AU726780B2 - Article of frozen confectionery containing inclusions and manufacturing process - Google Patents

Description

1

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant/s: Actual Inventor/s: Address of Service: Invention Title: Societe Des Produits Nestle S.A.

Gilles FAYARD and Martine FIAUX.

SHELSTON WATERS 60 MARGARET STREET SYDNEY NSW 2000 "ARTICLE OF FROZEN CONFECTIONERY

CONTAINING

INCLUSIONS AND MANUFACTURING PROCESS" a.

a The following statement is a full description of this invention, including the best method of performing it known to us:- (File: 19633.00) -la- Article of frozen confectionery containing inclusions, and manufacturing process The present invention relates to composite articles of frozen confectionery comprising distinct inclusions of fillings in the mass of a frozen composition.

It is known how to incorporate and uniformly distribute pieces, for example pieces of comfits or dried fruits, in a mass of frozen composition, for filling pots or trays in the manufacture of family or bulk portions. The device described in DE-A-3521612, for example, makes it possible to distribute uniformly already formed pieces of a certain size in a vein of ice cream, from a hopper with the aid of a rotating drum with retractable blades pressing against a cylindrical wall, the function of which is to load a constant quantity of pieces into a sector of the drum and to distribute it uniformly in the stream of ice cream.

In US-A-3014437, for example, different masses of plastic products such as ice cream masses with different flavours are co-extruded in the form of extrusions, and they are then twisted by imparting a rotating movement with the aid of a rotating blade in the form of a butterfly. One of the plastic products may be a fondant.

It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

Accordingly, the present invention provides a process for manufacturing a frozen composition containing inclusions, wherein extrusions are formed of a central filling 20 surrounded by a sleeve of frozen composition by co-extrusion at a temperature for the frozen composition of less than or equal to -8 0 C, and the said extrusions are then processed into a mass of frozen composition incorporating the said inclusions distributed oe in a random manner in the mass of frozen composition.

e: A process according to the present invention allows the production of a composite article of frozen confectionery comprising a mass of frozen composition and a filling in the form of inclusions which are stabilised and distributed in a random manner in the *"*said mass of frozen composition and in that the inclusions are produced by the coextrusion of a liquid central filling that can be pumped and a frozen composition that can be extruded at a temperature of less than or equal to -8 0

C.

-2- According to the invention, a "frozen composition" is understood to be an ice cream, a sorbet or a sherbet, which is aerated or expanded to a variable extent, or a frozen culinary mousse which is aerated to a variable extent.

Within the context of the invention, a filling consists of an aqueous or fatty composition having a dry matter content of preferably 28 to 80 containing a sugar.

As a sugar, use may be made of granulated sucrose, polysaccharides, more particularly a glucose syrup, burnt sugar, invert sugar, or a maltodextrin, more particularly with a high dextrose equivalent, for example approximately 100.

The filling may consist of a fruit or vegetable puree, preferably pure, ie without any additive. The filling may optionally contain a minimum quantity, much lower than that normally used, of a gelling or thickening agent such as, for example, a gum, a pectin or a *15 gelatin.

o* The filling may be honey, caramel or fruit puree and may have been prepared from a o paste of dried fruit, praline, nougat or nougatine. It may contain flavourings and colourings, for example chocolate, coffee, or fruit flavourings and, optionally, 20 preservatives.

Such fillings may contain small inclusions such as, for example, fragments of chocolate or dried fruit.

o• The filling may be in the form of a fondant or of a paste with a fatty composition, optionally aerated, for example a fruit or chocolate mousse.

According to the nature of its composition, the filling will result in solid inclusions in the mass of the frozen composition that are hard or liquid to a varying extent and that are -i viscous to a varying extent. It is important that it can be pumped and can be conveyed to i the outlet die.

In the process of the invention, it is important that the frozen composition can be extruded at a very low temperature and dissipates the energy that it has stored up in the form of negative calories on leaving the extrusion die, so that the emerging co-extrusion can be shaped. This can be achieved, for example, by coiling up the extrusion or folding it on itself by means of a moving co-extrusion nozzle, continuously delivering a coiled or folded extrusion at the outlet from the die, which can then be cut into portions, or it can be achieved by filling a container by means of a static co-extrusion nozzle, in a discontinuous manner. Such a container may be a pot, a comet, a tray for a family or "bulk" portion or an ice lolly mould. In this method of filling a container, the coextrusion nozzle may be given an up-and-down movement, for example so that it falls to a level close to the bottom of the container and then rises as the extrusion is metered in.

