Patent Application
20220071236
This application relates generally to foods and beverages, and more particularly to packaged food and beverage products suitable for large-scale manufacture and distribution, for retail sale to consumers.
Numerous food products combine fruits, berries and/or other plant-based ingredients with yogurt and/or other dairy components to provide desirable nutritional properties, including fortification, in combination with desired flavor profiles, textural characteristics and other organoleptic properties. Maintaining desired properties of products such as smoothies over a refrigerated shelf life suitable for large-scale distribution and sale to consumers at retail outlets can be challenging. Flavor profiles of smoothies containing ingredients such as fresh fruits and berries can degrade rapidly over time due to oxidation and/or other factors. High pressure processing (HPP), thermal treatments, and/or various preservatives can be helpful with some issues, but there is a need for improvement in this area, particularly where it is desired to avoid or minimize use of artificial preservatives or other artificial ingredients.
One challenge of producing a stable smoothie with one or more proteinaceous ingredients is that difficulties may be encountered in obtaining an acceptable texture. Another challenge is that exposure to ultraviolet (UV) light over the course of a product's shelf life can have deleterious effects on certain properties, e.g., color and stability. A further challenge is that addition of vitamins and minerals to enhance nutritional properties can result in undesirable effects on organoleptic properties.
In some embodiments, a spoonable smoothie includes between about 34% and about 45% by weight of a combination of fruit and vegetable sources, along with a texturant, a protein source, a vitamin source, and a mineral source. In some such embodiments, a fibrous, non-chalky, non-gritty texture is achieved using a whey protein isolate or an acid whey as a protein source. In some embodiments, the spoonable smoothie may be produced via high-pressure processing or thermal processing. In some embodiments in which high-pressure processing is employed, acid whey may be used to help obtain the non-chalky, non-gritty texture. In some embodiments in which thermal processing is employed, the order of ingredient addition may help obtain the non-chalky, non-gritty texture.
In one method of producing a spoonable smoothie, a protein source is hydrated to form a first mixture. In one aspect of the current disclosure, a mineral source may also be added to the first mixture. A pectin, an amount of sweetener, and other texturants are separately hydrated to form a second mixture. The method may further include separately shearing at least one fruit source and at least one vegetable source. The second mixture, the sheared fruit source, and the vegetable source may be cold mixed and sheared together to form a third mixture. The method may further include adding color and flavor to the third mixture. The first mixture may be then added to the third mixture and cold mixed and sheared together to form a final mixture. The method may include heating the final mixture in a first heat exchanger, then cooling the final mixture in a second heat exchanger. The method may also include cold filling the final mixture into a package and sealing the package.
Another method of producing a spoonable smoothie may include preparing a hot mix that includes a pectin, a sugar, and an amount of hot water. The method may also include preparing a first cold mix that includes at least one fruit source, at least one vegetable source, and a yogurt. The method may further include preparing a second cold mix that includes a whey protein source and an amount of cold water. A final mixture may be formed by cold mixing and shearing together the hot mix, the first cold mix, and the second cold mix. The method may include packing the final mixture into a package, then submitting the package to high-pressure processing.
