GB1604585A

GB1604585A - Edible product and method for making the same

Info

Publication number: GB1604585A
Application number: GB3912/78A
Authority: GB
Original assignee: Cadbury Schweppes Ltd; Mercer FB Ltd
Current assignee: Mercer FB Ltd; Mondelez UK Holdings and Services Ltd
Priority date: 1978-01-31
Filing date: 1978-01-31
Publication date: 1981-12-09
Also published as: FR2422344B1; JPS54163867A; DE2903091A1; NZ189508A; DE2903091C2; AU4346979A; FR2422344A1; CA1119876A; AU518944B2; ZA79313B

Description

(54) EDIBLE PRODUCT AND METHOD FOR MAKING THE SAME (71) We, F.B. MERCER LIMITED, a British Company of Kelly Street, Mill Hill, Blackburn BB2 4PJ, England, and CADBURY SCHWEPPES LIMITED, a British Company, of 1-10 Connaught Place, London W.2., do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention, in one of its aspects, provides a food product which comprises a net having mesh strands and net intersections which are integrally formed of an edible material by an extrusion process.

The present invention, in another of its aspects, provides a method of making an edible food product, comprising extruding an edible material so as to form a net having mesh strands and intersections which are integral.

The use of the net gives the food product a distinctive texture and can give it a distinctive appearance or decorative effect. Furthermore, the net can enable the flavour of the food product to be detected more quickly in the mouth.

The net may be of flat or tubular form or it may be of curved or trough shape. Thus the net can be formed by feeding the extrudible material through die orifices defined between a pair of die members of which at least one is linearly reciprocatable relative to the other in order to produce a planar net - the dies may be as described in Figures 1 to 10 of British Patent Specification No. 969 655 or Figures 7 and 8 of British Patent Specification No. 836 555. An alternative procedure is to use relatively oscillatable die members of circular or annular shape with the co-operating die orifices in spaced groups around the die members, each group producing a separate strip of net. The planar net produced may then be subjected to a subsequent deforming operation to impart a curved or more curved or trough shape thereto.

The edible net may constitute the whole of the food product or it may form only part of a composite food product including one or more other edible components. For example, the net may be coated with a food such as chocolate, a chocolate-like coating, a fat-based coating or a fondant.

The net is preferably substantially rigid and, if one or more other edible components are present, can act as a support for the other edible component(s).

The net may consist of any one or more of many food or confectionery materials including, for example, cereal bases, e.g. maize, oats, rice, wheat, potato, millet, modified starches and proteinaceous materials, e.g. edible soya, cotton seed protein, ground nut protein and wheat gluten.

For cereal bases, used to form the net, the normally preferred method of producing the base is that using a cook extruder - cook extruders are well known. In this the previously moisture-controlled cereal material is extruded under high pressure and high temperature through a die and as it leaves the die, rapid evaporation of moisture takes place to produce a "puffed" product.

Normally cook extruders produce an extruded product which still retains a high moisture content of approximately 10% w/w, which then requires drying down to a level of approximately 2% w/w. If the net contains a filling such as a fat-based filling with a low heat stability, such drying is impracticable. Thus, preferably, the moisture content of the net shortly after extrusion is such that no substantial drying is subsequently required, and is, for instance, approximately 2% w/w. This can be achieved if the net is extruded at high temperature and/or high pressure, for instance at a temperature substantially above 100"C, for example about 200"C, and at a pressure of for example 200-300 p.s.i. (about 0.15-0.2 Kg/mm2). The temperatures and pressures are preferably chosen so that the net "flashes-off" its moisture content immediately on extrusion; the pressures and temperatures also determine the ultimate density of the finished net.

A further application for cereal bases relies on extruding a starch-based paste in such a way that little or no flash-off of moisture takes place to produce a gelatinised, relatively dense product. This, after drying, is fried in fat to produce an expanded material containing a substantial proportion of fat from the frying oil. In each of these cases, the extruder has fitted to it a net-forming die, for example a die of the type described in British Patent Specification No. 836 555 or 1 072 113.

The method can also be applied to fat based materials such as chocolate, chocolate-like substances and fat based confections. For this application, the fat confection can be brought to the correct extrusion temperature and in the case of chocolate, tempered in the correct way to ensure good gloss and finish in the final product as in standard chocolate technology, then extruded through a cooled net-forming die, starting on a cooled mandrel and then passing on to a take away belt, preferably after cutting as the material leaves the mandrel.