During this operation, the container may remain o 04 C o o o o *o/ o go* stationary or, as a variant, the nozzle may remain stationary and the container falls during filling. When the nozzle moves, provision is made for it to be connected to the extruder by a flexible connection.

In practice, the extrusion has a certain plasticity over a certain period of time, for example of the order of seconds. It should be noted that, according to the invention, the rheological properties of the filling do not play a determining part in achieving co-extrusion. Thus it is possible to manufacture a composite extrusion and to shape it, in particular in a container, without taking ~special precautions as regards the physical properties of the filling, in particular its viscosity and density, relative to those of the frozen composition, since the stability of the inclusions is ensured by the state of the frozen composition surrounding the filling. The process of the invention also permits a large variation in the choice Sand nature of the fillings.

S In principle, any process enabling a frozen composition to be extruded at a very low temperature is applicable. It is oo preferable to use a single-screw or twin-screw extrusion apparatus, in which cooling and incorporation of air is carried out in a single apparatus.

According to a preferred embodiment of the process, the raw materials making up the composition to be frozen are passed through a device provided with two parallel endless screws, revolving in the same direction.

According to a particular embodiment, a gas, for example air, is injected into the barrel in sufficient quantity to give 20 to 150 and preferably 80 to 100 overrun.

In order to put the process into practice, a composition is prepared in a conventional manner for ice cream, low-fat ice cream, sorbet or sherbet, based, according to the recipe, on milk, skimmed milk, cream, concentrated milk, milk powder or butter oil to which has been added sucrose, glucose, fruit dextrose, fruit pulp or vegetable pulp and stabilizing hydrocolloids, such as, for example, carrageenates, alginates, carob gum, and emulsifiers, as for example partial glycerides, and flavourings. After mixing the ingredients intimately in the proportions dictated by the recipe, the mixture is pasteurized and cooled and then, optionally, it can be homogenized, preferably hot, under stringent conditions, enabling the mean size of the fat globules to be reduced to approximately 8-20 microns. After cooling the homogenizate to a low temperature, approaching 0 0 C, the composition may be left to mature for a certain time at this temperature.

Homogenization and maturing are optional stages.

This mass, which is optionally homogenized and matured, is referred to in the following description as the "mass to be frozen". It is introduced, preferably at approximately 2-5 0 C, into a twin-screw freezing device which will be described below in greater detail, in which it is blended by the co-rotating screws revolving at high speed, preferably at 100-600 revolutions per minute, is led to an ~air-injection zone where it is expanded 20-150 is strongly cooled to -8 0 C to -20 0 C, and is then forced through a die.

The work is carried out in the twin-screw device, surprisingly, without excessive shear, so that the pressure increase does not exceed approximately 50 bar at the die.

The emerging product is characterized in that it has a mean ice crystal diameter of 10 to 30 microns, which is appreciably smaller than that obtained with conventional freezers, and is also characterized in that it has a mean fat globule size of around 8-20 microns. The result is an improvement in texture as regards better oiliness and better creaminess.

The filling is injected into the heart of the vein of frozen composition leaving the extruder, by means of a coextrusion nozzle at the outlet from the barrel of the screw extruder, a nozzle which, as indicated previously, may be moving or static.

A device for putting the process into practice is illustrated in the accompanying drawings, given as a nonlimiting example, wherein figure 1 is a diagrammatic exploded view of the device in perspective, figure 2 is a diagrammatic section through a static coextrusion nozzle, figure 3 is a diagrammatic representation of the process S 15 for filling a container and o .figure 4 shows a slice through a co-extruded product, *°*.demoulded from the container, sliced and placed on a supporting sheet.

o..

S 20 In figure 1, the device comprises two identical and parallel endless screws 1 and 2, intermeshing with each *e-.*other and rotating in the same direction, driven by a motor (not shown). The screws 1 and 2 are placed in a barrel 3, which has a feed pipe 4 at one of its ends for the mixture 25 to be frozen, provided with a non-return valve 5 ensuring e air-tightness, and at the other end a die 6 in the form of a plate.

The device may optionally have means for feeding in air in the intermediate zone.