Described herein is a smoothie with a fibrous, non-gritty, non-chalky, spoonable texture. The spoonable smoothie has a high concentration of fruits and vegetables. In some embodiments, the combination of fruit and vegetable sources is more than 20%, more than 30%, more than 32%, more than 34%, more than 35%, more than 36%, more than 38%, more than 40%, or between 34% and 45% of the total weight of the spoonable smoothie. In some embodiments, the fruit sources may include, but are not limited to, apple, avocado, apricot, blueberry, blackberry, banana, blood orange, boysenberry, clementine, cherry, cantaloupe, coconut, cranberry, cucumber, currant, date, dragonfruit, elderberry, fig, goji berry, gooseberry, guava, grapefruit, grape, green pepper, honeydew, juniper berry, kiwi, kumquat, lemon, lime, lychee, mango, mulberry, nectarine, olive, orange, pineapple, passion fruit, papaya, pomegranate, pear, plum, peach, persimmon, pluot, pomelo, pumpkin, raspberry, strawberry, tamarind, tomato, watermelon, yuzu, or a combination thereof. Some fruits may be considered vegetables. In some embodiments, the vegetable sources may include, but are not limited to, artichoke, asparagus, eggplant, alfalfa sprouts, bean sprouts, black beans, chick peas, green beans, kidney beans, lentils soy beans, peas, broccoli, broccoflower, cauliflower, brussels sprouts, cabbage, carrot, celery, kale, spinach, bok choy, chard, collard greens, mustard greens, lettuce, arugula, onions, peppers, rhubarb, beets, ginger, parsnips, rutabaga, turnips, radishes, sweetcorn, squash, potato, sweet potato, yam, zucchini, or a combination thereof. Some vegetables may be considered fruits. The fruit and vegetable sources may be in the form of puree, puree concentrate, puree single strength, individual quick frozen (IQF), fresh, frozen, fresh frozen, canned, dried, freeze-dried, dehydrated, juice, milk, oil, natural coloring, natural flavoring, or combinations thereof.
In some forms, the spoonable smoothie may also include texturants, such as pectin, rice flour, tapioca flour, locust bean gum, iota carrageenan gum, other starches, or a combination thereof. Some texturants may also be considered a source of fiber. In some embodiments, the pectin may include high methoxyl pectin, low methoxyl pectin, or the like. In some aspects of the present disclosure, texturants may also include high cellulose gum, cellulose gel, guar gum, gellan gum, or a combination thereof. In one aspect of the present disclosure, pectin LM12 may be used. In some embodiments, the total amount of texturants may be in an amount of 1.0% to 3.1%, 2.0% to 3.1%, 2.3% to 3.1%, 2.4% to 3.1%, 2.6% to 3.1%, or 2.8% to 3.1% of the total weight of the spoonable smoothie. In some forms, the pectin may be in an amount of 0.20% to 0.35% or 0.25% to 0.30% of the total weight of the spoonable smoothie. In some embodiments, rice flour may be in an amount of 1.0% to 2.0%, 1.25% to 1.75%, or 1.50% to 1.75% of the total weight of the spoonable smoothie. In some embodiments, tapioca flour may be in an amount of 0.2% to 1.2%, 0.4% to 1.0%, 0.5% to 1.0%, or 0.70% to 1.0% of the total weight of the spoonable smoothie. In some embodiments, locust bean gum may be in an amount of 0.05% to 0.15%, 0.08% to 0.13%, or 0.10% to 0.13% of the total weight of the spoonable smoothie.
Some embodiments may also include a protein source, such as acid whey, whey protein isolate, soy, pea protein, or combinations thereof. In some embodiments, the amount of the protein source may be in an amount of 0.5% to 2.5%, 1.0% to 2.0%, 1.0% to 1.5%, or 1.1% to 1.3% of the total weight of the spoonable smoothie. Some forms of the spoonable smoothie may also include a dairy component, such as a yogurt. In some embodiments, the yogurt may be Greek, Skyr or Icelandic, Australian, Balkan-style, Swiss-style, Labneh, Lassi, Kefir, whole milk, reduced-fat, nonfat, unstrained, cow's milk, goat's milk, sheep's milk, soy, rice, almond, coconut, or a combination thereof. In some embodiments, the yogurt may also be considered a protein source. In some embodiments, the dairy component is between 15% and 25%, between 16% and 25%, between 17% and 25%, between 18% and 25%, between 18% and 23%, or between 18% and 21%.
Some embodiments of the spoonable smoothie may also include a vitamin source, such vitamin A, vitamin B1 (thiamine), vitamin B2 (riboflavin), Vitamin B3 (niacin), Vitamin B5 (pantothenic acid), Vitamin B6 (pyridoxine), Vitamin B7 (biotin) Vitamin B9 (folic acid), vitamin B12 (cobalamin), Vitamin C, ascorbic acid, Vitamin D, Vitamin E, Vitamin K, or a combination thereof. In some forms, the vitamin source may be in an amount of 0.0004% to 0.025% of the total weight of the spoonable smoothie. Some embodiments may include a mineral source, such as iron, phosphorous, folate, potassium, magnesium, calcium, selenium, sodium, zinc, or a combination thereof. In some forms, the mineral source may be in an amount of 0.2% to 0.4%, 0.25% to 0.35%, or about 0.345%. Some embodiments of the spoonable smoothie may also include preservatives.
