WO2012051140A2

WO2012051140A2 - Stabilized suspensions of nut butter beverage base

Info

Publication number: WO2012051140A2
Application number: PCT/US2011/055683
Authority: WO
Inventors: Michael Stoddard; Billy Kawai Ng
Original assignee: Blue Diamond Growers
Priority date: 2010-10-15
Filing date: 2011-10-11
Publication date: 2012-04-19
Also published as: WO2012051140A3

Abstract

A food base comprising a stabilized paste of finely ground nuts in oil, and methods of making the base are disclosed. The base is storable at room temperature for at least four weeks without exhibiting separation of nut oil from the paste. An almond food base is provided that is suitable for the preparation of almond milk and other foodstuffs.

Description

STABILIZED SUSPENSIONS OF NUT BUTTER BEVERAGE BASE

FIELD OF INVENTION

The present invention relates generally to the field of non-dairy beverages produced from foodstuffs. More specifically, the invention provides a stabilized solid-in-oil suspension of finely ground nuts, almonds in particular, and a process for making said suspension.

BACKGROUND

Nut-based beverages consisting essentially of nuts ground into a powder and mixed with water, milk or other dairy products to achieve the consistency of a beverage are known in the art. One such beverage that overcomes some of the limitations of the prior art in the field, such as poor dispersal of particulates into suspensions and poor behavior during suspension, including Ostwald ripening, flocculation, and phase separations (e.g., oil-water, liquid-solid), are disclosed in U.S. Pat. Nos. 6,123,976 and 6,153,247, incorporated herein by reference in their entirety, for all purposes, including their review of other beverages. The other identified beverages are derived from ground vegetables, fruits and grains, and from other pastes or "butters" made by grinding nuts such as peanuts, hazelnuts, and macadamia nuts.

The above-cited patents describe a process for making a nut beverage from a "concentrate," which concentrate comprises a viscous, pourable nut paste made of finely ground dry roasted, blanched almonds, wherein the particulate solids are suspended in almond oil released during grinding. The particulate solids in the paste fall out of suspension rapidly and tend to "pack" tightly in a layer at the bottom of any container into which the paste is poured. Over time, packing progresses until even very high shear forces fail to re-suspend the particles. To create the concentrate from which the beverage product is made, additional ingredients and processing aides are dispersed in the almond paste, preferably before it separates into oil and solid phases. Preferably, too, the concentrate itself is further processed (before phase separations develop) into the final beverage product.

What is needed is a nut paste wherein the particulate solids do not settle and pack down but remain in pourable or "scoopable" suspension in oil over time to combat the aforementioned stability problems, which tend to develop in supply chains.

SUMMARY OF THE INVENTION

In some embodiments, the invention provides a nut base comprising a solid-in- oil mixture, preferably in the form of a paste, combined with a stabilizer of said solid- in-oil mixture, wherein said solid-in-oil mixture comprises (i) an oil derived from a culinary nut, and (ii) a solid particle derived from said nut. Other embodiments provide methods of making said nut base by incorporating said stabilizer therein.

In one embodiment, said nut base further comprises an anti-oxidant. In one embodiment, said anti-oxidant comprises sodium or potassium or citrate.

In another embodiment, said nut base further comprises an emulsifier. In one embodiment, said emulsifier is an oil -water emulsifier. In one embodiment, said emulsifier is a soy lecithin. In one embodiment, said soy lecithin is non-hydroxylated.

In another embodiment, said nut base further comprises a thickening agent. In one embodiment, said thickening agent is a carrageenan gum.

In some embodiments, said anti-oxidant, emulsifier or thickening agent is added by mixing, before, during or after the formation of said nut paste. In some embodiments, said anti-oxidant, emulsifier or thickening agent is added by mixing, before, during or after adding said stabilizer.

The stabilizer used in certain compositional and methodological embodiments of the invention comprises an edible oil.

In a preferred embodiment, said stabilizer oil is a egetable oil or a crystallization fraction thereof. In some embodiments, said stabilizer oil comprises a mixture of at least two different vegetable oils.

In one embodiment, said stabilizer oil (or oil mixture) has a melting point less than about 160°F. and more than about 75°F., preferably less than about 150°F. and more than about 100°F. and, most preferably, less than about 145°F. and more than about 125°F.

