Patent Application
20120219669
The present invention relates to a ready-to-eat farinaceous product and to a method of preparing such a ready-to-eat farinaceous product.
The ready-to-eat food product of the present invention comprises a body of baked farinaceous dough, 40-70% of the surface area of said body of baked dough being coated with a layer of edible material, wherein the surface of the baked dough body that is not coated with the layer of edible material is fried and wherein at least 70 wt. % of the surface of the baked dough body that is covered with the layer of edible material is non-fried. An example of a ready-to-eat farinaceous product according to the present invention is a reduced fat, glazed doughnut.
The invention further provides a method of preparing a ready-to-eat farinaceous food product, said method comprising the successive steps of:
Ready-to-eat farinaceous products can be prepared using a variety of heat treatment methods, including oven baking, frying, infrared radiation, hot air impingement, superheated steam etc. Each of these heating techniques has its advantages and its drawbacks.
The preparation of fully cooked farinaceous products by means of frying yields fried products having a browned, crispy crust. Furthermore, fried products have a very distinct pleasant taste that is not found in ready-to-eat farinaceous products that have been prepared by means of other heating techniques. Doughnuts are a typical example of a fried farinaceous product.
An important drawback of fried farinaceous products resides in the high fat content of these products and the fact that these fats usually contain high levels of saturated fatty acids. Thus, from a nutritional perspective it is highly desirable to reduce the fat levels in these fried farinaceous products. This problem is well recognized in the prior art. Hence, it is not surprising that the prior art provides preparation methods that aim to yield ready-to-eat farinaceous products that are indistinguishable from fried products, except for the fact that they contain significantly less fat.
U.S. Pat. No. 5,910,264, for instance, describes a domestic, electrical cooking apparatus for cooking precooked, deep-frozen or fresh feed, of the fryer type, with no oil bath and no preheating, said apparatus comprising a removable rotary basket heated by infrared radiation. In the US patent it is observed that the fact that the apparatus is heated by infrared rays makes it possible to cook, without an oil bath, commercial precooked deep-frozen food, such as chips, doughnuts, pommes dauphines etc., or fresh or uncooked food, such as chips, chestnuts, spring rolls, etc., without any drawbacks and any risks, in a hygienic and dietetic manner.
A drawback of the apparatus described in U.S. Pat. No. 5,910,264 resides in the fact that the sensory properties of the crust of the cooked products prepared in such apparatus are sub-optimal. More particularly, both appearance and taste of the crust of these cooked products tend to be inferior to that of their fried counterparts.
Hence, there remains a need for a method that can suitably be used to prepare ready-to-eat farinaceous products with sensory properties that are comparable to those of fried products, but containing less fat than their fried counterparts.
The present inventors have designed a process that meets the aforementioned need. The invention provides a method of preparing a ready-to-eat farinaceous food product, said method comprising the successive steps of:
The present method uses hot oil for selectively frying the part of the surface of the ready-to-eat product that is not (to be) covered by a layer of edible material. By not frying the part of the surface that is covered by a layer of edible material fat uptake as a result of frying can be minimized. Since fried surface features such as crispiness and browning are barely perceivable by a consumer when a fried surface is covered with a layer of edible material, the present method offers the advantage that it can achieve a significant reduction in fat uptake during preparation of the ready-to-eat farinaceous product without introducing a perceptible adverse effect on product quality. In the present method the partially fried product is subjected to a baking treatment in order to obtain a fully cooked ready-to-eat product. During the baking also the parts of the dough that are still uncooked become fully cooked. Thus, the present method enables the preparation of, for instance, ready-to-eat glazed doughnuts having a substantially reduced fat content.
Another aspect of the invention relates to ready-to-eat food product comprising a body of baked farinaceous dough, 40-70% of the surface area of said body of baked dough being coated with a layer of edible material, wherein the surface of the baked dough body that is not coated with the layer of edible material is fried surface area and wherein at least 70 wt. % of the surface of the baked dough body that is covered with the layer of edible material is non-fried.
Accordingly, the present invention relates to a method of preparing a ready-to-eat farinaceous food product, said method comprising the successive steps of:
Throughout this document the terms “oil” and “fat” are used interchangeably and encompass triglycerides, diglycerides, monoglycerides, phospholipids and combinations thereof.