Specific flavors for the spoonable smoothie may include but not are limited to, e.g., triple berry-beet, strawberry-banana-rhubarb, mango-pineapple-banana-carrot, coconut-pineapple-banana-squash, green apple-kiwi-kale, raspberry-peach, blueberry-apple, and harvest berry. Ranges of product formulas that may be used in some embodiments are provided below in Table 1.
One challenge of producing a spoonable smoothie is the effect of UV light exposure on the color, organoleptic properties, and nutritional value, all of which affect the shelf life of the spoonable smoothie. For example, when exposed to light for extended periods, such as in a refrigerated dairy display case in a grocery store, one or more protein components or other components may degrade and/or break down. Protein degradation may result in a change in color, texture, or taste of the spoonable smoothie. Oxidation of unsaturated fatty acids may be associated with off-flavors and/or loss of nutrients. This oxidation may occur rapidly under exposure to high intensity light, or over a longer period of time under exposure to less intense fluorescent lighting. Light may also affect nutritional ingredients such as vitamins and minerals in the spoonable smoothie. For example, riboflavin (Vitamin B2) can be destroyed by ultraviolet light. To combat detrimental effects of light exposure, the package containing the spoonable smoothie may be opaque or may be surrounded by a non-transparent label. A translucent/transparent package may be more attractive to a potential customer, and can provide a benefit by enabling potential purchasers to view the contents, but may allow the spoonable smoothie to be more susceptible to light exposure. In some embodiments, the sides of the package may be covered by a non-transparent label, but the bottom of the package may be transparent. In some embodiments, a light blocking barrier may be employed to reduce deleterious effects of light exposure. Increasing amounts of one or more fruit and/or vegetable components while decreasing amounts of one or more sources of protein and/or unsaturated fatty acids (e.g., by decreasing amounts of dairy components) in the spoonable smoothie composition may reduce deleterious effects of light exposure. Further, employing a low-fat or no-fat dairy source or yogurt or an oxygen barrier may help reduce or prevent issues with off notes detected as a result of the oxidation.
Another challenge of producing a smoothie with a fibrous, non-chalky, spoonable texture is avoiding protein coagulation or sedimentation that may cause grittiness. In some embodiments, the order of ingredients added may help prevent protein precipitation, coagulation, or sedimentation. For example, it is believed that whey protein isolate and pectin may directly compete for water absorption, and that if the whey protein isolate absorbs too much water, then the resulting texture of the smoothie may be grainy. If the pectin absorbs too much water, then the resulting texture of the smoothie may be gel-like. Adding the pectin and the whey protein isolate at the same time may impair the functionality of one or both of the pectin and the whey protein isolate. However, it is believed that when a non-processed form of whey, such as acid whey, replaces the whey protein isolate in the same amounts, the grainy or gel-like texture may be avoided. In some embodiments, whey protein isolate and pectin may be hydrated separately to ensure that each ingredient only absorbs the desired amount of water to create the unique, fibrous, non-gritty, non-chalky, spoonable texture. Additional embodiments to help prevent protein sedimentation or coagulation may include the presence of buffering salts to increase pH, the replacement of pectin with iota carrageenan gum (as seen in the use of almond milk), and the addition of muriatic acid to lower the pH below 2.
