viscosity of this mixture is higher due to the swelling of the fiber. Therefore adding lipid to the fiber-water-suspension needs a longer mixing time or a higher mixing shear rate to obtain a homogeneous lipid-fiber-water mixture. In a preferred embodiment the fiber and lipid is mixed first and water is added afterwards and further mixed. This process sequence has the advantage that the resulting lipid-fiber-water-suspension ensures a better homogeneous mixture in less time or lower mixing shear rate.
“Flow-ability” means flow properties on how easily a powder flows. Flow-ability (ffc) is quantified as the ratio of consolidation stress σ1 to unconfined yield strength σc, according to “Schulze, D. (2006). Flow properties of powders and bulk solids. Braunschweig/Wolfenbuttel, Germany: University of Applied Sciences.” In an embodiment flow-ability (ffc) of the lipid-fiber powder is at least 1.8 at 23° C., preferably between the range of 1.8 to 12 at 23° C., preferably between the range of 1.9 to 10 at 23° C., preferably between the range of 1.9 to 8 at 23° C., preferably between the range of 1.9 to 6 at 23° C. In an embodiment flow-ability of the bouillon powder using lipid-fiber powder is at least 2.5 at 23° C., preferably between the range of 2.5 to 20 at 23° C., preferably between the range of 2.6 to 15 at 23° C., preferably between the range of 2.6 to 10 at 23° C., preferably between the range of 2.8 to 10 at 23° C., preferably between the range of 2.8 to 7 at 23° C., preferably between the range of 2.8 to 6 at 23° C.
“Bouillon powder” means a dehydrated stock that is in powder form. In an embodiment a bouillon powder comprises ingredients such as salt, taste enhancing compounds like monosodium glutamate (MSG), sugar, starch or flour, flavoring components, vegetables, meat extracts, spices, colorants and fat.
“Bouillon tablet” means a tablet or cube or other geometric forms obtained by pressing a free flowing bouillon powder into a tablet form, cube form or other geometric form”, preferably a tablet form or cube form.
“Crystalline ingredients” according to this invention means at least one ingredient of salt, monosodium glutamate or sugar. The bouillon tablet comprises 30 to 80% (by weight of the composition) crystalline ingredients of at least one of salt, monosodium glutamate, sugar or citric acid anhydrous, preferably 35 to 75%, preferably 40 to 75%, preferably 40 to 70%, preferably 40 to 65%, preferably 45 to 65% (by weight of the composition) crystalline ingredients of at least one of salt, monosodium glutamate or sugar. Salt is preferably sodium chloride, but can also comprise other edible salts capable of imparting or enhancing a salty taste perception, such as potassium chloride. In a further embodiment, the composition comprises salt in an amount in the range of 20 to 58% (by weight of the composition), preferably between 30 to 55%, preferably between 35 to 50% (by weight of the composition). In a further embodiment, the composition comprises monosodium glutamate in an amount in the range of 0 to 25% (by weight of the composition), preferably between 0 to 20%, preferably between 0 to 15%, preferably between 0.5 to 25%, preferably between 0.5 to 15%, preferably between 5 to 10% (by weight of the composition). In a further embodiment, the composition comprises sugar in an amount in the range of 0 to 20% (by weight of the composition), preferably between 0 to 15%, preferably between 0.5 to 15%, preferably between 5 to 10% (by weight of the composition). In a further embodiment, the composition comprises citric acid anhydrous in an amount in the range of 0 to 5% (by weight of the composition), preferably between 0.5 to 4%, preferably between 0.5 to 1.5% (by weight of the composition).
“Amorphous ingredients” according to this invention means at least one ingredient of yeast extract, maltodextrin, starches, flours, vegetable extract, glucose syrup, or onion powder. The bouillon tablet comprises 2 to 35% amorphous ingredients (by weight of the composition) composed of at least one of yeast extract, maltodextrin, starches, flours vegetable extract or glycose syrup, preferably 3 to 35%, preferably 5 to 35%, preferably 5 to 30%, preferably 5 to 25%, preferably 5 to 20%, preferably 5 to 15%, preferably 7 to 15% (by weight of the composition). In a further embodiment, the composition comprises yeast extract in an amount in the range of 0 to 15% (by weight of the composition), preferably between 1 to 15%, preferably between 5 to 10% (by weight of the composition). In a further embodiment, the composition comprises starches and/or flours in an amount in the range of 0 to 15% (by weight of the composition), preferably between 1 to 15%, preferably between 5 to 10% (by weight of the composition). In a further embodiment, the composition comprises glucose syrup in an amount in the range of 0 to 15% (by weight of the composition), preferably between 1 to 15%, preferably between 5 to 10% (by weight of the composition). In a further embodiment, the composition comprises maltodextrin in an amount in the range of 0 to 15% (by weight of the composition), preferably between 1 to 15%, preferably between 5 to 10% (by weight of the composition).