Alternatively, the net can be made from sugar base, e.g. caramel (toffee), nougat, liquorice paste, high boiled sugar, mallow, fudge, fondant and marzipan, provided that such a sugar base is extrudible.

For edible products such as caramel or nougat, a gear or screw extruder can be used and extrusion take place at relatively low temperatures, although for high boiled sugar a higher temperature is used, say, in the region of 137"C.

In some cases it is essential to cool the extruded material as it leaves the die so that it maintains its shape, particularly when producing tube-like products. For this purpose cold air or nitrogen from a liquified supply can be applied. In other cases, for instance when extruding a caramel or a fondant, the extrudate can be allowed to collapse. However, in general, the mesh structure of the net will remain visible, and the net will not be collapsed or compressed to such an extent that the meshes of the net are completely closed.

Other methods of production are possible. For instance, particularly when using a cold extrusion process, the net can be cut into lengths at the extruder die faces. Such a method is particularly suitable for the subsequent production of preshaped products such as crisps by cooking, e.g. frying, between profiled forms.

In general, the food product could be specifically designed to be suitable as an animal foodstuff, but the invention is primarily directed towards food products for human consumption.

The product is preferably in the form of a snack, that is to say in the form in which it can be sold as an individual item to be held in the hand and eaten.

The following are examples of food products according to the present invention: (a) Substantially rigid extruded tubular net of cereal-based material such as corn-based, wheat-based or rice-based material.

(b) Substantially rigid extruded tubular net of potato-based material.

(c) As (a) or (b) and dipped in an onion-flavoured coating.

(d) Substantially rigid extruded tubular net of caramel.

(e) Substantially rigid extruded tubular net of cereal-based material, dipped in a chocolate coating.

The invention will be further described, by way of example, with reference to the accompanying drawings, of which: Figures 1 to 6 illustrate a number of forms of the net mesh construction; and Figure 7 is a schematic view, looking on the face of a die head which can be used in a different embodiment of the invention.

The net mesh construction can take a variety of forms, some of which are illustrated as follows: Figure 1 rotating either inner or outer die of British Patent Specification No. 836 555 whilst keeping the other die stationary; Figure 2 rotating both the inner and outer dies of British Patent Specification No. 836 555; Figure 3 oscillating either the inner or outer die of British Patent Specification No. 836 555 whilst keeping the outer die stationary; Figure 4 oscillating both the inner and outer dies of British Patent Specification No. 836 555; Figure 5 varying the number of slots or the pattern in which they are cut into the die of British Patent Specification No. 836 555, thereby further varying the pattern; Figure 6 square mesh pattern in accordance with British Patent Specification No. 1 072 113.

The products can be further varied by operating at different speeds or by oscillating by a greater or lesser amount in the case of Figures 3 and 4.

Figure 7 shows a die head of an embodiment which can be used for producing flat strips of food product net. The die head has two annular dies 15, 16 each of which has a number of spaced groups of co-operating die orifices 17. The die members 15, 16 are oscillated relative to each other by for instance the distance apart of the die orifices in one die member and in one group, each group thereby producing a separate strip of net, for instance as shown in Figure 3 or 4.

Embodiments of the present invention and their methods of manufacture will now be described in the following examples where, unless otherwise specified, all percentages or parts are by weight: Example 1 A paste consisting of: 58% potato granules 19.5 o potato starch 19.5% wheat starch 3% salt is dry mixed and fed into the infeed screw of a cook screw extruder. Water is pumped into the extruder to give a total moisture of approximately 40-45% (although a moisture content in the range of 35-70% can be employed at this stage) in the resulting dough as it passes through the extruder to the die. The material passes through a die as described in British Patent No. 836 555 at a temperature of approximately 75"C (a temperature in the range of 60"C-100"C can be employed) to produce a tubular net. The net thus produced is collected and cut into 15 mm lengths. At this stage the material has a moisture content of approximately 35-38% (although the moisture content can be in the range of 30-45% at this stage). The lengths of extruded net are then placed in a drying room at a temperature of 45-50"C for 16 hours during which time the moisture content is reduced to 7-9%. The resulting dried material is then fried in a conventional oil frier at 200-2300C, in this Example 205"C for 15-20 seconds to produce an expanded material (although this time could be in the range of 5-20 seconds). These are then flavoured as required by powdering the surface with a powdered flavour which generally is of a savoury nature. The resultant product is a fried and flavoured extruded snack having a distinctive appearance and texture and possessing good eating qualities.