After the spoonable smoothie is produced, high-pressure processing (HPP) or a thermal process may be employed to inactivate spoilage organisms and/or to otherwise increase stability. In some embodiments, HPP may occur for about 4 to 6 minutes, or specifically about 5 minutes, at a pressure of between 58 k Psi and 87 k Psi, between 63 k Psi and 87 k Psi, between 68 k Psi and 87 k Psi, between 73 k Psi and 87 k Psi, between 78 k Psi and 87 k Psi, between 80 k Psi and 87 k Psi, or about 86 k Psi and at a temperature of about 0° C. to about 10° C., or specifically at about 5° C. In some embodiments, thermal processing may be completed in a tube-in-tube heat exchanger, shell-and-tube heat exchanger, plate heat exchanger, scraped-surface heat exchanger, or other apparatus. In some embodiments, the thermal processing may occur at about 160° F. to 180° F., or at about 170° F., for about 20 to 40 seconds, or specifically about 30 seconds. Any of the processes may be carried out in a manner that hinders or prevents denaturing or precipitation of proteins. The hindrance or prevention of protein coagulation may ultimately prevent the release of free water from the matrix, which may help maintain the unique, homogenous, fibrous texture of the spoonable smoothie. This texture may be somewhere between that of a full-fat dairy yogurt and a full fat, high-protein Greek yogurt. This texture may be spoonable, non-chalky, non-gritty, and/or fibrous, may have a water activity greater than about 0.85 and a degree of Brix of 13 to 24, about 14 to about 18, or about 14.5.
In some embodiments of the spoonable smoothie produced using HPP, further adjustments may be made to ensure the desired consistency of a smoothie with a fibrous, non-gritty, spoonable texture. For example, when HPP is employed to inactivate spoilage organisms, the resulting embodiment may not have the desired viscosity, mouth feel, and firmness. However, the use of acid whey rather than whey protein isolate as a protein source may help improve the viscosity to the fibrous, non-gritty, spoonable texture. In other aspects of producing a spoonable smoothie using HPP, an increased amount of iota carrageenan may also improve the viscosity of the spoonable smoothie. In yet other embodiments, the use of homogenized yogurt may also improve the viscosity of the spoonable smoothie.
Another method of producing a spoonable smoothie shows a first mixture created from an amount of protein source and an amount of water to hydrate the protein source. Separately, a second mixture is created from an amount of pectin and an amount of water to hydrate the pectin. Vegetable and fruit sources are sheared together to form a third mixture. The first, second, and third mixtures are cold mixed and sheared together with an amount of sweetener, an amount of yogurt, and an amount of a texturant to a final mixture. Any natural colors or flavors may also be added. The final mixture is heated in a first heat exchanger, transferred to a hold tube, then cooled in a second heat exchanger. The final mixture is then cold filled into a package, which is then sealed. In some embodiments, the final mixture may be ambient filled into the package.
Any vitamins powdered forms which may be needed for the desired formulation may be mixed in with the remaining 50% of the sugar. This mixing may take place in a bag, a vat, a tank, or any other appropriate container.
With respect to the fruit and vegetable sources, some formulations of the spoonable smoothie may require fruit or vegetable ingredients not available as purees. If any ingredients are individually quick frozen (IQF), then those IQF ingredients may be slacked out in refrigerated conditions and processed in a high shear chopping process to create a puree.
Referring to
The final mixture may be pumped to a balance tank 230, then directly to two scraped surface heat exchangers 232, 234. The first heat exchanger 232 may preheat the final mixture to approximately 140° F. The second heat exchanger 234 may heat the final mixture to between 172° F. and 175° F. The final mixture may then enter a hold tube 236 designed to provide a minimum of 170° F. throughout hold for a minimum of about 30 seconds. The flow rate of the final mixture may be approximately 10 to 12 gallons per minute. From the hold tube, the final mixture may enter a series of three double-walled scraped surface heat exchangers 238, which may reduce the final mixture to a temperature between 50° F. and 60° F. after the third heat exchanger. The final mixture may be maintained at a temperature below about 75° F. to maintain a desired quality. In some methods, the final mixture is cooled to between 30° F. and 45° F., between 35° F. and 40° F., or about 42° F. The final mixture may proceed to a holding tank 240, filling/sealing machinery 242, and then packaging 244.
The mouth texture and spoonability of the spoonable smoothie may be quantified by analyses of the viscosity of the embodiments disclosed herein. The zero shear viscosity, representative of mouth texture, is related to the internal structure of the sample and is independent of applied strain. Yield stress, the minimum stress required for the material to start flowing, is estimated as the product of zero shear viscosity and critical shear rate, where critical shear rate is the minimum shear rate at which the material starts shear thinning. Yield stress is representative of the spoonability of the sample.