In one embodiment, said stabilizer oil comprises a saturated fatty acid. In one embodiment, said stabilizer oil comprises an unsaturated fatty acid. In one embodiment, said unsaturated fatty acid is polyunsaturated.

In another embodiment, said stabilizer oil comprises a trans-unsaturated fatty acid.

In one embodiment, said stabilizer oil comprises a fractionated palm oil stearine.

In another embodiment, said stabilizer oil comprises a cottonseed oil. In one embodiment, said cottonseed oil is hydrogenated.

In another embodiment, said stabilizer oil comprises a rapeseed oil. In one embodiment, said rapeseed oil is hydrogenated.

In another embodiment, said stabilizer oil comprises a palm oil. In one embodiment, said palm oil stabilizer is hydrogenated.

In another embodiment, said stabilizer oil comprises a palm kernel oil. In one embodiment, said palm kernel oil stabilizer oil is hydrogenated.

In another embodiment, said stabilizer oil comprises a coconut oil. In one embodiment, said coconut oil stabilizer is hydrogenated.

In one embodiment, said stabilizer oil comprises Revel™ A. In another embodiment, said stabilizer oil comprises Dritex^™ C. In another embodiment, said stabilizer oil comprises Sta-Set RCS™. In another embodiment, said stabilizer oil comprises Sta-Set RC™. In another embodiment, said stabilizer oil comprises 27 Stearme .

In one embodiment, said stabilizer comprises less than about 20% by weight of said nut base and more than about 1%, preferably more than about 2%, more preferably more than about 5% and, most preferably, more than about 10% by weight of said nut base.

In one embodiment, said nut base is storable without oil separation for at least seven days.

In a preferred embodiment, said nut base is storable without oil separation for at least four weeks.

In one embodiment, said nut is an almond. In another embodiment, said nut is selected from the group consisting of cashew, filbert, hazel, macadamia, pecan, pistachio, walnut and butternut. In one embodiment, the invention provides a nut base comprising

a) a mixture of solid particles in oil, said mixture produced from grinding nuts under conditions that

i) create a plurality of solid nut particles and

ii) release an oil from said nuts to create a nut paste, and

b) a stabilizer of said mixture, wherein

i) said stabilizer comprises fatty acids having a melting point between 75°F. and 160°F.;

ii) said nut base comprises between 1 % and 20% stabilizer, and iii) said nut base can be stored for at least four weeks without displaying oil separation.

In another embodiment, the invention provides a method of making a nut base from a nut paste, said method comprising the steps of:

a) providing

i) a nut paste of solid particles in oil, said nut paste produced from grinding nuts under conditions that create a plurality of solid nut particles and release an oil from said nut to create said nut paste, and ii) a stabilizer of said nut paste, wherein said stabilizer comprises fatty acids and has a melting point between 75°F. and 160°F.;

b) combining said nut paste with said stabilizer to create a mixture such that between 1% and 20% of said mixture is stabilizer;

c) heating said stabilizer under conditions that cause said stabilizer to melt; d) mixing said nut paste and said melted stabilizer to create a homogeneous paste-stabilizer mixture; and

e) stabilizing said homogeneous paste-stabilizer mixture to create said nut base.

In a preferred embodiment, said stabilizing comprises cooling said paste- stabilizer mixture to a temperature between 75°F. and 120°F.

In one embodiment, said cooling comprises spreading said paste-stabilizer mixture onto a surface cooled by a heat-exchanging means.

In one embodiment, the method further comprises storing said stabilized nut paste for at least seven days at room temperature, during which time no oil separation is evident in said nut paste. In a preferred embodiment, the method comprises storing said stabilized nut paste for at least four weeks at room temperature, during which time no oil separation is evident in said nut paste.

In another embodiment, the invention provides a method of making a nut base from a nut paste, the method comprising the steps of:

a) providing

i) a stabilizer comprising fatty acids and having a melting point between 75° and 160°F, and

ii) a plurality of nuts;

b) grinding said nuts in the presence of said stabilizer under conditions such that the heat generated from the grinding creates a heat of grinding that melts the oil stabilizer so as to make a homogeneous, heated paste- stabilizer mixture, wherein between 1 and 20% of said mixture is stabilizer, and

c) stabilizing said paste-stabilizer mixture to create said nut base.