The term “flavourings” in the context of the composition means flavoring agents, herbs, spices, vegetables, meat and fish components (in wet or powder form). Flavoring agents can include parsley, celery, fenugreek, lovage, rosemary, marjoram, dill, tarragon, coriander, ginger, lemongrass, curcuma, chili, ginger, paprika, mustard, garlic, onion, turmeric, tomato, coconut milk, cheese, oregano, thyme, basil, chillies, paprika, tomato, pimento, jalapeno pepper, white pepper powder and black pepper. In a further embodiment, the composition comprises flavorings in an amount in the range of 0.5 to 20% (by weight of the composition), preferably between 1 to 20%, preferably between 5 to 20% (by weight of the composition).
In an embodiment the bouillon tablet is shelf-stable over 12 months and therefore has a water activity of below 0.5, preferably between 0.1 to 0.5.
In an embodiment, the bouillon tablet has a tablet hardness of at least 90 N, preferably at least 100N, preferably at least 110N, preferably at least 120N, preferably between 90 to 500N, preferably between 90 to 300N, preferably between 90 to 250N, preferably between 100 to 500N, preferably between 100 to 300N, preferably between 100 to 250N.
The invention is further described with reference to the following examples. It is to be appreciated that the examples do not in any way limit the invention.
The general procedure for preparing oil powder of the invention is as follows:
Fiber was mixed with oil in a Thermomix TM5 (Vorwerk &Co. KG). Mixing speed was set to speed 3. Mixing was performed at room temperature for 5 minute, until homogeneous slurry was obtained. Subsequently, water was gradually added to the mixture while mixing parameters were maintained. Mixing was maintained for another 3 minute. The slurry was then spread onto a baking pan; slurry thickness was maintained between 5 and 10 mm, then dried in Rational Self Cooking Centre Electric Combination Oven SCC202E (Rational AG, Germany). Drying was carried out for 12 h at 70° C. with 30% fan speed.
In order to evaluate and understand rate of hydration of fiber, experiments were performed in the laboratory under controlled conditions using a Rapid Viscosity Analyser (Newport Scientific, Australia). The method has been slightly modified as described within the reference “Instant Emulsions, Tim Foster et al, pages 413-422 in Dickinson, E. and M. E. Leser (2007). Food Colloids: Self-assembly and Material Science, Royal Society of Chemistry.” Rate of hydration of fibers were measured by following the change in viscosity with time. 2.5 g of fiber or non-fiber material was weighed and added to 22.5 g of water. Measurement was carried out at 25° C. under continuously steering at 160 rpm. The value for rate of hydration is determined by subtracting the final viscosity value from the initial viscosity value and then divided by the time, i.e. 10 min. When maximum (peak) viscosity value is observed earlier than 10 min (e.g. for the case of citrus fiber), the rate of hydration is determined by subtracting the maximum viscosity from the initial viscosity values and then divided by the time to reach this maximum viscosity value.
In case oil is mixed only with fiber alone (no water added), no oil powder can be obtained independently if the rather slurry mixture has been dried and independently of the used oil-fiber ratio (comp. examples 2 to comp. examples 5)
Examples 6-8 have been prepared according to the process of example 1 (water added) resulting in an oil powder.
The induction period of example 6 is defined as the period (measured in hours) during which no oxidative, volatile components are generated under certain defined conditions. The induction period is determined based on ISO method 6886:2006; Rancimat/Oxidative Stability Instrument; at 100.0±0.1° C.; 3.85±0.1 g powdered oil, airflow: 10.0 l/h. Example 6 has an induction period of 58 hours, wherein the corresponding standard sunflower oil has an induction period of 38 hours.
Different kind of fibers have been tested according the process of example 1. Only vegetable fibers are resulting in an oil powder. All tested other fibers show oil separation and do not result in an oil powder. Examples 9 to 16 show that the rate of hydration of fiber should be between 15 to 500 cP/min to obtain an oil powder.