The two endless screws may have successive segments F1 to F9, where the form of the screw varies from one segment to the other, for example from the point of view of the orientation of the threads and their pitches. The configuration of the screw is such that operations can be carried out in which the mass is conveyed, mixed, sheared and compressed towards the die and, optionally,-gas may be incorporated so as to obtain satisfactory expansion.

Intermediate zones may be provided for stirring, for example using mono-lobe or bi-lobe discs with a positive orientation, having a conveying effect, or with a negative S orientation having a returning effect, or even a segment with an inverse screw pitch inducing a return.

The barrel 3 is provided with means for cooling consisting of a double envelope through which cooling fluids circulate.

The means for cooling preferably comprise one selfcontained cooling circuit 7 per segment, with valves 8 *o*controlling the flow rate of the cooling agent, for example 15 a water-alcohol mixture, which enables the temperature of *"*each segment to be individually controlled. The screws may also be cooled in a controlled manner, for example by means of a cooling fluid circuit which may be controlled independently.

Gas, for example air, may be injected by means of flow meters through the pipes 9 at various points of the barrel 3, and preferably in the second half of its length, preferably on each side of it. The air flow may be

S

25 regulated individually by the valves 10. In this way, it is possible to achieve, preferably, 80 to 150 overrun.

The die is preferably in the form of a counter-cone, the function of which is to join together the spaces surrounding each screw into a single outlet orifice. It may be a horizontal, vertical or inclined outlet. The geometry and the dimensions of the die or, where appropriate the diameter and length of the outlet pipe which may be connected to it, are designed to ensure a counter-pressure of the order of 4 to 50 bar and preferably 4 to 25 bar. The counter-pressure is ensured by the geometry of the passage taken by the frozen composition in the co-extrusion nozzle; for example in the case of an outlet temperature for the product close to the lower limit, the working diameter of the outlet passage must be increased to compensate for the fall in pressure due to the loss in load caused by the increase in viscosity when the temperature of the mass falls. The die may preferably be cooled, for example by means of a sleeve through which a cooling fluid flows.

The filling is injected, at the outlet from the die 6, by means of a pump (not shown), through the pipe 11 to the core of the vein of frozen composition leaving the extruder, by means of the co-extrusion nozzle 12 positioned at the outlet from the barrel of the screw extruder, a 1 nozzle which, as indicated previously, may be moving or static. The procedure to be adopted is to form a hollow S• tube of frozen composition into which a filling component is injected with the aid of a pump. The principle consists of pushing the mass of frozen composition around a 2 deflecting device in the form of a needle into which is inserted a passage for the filling.

In figure 2, the nozzle 12, fitted to the die 6, comprises a central passage 13 for the filling, connected to a pipe 11 and an annular passage 14 for the frozen composition *S9.

25 leaving the die 6. This nozzle delivers a co-extruded extrusion with a central filling surrounded by a sheath of frozen composition, the form of which may be varied according to the configuration of the sections of the respective outlet orifices 15 and 16. According to the nature of the filling, for example if it consists of a fatty composition, thermal insulation such as 17 may be provided in the body 18 of the nozzle and around the inlet part of 19 of the passage 13, for example an insulating material or an annular chamber connected to vacuum.

As shown in figure 3, the composite extrusion 20 coming from the co-extrusion nozzle 12 is metered into a tray 21, conveyed by a conveyer 22 travelling stepwise under the nozzle. The composite extrusion 20, which still has a plastic consistency, is then folded on itself in successive layers and the filling is distributed in a random manner in the spaces created between the layers as they occupy the volume delimited by the tray within which the mass of frozen composition is confined. Stable solid or liquid inclusions are thus obtained such as 23, held in place due to the particular physical state of the mass of frozen composition. In particular, it should be noted that there is no migration or accumulation of inclusions by gravity at the bottom of the container.

**op.

The process according to the invention is described in greater detail in the following examples given by way of 15 illustration. Percentages are by weight, unless stated to the contrary.

S9 9 9" o Example 1 1) Mass of frozen composition A composition to be frozen was prepared having a low freezing point and containing 2 of milk fat (in the form of cream with 35 fats), 12.5 of non-fat milk solids, 13.5 of sucrose, 5 of glucose syrup (with a dextrose equivalent of 38-42), 3 of maltodextrin (with a dextrose equivalent of 15-18), 0.6 of partial glycerides as stabilizers/emulsifiers and 0.4 of vanilla flavouring.