Samples of the spoonable smoothies were analyzed by a Discovery Hybrid Rheometer DHR-3 (TA Instruments located in New Castle, Del.). A flow ramp test was executed to determine viscosity, as a measured function of shear rate between 0.001 (1/s) and 1000 (1/s) at a constant temperature of 5° C. Total ramp time was 900 s with data collected at 30 points per decade. Viscosity was tested for embodiments produced using HPP and for embodiments produced using thermal processing.
Four of the samples analyzed were produced by HPP (shown in Table 2). Sample 1 is a control sample produced with whey protein isolate as the protein source and locust bean gum as a texturant. Sample 2 is a sample produced with acid whey as the protein source and locust bean gum as a texturant. Sample 3 is a sample produced with whey protein isolate as the protein source and iota carageenan as a texturant. Sample 4 is a sample produced with whey protein isolate as the protein source and locust bean gum as a texturant, except that the dairy source is a homogenized yogurt. Seven of the samples were produced by thermal processing (shown in Tables 3). In all samples, the base includes the fruit and vegetable sources and, if any, flavors, colors, vitamins, and minerals.
The data from the analyses and resulting graphs were fit to the Williamsons Model:
where, η=viscosity at a shear rate of {dot over (γ)}; η0=zero shear viscosity; c=rate constant (the inverse of the rate constant will give the critical shear rate where the material will begin shear thinning); n=flow index (n will vary between 0 and 1); and K=consistency; it is the viscosity at a shear rate of 1.0 (1/s) and can be estimated using the CROSS model as
The Williamsons Model calculated the zero shear viscosity (representing mouth texture) and critical shear rate, from which yield stress (representing spoonability) was calculated. As shown below in Table 4, Samples 2-11 had improved mouth texture (greater zero shear viscosity) and spoonability (greater yield stress) than the control (Sample 1). In some embodiments, the zero shear viscosity may be at least 4,500 Pa·s; at least 4,600 Pa·s; at least 4,700 Pa·s; at least 4800 Pa·s; at least 4900 Pa·s; at least 5000 Pa·s; at least 5500 Pa·s; at least 6000 Pa·s; at least 6500 Pa·s; at least 7000 Pa·s; at least 7500 Pa·s; at least 8000 Pa·s; at least 8500 Pa·s; at least 9000 Pa·s; at least 10,000 Pa·s; at least 15,000 Pa·s; at least 20,000 Pa·s or between about 4500 Pa·s and 98,000 Pa·s. In some embodiments, the yield stress may be at least 10 Pa, at least 15 Pa, at least 20 Pa, at least 25 Pa, at least 30 Pa, at least 35 Pa, at least 40 Pa, at least 50 Pa, at least 100 Pa, at least 200 Pa, at least 300 Pa, at least 400 Pa, at least 500 Pa, at least 1,000 Pa, at least 1,500 Pa, or between about 15 Pa and about 1620 Pa.
The firmness of the spoonable smoothie may be measured in a frequency sweep test which represents the gel strength of the embodiments disclosed herein. Samples of the spoonable smoothies were analyzed by a Discovery Hybrid Rheometer DHR-3 (TA Instruments located in New Castle, Del.). A frequency sweep test was executed to determine the linear viscoelastic properties of the material, as a measured function of frequency at a test temperature of 5° C. The test geometry was a 40 mm cross hatched parallel plate with 60 mm cross hatched bottom plate with a geometry gap of 2 mm. Firmness was measured for Samples 1-11 produced using HPP or thermal processing.