Example 2 Example 1 is repeated using a paste containing 19.5% maize starch instead of wheat starch to produce a fried and flavoured extruded snack having a distinctive appearance and texture and possessing good eating qualities.

Example 3 57% White Flour 20% Maize Grits 20% Potato Pectin Cellulose 3% Salt is mixed together and fed at room temperature into a screw extruder. The material passes through the extruder where it is heated to a temperature of approximately 1750C (although it could be in the range of 150-200 C) and emerges from a net-forming die of the type described in Figures 1 and 2 of British Patent Specification No. 836 555 where expansion takes place as moisture is quickly released. The final moisture content is approximately 6% (although it could be 6-9 o) and the resulting puffed net is sprayed with a fat and, in this Example, has a powdered flavour applied to it and then after cooling is cut to the desired length, prior to packing.

Example 4 Example 1 is repeated using: 57% Wholemeal Flour 20% Maize Grits 20% Rolled Oats 3% Salt to produce a food product consisting of a substantially rigid tubular net.

Example 5 Example 1 is repeated using: 57% Wholemeanl Flour 16% Maize Grits 8% Milled Wheatgerm 18% Instant Potato Granules 3% Salt to produce a food product consisting of a substantially rigid tubular net.

Example 6 A caramel made, in a conventional manner, to the following recipe Glyceryl Monostearate 0.326 Trisodium Citrate 0.776 Skimmed Sweetened Condensed Milk 12.674 Whey Powder 17.557 42DE Glucose 42.657 Granulated Sugar 16.941 HPKO 13.320 Salt 0.419 Ethyl Vanillin 0.005 Isopropyl Alcohol 0.035 Butter Flavour 0.181 Egg Albumen Powder 0.171 Calcium Lactate Anhydrous 0.017 Water 6.000 is cooled to approximately 45-60"C and fed to a conventional gear or screw extruder. This forces the material through a net-forming die which continuously produces a tubular net of caramel. This is supported for approximately 15cms on a mandrel which is coated with a suitable anti-stick material such as poly-tetrafluoroethylene, and the caramel tube is then cooled rapidly with either cold air or spray liquid nitrogen before passing onto a band which takes the tube through a conventional recirculated air cooler. After this it is cut to the desired length and passed directly to a conventional chocolate enrober where the lengths of extruded caramel net are covered with chocolate or a chocolate-like substance. In some instances, the chocolate or chocolate-like substance may be sprayed onto the tube as it leaves the first air cooler.

Example 7 A milk chocolate composition having the following ingredients: Sugar 46.29% Cocoa Solids 5.21% Non-Fat Milk Solids 18.99% Milk Fat 7.94% Cocoa Butter 21.37% Lecithin 0.2% is manufactured in a manner known per se. After tempering, the chocolate composition is passed to a net-forming die of the type disclosed in Figures 6, 7 and 8 of British Patent Specification No. 836 555. The temperature of the composition is 28-31"C and the composition has viscosity properties at this temperature which enable it to be extruded.

Immediately after emerging from the die, the resultant integrally extruded planar net of milk chocolate is cooled to 15-200C by an air blast and is fed on to a moving band conveyor to be cut to length and packed. The resultant product is a length of milk chocolate net which gives an immediate flavour of chocolate upon tasting in view of its easy melting qualities in the form provided.

Example 8 Example 7 is repeated using a dark chocolate composition having the following ingredients: Sugar 58.4% Cocoa Mass 32.95% Hardened Fat 3.27% Dairy Butter 4.0% Lecithin 1.38% to produce lengths of planar, integrally extruded net formed of dark chocolate.

Attention is drawn to our copending British Patent Application No. 8037225 (Serial No 1604586) which is divided out of the present Application and which describes and claims a food product comprising a filled net tube and a method of manufacturing such a food product.

WHAT WE CLAIM IS: 1. A food product which comprises a net having mesh strands and net intersections which are integrally formed of an edible material by an extrusion process.

2. The food product of Claim 1, wherein the food product is a composite food product and includes one or more edible components in addition to the net, the net being substantially rigid and acting as a support for the other edible component(s).