The total solids content of the composition was 33 the balance being represented by water. The mixture was homogenized in two stages at 135 and then 35 bar, was 15 pasteurized at 86 0 C for 30 s, cooled to 4 0 C and stored for 24 h at this temperature.. This composition was introduced into the extrusion device under the following operating conditions 66o.

20 Configuration of screws 1 and 2 Segments Fl F2 F3 F4 F5 F6 F7 F8 F9 Type of screw T T/M T/M M/C T CO M/CO M/CO CO Where T conveyance, M mixing, C shearing and 25 CO compression.

*6 Flow rate of product entering 8 kg/h.

Air injection: in 9 from both sides into F5 and F6, that is through 4 pipes at a flow rate of Speed of rotation of the screws: 300 rpm.

Cooling of zones F2 to F9 with a cooling liquid at 0 C/-35 0 C, the temperature profile being Fl-F3, -14 0

C/

F4-F8, -20 0 C/ F9, -23 0

C.

External diameter of the die: 9 mm.

The temperature of the product as it emerged was -9.5 0 C and the overrun 90 2) Filling liquid Instant cocoa containing sucrose (Nesquik was diluted with skimmed milk at a rate of 1.5 kg of cocoa per 1 1 of skimmed milk. This liquid was introduced at a flow rate of kg/h through the pipe 11 of the co-extrusion nozzle, having a diameter of 4 mm.

3) Composite product obtained After filling a bulk tray, it was not possible to distinguish the form of the co-extruded extrusion. The appearance of the surface of the product was similar to 15 that of a standard ice cream. After removing the composition from the mould and cutting it up, inclusions were observed such as 23, figure 4, very regularly distributed throughout the ice cream mass which, at the end of a few minutes at room temperature, flowed slowly to give a sort of covering. The ice cream, which had a low fat content, had a very creamy texture.

Examples 2-3 25 The procedure was as in example 1, but with a cocoa/chocolate mass having the following composition Example 2: Cocoa filling with 63 dry matter Ingredient Granulated sugar Dehydrated glucose syrup 16 Dark chocolate paste Dark cocoa powder 2 Gelling agent 0.55 Water 36.45 Example 3: Chocolate filling with 80 dry matter Ingredient Chocolate powder 30.5 Glucose syrup, invert sugar, 49.5 hydrogenated vegetable fat, salt, vanilla flavouring Water Example 4 The procedure was as in example 1, but with a caramel filling mass consisting of a caramelized sugar syrup containing 76 dry matter.

S* The filling flowed slightly when cut.

Example The procedure was as in example 1, but with a filling consisting of pure concentrated blueberry juice containing 63 dry matter.

The filling flowed when cut to give a regular covering of 25 the ice cream.

Examples 6-9 The procedure was as in example 1, but with a filling consisting of a mass of fruit puree having the following composition: Example 6: Mango filling with 55 dry matter Ingredient Granulated sugar 48.9 Mango pulp Lemon juice 1 Pectin 0.77 Water 19.33 Example 7: Red currant fillin with 64.4 dry matter o Ingredient Dehydrated glucose syrup 52.7 Red currant puree 15 Cerelose dextrose (dextrose 12 equivalent 100) Lemon juice 0.3 Example 8: Apricot filling with 30-50 dry matter Ingredient Sucrose Apricot puree, glucose syrup, gelling agent (fruit pectin), S.I 25 flavourings, malic acid Example 9: Chestnut filling with 30-50 dry matter So that the filling could be pumped, chestnut puree was mixed with skimmed milk at a rate of 1 kg of puree per dl of milk.

The inclusions obtained remained solid when the product was sliced, thus giving the illusion of pieces of fruit.