The term “baking” as used herein refers to the prolonged cooking of the partially fried dough pieces by dry heat, as opposed to e.g. boiling or frying. It should be understood that the term “baking” encompasses the contacting of the partially fried dough pieces with superheated steam as well as the exposure of said dough pieces to hot air impingement or infrared radiation.
The terminology “fried surface area” as used herein refers to the surface area of the shaped dough pieces that has been contacted with hot oil during a period of at least 10 seconds. The contacting with hot oil can be achieved in many different ways, e.g. by immersing part of the shaped dough pieces in hot oil, by spraying the shaped dough pieces with hot oil or by placing the shaped dough pieces onto a hot layer of oil (shallow frying).
In the present method 30-70% of the total surface area of the one or more shaped dough pieces is contacted with hot oil during a period of at least 10 seconds, thereby producing one or more partially fried dough pieces comprising a fried surface area representing 30-70% of the total surface area and the remainder of the total surface area being non-fried surface area.
The hot oil that is employed in the present method to partially fry the shaped dough pieces typically has a temperature of at least 160° C. Preferably, the hot oil has a temperature of 170-350° C., most preferably of 180-300° C. Contact time between the shaped dough pieces and the hot oil is advantageously within the range of 10-180 seconds, most preferably within the range of 10-60 seconds.
In the present method the shaped dough pieces can be contacted with the hot oil in different manners, e.g. by dipping or by partially immersing the shaped dough pieces in hot oil; or by spraying the shaped dough pieces with hot oil.
The benefits of the present invention in terms of fat reduction are most pronounced if only a limited part of the total surface area of the shaped dough pieces is contacted with the hot oil. Preferably, not more than 60%, more preferably not more than 55% of the total surface area of the one or more shaped dough pieces is contacted with the hot oil during the contacting with the hot oil. Typically, at least 35%, most preferably at least 40% of the total surface area of the one or more shaped dough pieces is contacted with the hot oil.
Likewise, it is preferred that only a minor portion of the fried surface area is covered by the layer of edible material. More particularly, the fried surface area that is covered by the layer of edible material represents less than 30%, most preferably less than 20% of the total surface area. Expressed differently, the fried surface area that is covered by the layer of edible material preferably represents less than 40%, more preferably less than 30% of the total fried surface area.
The inventors have discovered that the fat content of the ready-to-eat product can be reduced even further by frying the upside of the proved dough pieces, i.e. the side of the dough pieces that represented the upside, as opposed to the bottom side, of the dough pieces during at least 70%, most preferably at least 90% of the proving process. Although the inventors do not wish to be bound by theory, it is believed that during proving less and/or smaller gas cells are formed in the exterior layer of the dough pieces that is located at the upside than in the same layer on the bottom side. Probably, because the carbon dioxide that is formed during proving can diffuse out of the dough pieces more easily at the upside than the bottom side where it is in contact with e.g. a moving belt. Due to the fact that the upside of the proved dough contains less (or smaller) gas cells than the bottom side, the oil uptake through the upside tends to be substantially lower than through the bottom side.
Accordingly, in a particularly preferred embodiment of the present invention, at least 60% of the upside and less than 30% of the bottom side of the proved dough pieces is contacted with the hot oil.
The edible material that is applied as a layer in the present method can suitably be a solid mass, a powder, a liquid or a paste. In case the edible material is a solid mass (e.g. chocolate) it is preferred to apply this solid mass in liquefied form (e.g. in molten form). In accordance with a particularly preferred embodiment, the layer of edible material is applied in the form of a powder, a liquid or a paste. Most preferably, the layer of edible material is applied in the form of a liquid or a paste. In case the edible material is applied as a liquid, it is advantageous to employ a viscous liquid, a gel-forming liquid or a molten liquid in order to avoid that the liquid runs off the farinaceous product. It should be understood that the present invention encompasses a method wherein a first layer of edible material is applied as a liquid or a paste, following which solid edible material is deposited onto the first layer, e.g. by sprinkling an edible powder onto said first layer.