3. The food product of Claim 1 or 2, wherein the net is tubular.

4. The food product of Claim 1 or 2, wherein the net is flat.

5. The food product of Claim 1 or 2, wherein the net is of curved or trough shape.

6. The food product of any preceding Claim, wherein the edible material is a cereal-based edible material.

7. The food product of any one of Claims 1 to 5, wherein the edible material is a sugar-based edible material.

8. The food product of any one of Claims 1 to 5, wherein the edible material is a fat-based edible material.

9. The food product of Claim 8, wherein the fat-based edible material is chocolate or is chocolate flavoured.

10. The food product as claimed in any one of the preceding Claims, wherein the net is coated with an edible composition.

11. The food product of Claim 1, and substantially as herein described.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **.

Example 7 A milk chocolate composition having the following ingredients: Sugar 46.29% Cocoa Solids 5.21% Non-Fat Milk Solids 18.99% Milk Fat 7.94% Cocoa Butter 21.37% Lecithin 0.2% is manufactured in a manner known per se. After tempering, the chocolate composition is passed to a net-forming die of the type disclosed in Figures 6, 7 and 8 of British Patent Specification No. 836 555. The temperature of the composition is 28-31"C and the composition has viscosity properties at this temperature which enable it to be extruded.

Immediately after emerging from the die, the resultant integrally extruded planar net of milk chocolate is cooled to 15-200C by an air blast and is fed on to a moving band conveyor to be cut to length and packed. The resultant product is a length of milk chocolate net which gives an immediate flavour of chocolate upon tasting in view of its easy melting qualities in the form provided.

Example 8 Example 7 is repeated using a dark chocolate composition having the following ingredients: Sugar 58.4% Cocoa Mass 32.95% Hardened Fat 3.27% Dairy Butter 4.0% Lecithin 1.38% to produce lengths of planar, integrally extruded net formed of dark chocolate.

Attention is drawn to our copending British Patent Application No. 8037225 (Serial No

1604586) which is divided out of the present Application and which describes and claims a food product comprising a filled net tube and a method of manufacturing such a food product.

WHAT WE CLAIM IS: 1. A food product which comprises a net having mesh strands and net intersections which are integrally formed of an edible material by an extrusion process.
2. The food product of Claim 1, wherein the food product is a composite food product and includes one or more edible components in addition to the net, the net being substantially rigid and acting as a support for the other edible component(s).
3. The food product of Claim 1 or 2, wherein the net is tubular.
4. The food product of Claim 1 or 2, wherein the net is flat.
5. The food product of Claim 1 or 2, wherein the net is of curved or trough shape.
6. The food product of any preceding Claim, wherein the edible material is a cereal-based edible material.
7. The food product of any one of Claims 1 to 5, wherein the edible material is a sugar-based edible material.
8. The food product of any one of Claims 1 to 5, wherein the edible material is a fat-based edible material.
9. The food product of Claim 8, wherein the fat-based edible material is chocolate or is chocolate flavoured.
10. The food product as claimed in any one of the preceding Claims, wherein the net is coated with an edible composition.
11. The food product of Claim 1, and substantially as herein described.
12. A food product, substantially as herein described in any one of the foregoing

Examples.
13. A method of making an edible food product, comprising extruding an edible material so as to form a net having mesh strands and intersections which are integral.
14. The method of Claim 13. wherein the extrusion is performed using two relatively oscillating die members, each having die orifices in spaced groups therearound, each group of die orifices in one of the members cooperating with a respective group of the die orifices in the other member so that a respective separate strip of net is produced thereby upon relative oscillation of the die members.
15. The method of Claim 13 or 14, wherein moisture-containing cereal material is extruded under high pressure and high temperature through a die, and as it leaves the die, rapid evaporation of moisture takes place to produce a "puffed" product.
16. The method of Claim 15, wherein the moisture content of the net shortly after extrusion is such that no substantial drying is subsequently required.
17. The method of Claim 16, wherein the net flashes off its moisture content immediately on extrusion.
18. The method of Claim 13 or 14, wherein the net is formed of a starch-based paste and little or no flash-off of moisture takes place on extrusion, the extrusion producing a gelatinised, relatively dense product which is dried, and is fried in fat to produce an expanded material containing a substantial proportion of fat from the frying oil.
19. The method of Claim 13 or 14, wherein the edible material is extruded at an elevated temperature.
20. The method of any one of Claims 13 to 19, wherein after extrusion the net is cut into pieces of the desired length.
21. The method of Claim 13, and substantially as herein described.
22. The method of Claim 13, substantially as hereinbefore described in any one of Examples 1 to 8.
23. A food product when produced by the process as claimed in any one of Claims 13 to 20.