Examples 10-12 The procedure was as in example 1, but with a vegetable sorbet as the frozen composition and a vegetable-based filling which could have been the same or different, with the following composition for the filling Example 10: Vegetable filling with 30 dry matter Ingredient Vegetable pulp (avocado, carrot) Granulated sugar 17 Microbiological stabilizer 0.3 Lemon juice 1.7 15 Pepper 1 Salt 1 Water '.Example 11: Tomato filling with 28 dry matter Ingredient Tomato puree Cerelose dextrose (dextrose equivalent 100) .i 25 Polydextrose Granulated sugar 3 Glucose syrup Microbiological stabilizer 0.4 Lemon juice 0.6 Flavouring 0.05 Colouring 0.01 Water 25.04 Example 12: Melon filling with 28.7 dry matter Ingredient Melon puree Liquid sucrose 14.7 Glucose syrup 6.3 Invert sugar 2/3 Flavouring 2 Gelatin 0.4 Carob gum 0.15 Colouring 0.005 Water 25.95 In the preceding examples, the process and apparatus have 15 been described in relation to the manufacture of a frozen S. composition without it being specified that it is possible to process by co-extrusion several ice creams, sorbets or sherbets with different flavours and colours at the same time, thus to obtain composite products, for example marbled products, containing inclusions.

The process is of course applicable to the manufacture of frozen products such as mousses, creams and spreads, either :**sweet or salt, for example made with cheese, vegetables, S. 25 meat or fish or culinary sauces or salad creams. In these cases, the flexibility of the process makes it possible to adjust the inclusion of air in the composition to be frozen according to the varying degree of overrun desired in relation to the characteristics of the products aimed at.

Claims (15)

1. A process for manufacturing a frozen composition containing inclusions, wherein extrusions are formed of a central filling surrounded by a sleeve of frozen composition by co-extrusion at a temperature for the frozen composition of less than or equal to -8 0 C, and the said extrusions are then processed into a mass of frozen composition incorporating the said inclusions distributed in a random manner in the mass of frozen composition.

2. A process according to claim 1, wherein in order to prepare the frozen composition, a composition to be frozen is mixed, aerated and frozen at a temperature equal to or less than -8'C and that it is passed through a die, in that these operations take place in a single step in a single device consisting of two parallel endless screws, turning in the same direction by being intermeshed with each other and being situated in a barrel provided with means of aeration and cooling so as to shape the emerging co-extruded extrusion.

3. A process according to claim 2, wherein the extrusion is coiled up or folded on itself by means of a moving co-extrusion nozzle, continuously delivering a coiled or folded extrusion at the outlet from the die or by means of a static co-extrusion nozzle filling a container with this coiled or folded extrusion in a discontinuous manner.

4. A composite article of frozen confectionery comprising distinct inclusions of 20 fillings in the mass of a frozen composition, comprising a mass of frozen composition manufactured according to the process of claim 1 and the inclusions are stabilized and :distributed in a random manner in the said mass of frozen composition and in that the inclusions are produced by the co-extrusion of a liquid central filling that can be pumped ~and a frozen composition that can be extruded at a temperature of less than or equal to 8 0 C.

5. An article according to claim 4, wherein the frozen composition is an ice cream, a S" sorbet or a sherbert, which is aerated or expanded to a variable extent or a frozen culinary mousse, aerated to a variable extent and in that the filling consists of an aqueous or fatty composition having a dry matter content containing sugar.

6. An article according to claim 5, wherein the dry matter content is between 28 to -17-

7. An article according to claim 5, wherein the filling contains, as a sugar, granulated sucrose, polysaccharides.

8. An article according to claim 7, wherein the filling contains a glucose syrup, burnt sugar, invert sugar, or a maltodextrin, more particularly with a high dextrose equivalent.

9. An article according to claim 4, wherein the filling is honey, caramel, fruit puree or vegetable puree.

An article according to claim 4, wherein the filling consists of a fruit puree or vegetable puree, more particularly without an additive or contains a minium quantity, much less than that normally used, of a gelling or thickening agent, more particularly a gum, a pectin or a gelatin.

11. An article according to claim 4, wherein the filling contains flavourings.

12. An article according to claim 11, wherein the flavourings include chocolate, coffee or fruit flavourings.

13. An article according to claim 12, wherein the filling further contains preservatives.

14. An article according to claim 4, wherein the filling contains small inclusions, more particularly fragments of chocolate or dried fruit. too

15. An article according to any one of claims 4 to 14, wherein it is in the form of a tray, a pot, a lolly or a comet. DATED this 20th day of April, 2000 SOCIETE DES PRODUITS NESTLE S.A. Attorney: KEN BOLTON Registered Patent Attorney of t o. l Istitute of Patent and Trade Mark Attorneys of Australia of BALDWIN SHELSTON WATERS too.