The layer of edible material may be applied to the shaped dough pieces, to the partially fried dough pieces or to the baked dough pieces. Preferably, the layer of edible material is applied after the partial frying of the shaped dough pieces, i.e. to the partially fried dough pieces or the baked dough pieces. Most preferably, the layer of edible material is applied to the baked dough pieces.
The layer of edible material can comprise a wide variety of food materials. Advantageously, the layer of edible material contains at least 50 wt. % of an edible material selected from chocolate, fruit preparation, custard, glaze, sugar, fat, cocoa, milk protein, egg yolk, egg white and combinations thereof. Examples of ready-to-eat farinaceous products that can suitably be prepared by the present method include doughnuts, lardy cakes, Spritzkuchen, Krapfen, churros, bu{hacek over (n)}uelos and xuxos. Most preferably, the ready-to-eat product is a doughnut.
In the present method, the partial frying of the shaped dough pieces causes the surface that has been contacted with the hot oil to become more firm as a result of e.g. starch gelation. Thus, the contacting with the hot oil can advantageously be used to set the shape of the shaped dough pieces prior to baking, thereby avoiding loss of shape during the baking. According to a particularly advantageous embodiment of the present method (i) the one or more dough portions are shaped into shaped dough pieces having a rounded bottom; (ii) the fried surface area includes the surface area of the rounded bottom; and (iii) during baking the one or more partially fried dough pieces rest on the rounded bottom part. This particular embodiment of the invention offers the advantage that the rounded shape of the dough pieces is not lost as a result of sagging.
As explained herein the present method can employ a variety of baking techniques. In accordance with a preferred embodiment of the present invention the partially fried dough pieces are baked by subjecting the dough pieces to one or more of the following heat treatments:
The terms “superheated steam” as used herein refers to steam having a (static) pressure that is below the saturated vapour pressure of said steam. The saturated vapour pressure of steam varies with temperature. The higher the temperature, the higher the saturated vapour pressure. Because the pressure of the superheated steam employed in the present method is lower than the saturated vapour pressure, the steam is capable of drying, that is, vaporising the water out of the partially fried dough pieces with which the superheated steam flow is contacted.
The term “infrared radiation” as used herein refers to electromagnetic radiation having a wavelength of 0.7 μm to 1 mm. Whenever reference is made herein to infrared radiation having a wavelength within a certain range, what is meant is that more than 50%, preferably more than 80% of the energy content of the infrared radiation stems from infrared radiation having a wavelength within said range.
The term “air” as used in relation to impingement with hot air should not be construed narrowly, as impingement with gases or gas mixtures other than air may produce similar results. Preferably, the hot air employed in the present method contains at least 50 wt. % of air. Most preferably, the hot air employed consists of air.
If the partially fried dough pieces are baked in an oven, advantageously an oven temperature in the range of 150-350° C., most preferably in the range of 180-320° C. is used. Typically, the partially fried dough pieces will be held in an oven at the indicated oven temperature for a period of 1-15 minutes, most preferably for 3-8 minutes.
The temperature of the superheated steam employed in the present process can vary within a broad range. In order to obtain a ready-to-eat foodstuff with a slightly browned skin and a fully cooked interior an adequate combination of steam temperature and contact time should be chosen. Generally speaking, the higher the steam temperature, the shorter the contact time. Preferably, the superheated steam employed in the present method has a temperature in the range of 130-280° C., most preferably of 150-250° C. The partially fried dough pieces are suitably contacted with the superheated steam for at least 30 seconds, more preferably for 75-150 seconds.
The partially fried dough pieces are advantageously contacted with superheated steam having a pressure that is substantially below its saturated vapour pressure. According to a particularly preferred embodiment, the superheated steam has a pressure of 0.15 to 0.95 times, preferably of 0.3 to 0.8 times the water vapour pressure of the superheated steam.
The contacting of the partially fried dough pieces with the superheated steam is suitably achieved by passing a steady flow of superheated steam over the partially fried dough pieces. In order to ensure that the cooking process will proceed at an adequate rate it is preferred to pass superheated steam over the dough pieces at a flow rate of at least 1 m/s, preferably of at least 3 m/s. Usually, the flow rate does not exceed 50 m/s, preferably it does not exceed 30 m/s.