When starch, inulin or hydrolyzed whey protein is used instead of fiber, no oil powder according to the process within example 1 can be obtained as the rate of hydration is not between 15 to 500 cP/min.
Different amount of water added to oil and carrot fiber have been tested according the process of example 1.
Different oils resulted in an oil powder according to example 1.
Four different carrot fibers regarding the particle size have been tested according to example 1.
It can be concluded that the tested particle size does not have an influence on the preparation of an oil powder.
Different fiber/oil ratios have been tested according to example 1.
The sequence of mixing has been changed as follow compared to example 1:
It is shown within examples 39-41 that also with a different sequence of mixing the fiber, oil and water a powdered lipid-fiber can be obtained.
Preparation of Bouillon (Seasoning) Powder with Powdered Fat:
All non-lipid-fiber ingredients (crystalline ingredients, amorphous ingredients and flavorings were weighted in PG5002S balance (Mettler-Toledo, USA) and then mixed manually. The powdered lipid-fiber was added to the other pre-mixed ingredients and further mixed using Thermomix Type 31-1 (Vorwerk Elektrowerke GmbH & Co.AG, Germany) at speed 3 for 30 s with propeller rotation set to reverse direction. One batch mixing was carried out for 500 g bouillon powder. The resulting powder was then immediately used to measure flow-ability as no fat recrystallization time is relevant.
Pressing of Bouillon Tablet
Bouillon pressing was carried out with Flexitab Tablet Pressing equipment (Röltgen GmbH, Germany). Ten gram of bouillon powder was fed to tableting mold (31 mm in length and 23 mm in width) and the Röltgen tablet pressing was adjusted (between 8 and 11 mm) to reach a pressing force of 15 kN.
Measurement of Bouillon Tablet Hardness
Hardness measurement was carried out using Texture Analyser TA-HDplus (Stable Micro System, UK) equipped with 250 kg load cell and P/75 compression platen. Texture Analyser test mode was set to “Compression” with pre-test speed of 1 mm/s, test speed of 0.5 mm/s, post-test speed of 10 mm/s, target mode of “Distance”, distance of 3 mm, halt time was set to “No”, way back of 10 mm, trigger type to “Auto(Force), and trigger force of 50 gram. Bouillon tablet was placed centrally in vertical-landscape orientation. Hardness measurement was carried out in 10 replication.
Oiling Out Assessment
Immediately after pressing, bouillon tablets/cubes were placed horizontally on “Maggi” hard bouillon primary packaging. Subsequently the samples were stored for 4 days in a Climate Chamber ICH110 (Memmert GmbH+Co.KG, Germay) set to relative humidity (RH) of 30%, fan speed of 40%, and a temperatures of 37° C.
Examples 44-48 shows that by using a powdered lipid-fiber of the invention especially a powdered chicken fat leads to a better flow-ability of a bouillon powder instead the comparison examples 42 and 43 using chicken fat itself for the preparation of a bouillon powder. The better flow-ability of bouillon powder minimize weight variations in case a bouillon tablet is pressed. In addition after pressing the bouillon powder a better hardness of the bouillon tablet and therefore less tablet breakages and also less oil staining of the resulting bouillon tablet is obtained. These results of having a better flow-ability of a bouillon powder are further confirmed by examples 51-52 by using a powdered sunflower oil according to the invention instead of comparison examples 49-50 wherein sunflower oil itself is used. Also the resulting bouillon tablet has a higher hardness and therefore less tablet breakage and less oil staining in case a powdered sunflower oil is used. The bouillon tablet hardness is important for wrapping the bouillon tablet without breaking.
Comparison examples 53 and 54 are prepared according to WO2007085609 by using pre-wetted carrot fibers. Examples 55 and 56 are prepared according to the invention as described above.
It is shown within comparison example 53 and example 55 that in case the process of the invention is used a better flow-ability of the bouillon mass can be obtained compared to WO2007085609. Comparison example 54 and 56 use a higher amount of oil as mentioned in WO2007085609. Nevertheless the effect to obtain a better flow-able bouillon powder is increased, wherein in addition within comparison example 55 an encrustation is observed and within example 56 no encrustation is observed.
| Number | Date | Country | Kind |
|---|---|---|---|
| 17198522.9 | Oct 2017 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2018/078838 | 10/22/2018 | WO | 00 |