G1 is the firmness of a sample at the frequency of 1 rad/s. Complex viscosity is viscosity during forced harmonic oscillation of shear stress (i.e., how viscous the sample remains when both stress and strain vary harmonically with time). Relaxation time may be indicative of network structure of a material. Samples with stronger network structures will have longer relaxation times. As shown below in Table 5, Samples 2-11 had improved firmness (greater G1) and stronger network structures (longer relaxation times), except Sample 2, than the control (Sample 1). In some embodiments, the firmness may be at least 70 Pa, at least 100 Pa, at least 110 Pa, at least 120 Pa, at least 130 Pa, at least 140 Pa, at least 150 Pa, at least 160 Pa, at least 170 Pa, at least 180 Pa, at least 190 Pa, at least 200 Pa, at least 210 Pa, at least 220 Pa, at least 500 Pa, at least 1,000 Pa, at least 1,500 Pa, or between about 115 Pa and about 1790 Pa.
Yet another challenge to producing a smoothie with a fibrous, non-gritty, spoonable texture may occur when the mixture is fortified with minerals and vitamins, or a combination thereof. Specifically, the addition of riboflavin as a source of Vitamin B2 may add (or intensify) an orange color. In some embodiments, thiamine hydrochloride may be used instead of riboflavin, which may help prevent any undesirable orange coloring. In some embodiments, addition of calcium carbonate as a source of the mineral, calcium, may cause unwanted precipitation in the spoonable smoothie, which may result in an undesirable texture. In some embodiments, calcium citrate may replace calcium carbonate, and may help provide a more desirable texture. The calcium citrate may be added with sugar later in the process rather than with the whey protein isolate when the whey protein isolate is hydrated.
In some embodiments, there is provided a spoonable smoothie product that is entirely or almost entirely natural (with minimal or no artificial ingredients, preservatives, colors, or flavors) with a refrigerated shelf life of at least 15 days, at least 30 days, at least 45 days, or between about 142 days. In some embodiments, the product may have a longer refrigerated shelf life, e.g., 60 days, 75 days, 90 days, or 142 days. In some embodiments, the product may be packaged in a polymeric cup made of polypropylene, PET, or other food grade materials, with a peelable foil lid.
In some embodiments, the cup may be entirely or partly transparent or translucent. This may result in the smoothie composition being exposed to light during its shelf life. Ideally, in addition to having microbial stability for its entire shelf life, the product will also have flavor and color stability as well as nutritional stability for its entire shelf life, when exposed to light typically associated with retail display, e.g., light intensity typically associated with a refrigerated display case in a supermarket. In some embodiments, the smoothie will have a color, texture and flavor comparable to those of a freshly made smoothie made from fresh fruit and other fresh ingredients, including a fibrous texture obtained by use of a blender, wherein bits of pulp and/or other solids, seeds, or fibrous materials contribute to a desirable mouthfeel. In some embodiments, the bits of pulp and/or other solids, seeds, or fibrous materials may not be larger than the width of a drinking straw such that they may be drinkable through a straw. In some embodiments, the smoothie may leave little to no mouth coating after it is consumed. In some embodiments, the spoonable smoothie may have a vibrant color. In some embodiments, the pH of the spoonable smoothie may be 3.6 to 4.3, and preferably 3.6 to 4.0.
The spoonable smoothie may be self-supporting, so that a spoonful of the smoothie composition in any particular spoon may, if desired, have a volume greater than a spoonful of liquid in the same spoon, while still being flowable. Particularly, the smoothie may have a viscosity between about 10,000 Pa·s to about 30,000 Pa·s, or between about 15,000 Pa·s and 17,000 Pa·s at refrigerated temperatures. All viscosities refer to zero shear viscosity measured using the rheometer by TA Instruments. In some embodiments, the viscosity and the texture may be somewhere between that of a full-fat dairy yogurt and of a high-protein Greek yogurt.
Each of the various features described above may be used in combination with any other compatible features described above, or with features not described herein. Various aspects of the products and processes described herein are further described in the following claims. Unless otherwise noted, all percentages are percentages by weight.
This application is a continuation of U.S. patent application Ser. No. 16/397,887, filed on Apr. 29, 2019, which claims the benefit of U.S. Provisional Application No. 62/664,737, filed on Apr. 30, 2018.
| Number | Date | Country | |
|---|---|---|---|
| 62664737 | Apr 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16397887 | Apr 2019 | US |
| Child | 17516839 | US |