Direct contact between the superheated steam and the partially fried dough pieces is required to achieve the desired product characteristics. Direct contact is particularly relevant for achieving adequate surface browning and moisture reduction. Hence, if the dough pieces are contacted with the superheated steam while being placed on a tray or being held in a basket, it is essential that superheated steam can penetrate through such a tray or basket to reach the surface of the dough pieces. Typically, in the present method at least 80%, preferably at least 90% of the surface of the partially fried dough pieces is exposed directly to the superheated steam.
In the present method the infrared radiation can suitably be provided by any type of infrared heater that is capable of producing infrared radiation with the right wavelength. The latter wavelength is dependent on the temperature of the emitting body. Most commercially available infrared heaters employ a flame or an electrically heated filament as the emitting body. The present method advantageously employs a infrared heater that contains an electrically heated filament as the emitting body. This filament may be protected by a heat-resistant quartz glass tube. Furthermore, said quartz tube may be filled with inert gas to prevent filament degradation. In the present method the infrared radiation is advantageously provided by infrared tube heaters.
The present method preferably employs infrared radiation having a very high energy content. Consequently, in a particularly preferred embodiment, the infrared radiation employed has a wavelength of 0.7-5.0 μm.
Preferably, in the present method the infrared radiation to which the partially fried dough pieces are exposed has a high power density. Advantageously, the partially fried dough pieces are exposed to a heat flux of at least 2 kW/m2, more preferably of at least 5 kW/m2 and most preferably of 8-80 kW/m2 for at least 20 seconds. Advantageously, the total time period during which the partially fried dough pieces are exposed to the aforementioned heat flux is at least 40 seconds, more preferably at least 60 seconds and most preferably at least 90 seconds. Typically, the time period during which the portions are exposed to the earlier mentioned heat flux does not exceed 700 seconds. Preferably, said time period does not exceed 500 seconds.
Also the hot air impingement employed in the present method advantageously is used to achieve a very intense heat transfer into the partially fried dough pieces. Accordingly, the portions are preferably exposed to impingement with hot air having a temperature of 180-340° C., more preferably of 200-320° C.
The effectiveness of the impingement with hot air depends on the temperature of the hot air, but also on the flow rate of said hot air. Advantageously, the impingement with hot air comprises impinging the portions with hot air having a velocity of at least 1 m/s, preferably of 5-20 m/s.
The baked dough pieces obtained in the present method immediately after the baking typically have a core temperature of at least 85° C., more preferably of at least 90° C. and most preferably of at least 95° C.
The present method is particularly suitable for preparing ready-to-eat products that have been leavened with the help of yeast and/or a chemical leavening agent prior to the contacting with the hot oil. Advantageously the leavened shaped dough pieces have a specific volume of at least 1.2 ml/g, more preferably of at least 2.0 ml/g before they are contacted with the hot oil.
As explained herein before, the present method offers the advantage that it enables the preparation of ready-to-eat farinaceous products having a reduced fat content. Accordingly, it is preferred to employ a dough that has a relatively low fat content. Preferably, the dough employed contains less than 10% fat by weight of flour. Even more preferably, the dough contain 0 -7% fat by weight of flour.
Typically, the dough employed in the present method contains 40-60% of water by weight of flour and 0-50% of other bakery ingredients by weight of flour.
Another aspect of the invention relates to a ready-to-eat food product comprising a body of baked farinaceous dough, 40-70% of the surface area of said body of baked dough being coated with a layer of edible material, wherein the surface of the baked dough body that is not coated with the layer of edible material is fried surface area and wherein at least 70 wt. % of the surface of the baked dough body that is covered with the layer of edible material is non-fried. Such ready-to-eat food product may suitably be prepared by a method as defined herein before.
According to a particularly preferred embodiment, the baked dough body has a fat content of 1-15 wt. %, more preferably of 2-10 wt. %.
Typically, the baked dough body has a weight of 10-200 g and the layer of edible material has a weight of 2-40 g. More preferably, the baked dough body has a weight of 20-100 g and the layer of edible material has a weight of 4-20 g.
The layer of edible material preferably contains at least 50 wt. % of an edible material selected from chocolate, fruit prep, custard, glaze, sugar, fat, cocoa, milk protein, egg white, egg yolk and combinations thereof. The layer of edible material preferably is a continuous layer, i.e. a layer that does not comprise holes showing the underlying baked (non-fried) dough body.
The ready-to-eat farinaceous product is preferably selected from the group consisting of doughnuts, fried noodles, lardy cakes, Spritzkuchen, Krapfen, churros, bu{hacek over (n)}uelos and xuxos. Most preferably, the ready-to-eat product is a doughnut.
The invention is further illustrated by means of the following, non-limiting examples.
Ring doughnuts (41 grams) were prepared using the following recipe:
Dough was made in a spiral mixer by mixing the ingredient for 2 minutes at slow and 6 minutes at fast speed. After 10 minutes rest at room temperature the dough was laminated and rings were cut. The rings were rested/stored at 5° C. till further use.
The doughnut rings were put in a proving cabinet and proved at 38° C., 60% RH, for 54 minutes. The proved products were fried on 1 side, for 20 seconds in oil with a temperature of 190° C. Products were than transferred into a small super heated steam unit where they were baked at 200° C. for 75 seconds in superheated steam at a heat transfer coefficient of 55-70 W/m2.° C. till a core temperature of 96° C. After cooling down for 1 hour at room temperature, the non-fried surface area of the products was decorated with a decoration of the following formulation:
In terms of appearance and eating quality the fully cooked doughnuts so obtained were essentially indistinguishable from ordinary fully fried doughnuts. The fat content of the fully cooked doughnuts (decoration excluded) was about 7 wt. %
Proved ring doughnuts (41 grams) were prepared using the recipe and procedure described in Example 1. The proved products were fried on both sides, for 75 seconds in oil with a temperature of 180° C.
After cooling down for 1 hour at room temperature, the products were decorated in the same way as described in Example 1.
Appearance and eating quality of the so obtained doughnuts were typical for ordinary fully fried doughnuts. The ready-to-eat doughnuts had a fat content (decoration excluded) of about 23 wt. %.
Proved ring doughnuts (41 grams) were prepared using the recipe and procedure described in Example 1.
The proved products were than transferred into a small super heated steam unit where they were baked at 200° C. for 115 seconds in superheated steam and an heat transfer coefficient of 55-70 W/m2.° C. till a core temperature of 96° C. After cooling down for 1 hour at room temperature, the products were decorated in the same way as described in Example 1.
The appearance and eating quality of the fully cooked doughnuts so obtained were inferior to those of the fully cooked doughnuts described in Examples 2 and 1. The fat content of these doughnuts (decoration excluded) was about 5 wt. %
Proved ring doughnuts (41 grams) were prepared using the recipe and procedure described in Example 1.
The proved products were fried on 1 side, for 20 seconds in oil with a temperature of 190° C. and subsequently transferred into a travelling infrared oven that had additionally been equipped with hot air impingement nozzles. The oven consisted of a moving wire mesh belt the speed of which could be controlled. The infrared heating lamps and the hot air impingement nozzles were mounted above the moving belt. Half way along the belt there was a switchback, which effectively flipped the doughnuts. The heating elements consisted of six sets of two lamps mounted at adjustable angles, each set of which could be adjusted in intensity. The sets of lamps were evenly distributed across the length of the moving belt. In addition two hot air impingement nozzles were mounted, one near the centre of the belt and one near the end, so that each side of the doughnuts was exposed to the hot air directly. The temperature of the hot air was adjustable.
Lamp intensities and impingement temperatures depicted in Table I (zone 1 representing the first and zone 8 representing the last zone of the oven that the belt passes through) were applied. The residence time within the oven was 3 minutes.
After cooling down for 1 hour at room temperature, the non-fried surface area of the products was decorated in the same way as described in Example 1.
In terms of appearance and eating quality the fully cooked doughnuts so obtained were essentially indistinguishable from ordinary fully fried doughnuts. The fat content of the fully cooked doughnuts (decoration excluded) was about 7 wt. %
| Number | Date | Country | Kind |
|---|---|---|---|
| 09168591.7 | Aug 2009 | EP | regional |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/NL10/50528 | 8/24/2010 | WO | 00 | 5/7/2012 |