In a preferred embodiment, said heat of grinding raises the temperature of said stabilizer above 160°F.

In another preferred embodiment, said stabilizing comprises cooling said heated mixture to between 120°F. and 75°F.

In one embodiment, said grinding is performed in a mill. In one embodiment said plurality of nuts are almonds. In one embodiment, said stabilizer and said nuts are fed into said mill. In one embodiment, said nuts are fed into the mill on a separate feed. In one embodiment, said stabilizer is provided in the form of a flake or a bead. In one embodiment, said grinding is performed in at least two milling steps.

In one embodiment, said grinding creates a population of said nut particles, the diameter of which nut particles is less than about 50 um and more than about 0.05 μιη. In a preferred embodiment, the diameter is less than about 10 μιη and more than about 0.05 μπι. In a more preferred embodiment, the diameter is less than about 2 μηι and more than about 0.05 μπι.

In one embodiment, said grinding releases a volume of oil to create a solids- to-oil ratio (v/v or w/w) of more than about 5% and less than about 50% solids. In one embodiment, a portion of said released oil may be decanted to increase said solids-to- oil ratio. In another embodiment, an augmenting oil may be added, wherein said avigmenting oil may be the same as or different from said released oil, to decrease said solids-to-oil ratio.

In one embodiment, said stabilizing comprises cooling said mixture to create a nut base in a pourable condition. In one embodiment, said nut base is poured into a plurality of containers .

In another embodiment, said nut is selected from the group consisting of cashew, filbert, hazel, macadamia, pecan, pistachio, walnut and butternut.

In another embodiment, the invention provides a method of making an oil stabilized nut paste, the method comprising the steps of:

a) providing i) an oil stabilizer, said oil stabilizer comprising fatty acids and having a melting point between 130° and 160°F, and ii) a plurality of nuts; b) grinding said nuts in the presence of said oil stabilizer under conditions such that the heat generated from the grinding melts the oil stabilizer so as to create a mixture; and

c) cooling said mixture to a temperature between 90° and 125°F so as to make an oil stabilized nut paste, wherein the concentration of said stabilizer in said oil stabilized nut paste is between 1% and 3%, wherein said stabilized nut paste can be stored for at least four weeks without displaying oil separation.

In another embodiment of the method, the heat from said grinding raises the temperature of said oil stabilizer above 160°F.

another embodiment, the method further comprises the step of d) storing said oil stabilized nut paste for at least seven days, during which time no oil separation is evident in said oil stabilized nut paste.

In one embodiment of the method, said oil stabilizer comprises at least one vegetable oil.

In another embodiment of the method, said oil stabilizer comprises a mixture of two different vegetable oils.

In one embodiment of the method, said two vegetable oils are cotton seed oil and rape seed oil.

In one embodiment of the method, the concentration of said oil stabilizer in said oil stabilized nut paste is 1.5%.

In another embodiment of the method, said grinding is performed in a mill.

In a preferred embodiment of the method, said plurality of nuts are almonds. In one embodiment of the method, the oil stabilizer and the nuts are fed into the mill. In one embodiment, the nuts are fed into the mill on a separate feed.

In one embodiment of the method, said oil stabilizer is in the form of a flake or bead.

In a preferred embodiment of the method, said cooling is to a temperature between 100°F and 120°F.

In one embodiment of the method, said oil stabilized nut paste after said cooling is poured into a plurality of containers.

In one embodiment, the invention provides an oil stabilized nut paste produced according to the above- summarized method.

In another embodiment, the invention provides a method of making an oil stabilized nut paste from ground nuts, the method comprising the steps of:

a) providing i) an oil stabilizer, said oil stabilizer comprising fatty acids and having a melting point between 130° and 160°F, and ii) a first mixture of solid particles in oil, said first mixture produced from grinding nuts under conditions that release oil from said nuts;

b) heating said oil stabilizer above said melting point;

c) combining said first mixture with said heated oil stabilizer to make a second mixture; and

d) cooling said second mixture to a temperature between 90° and 125°F so as to make an oil stabilized nut paste, wherein the concentration of said stabilizer is between 1 and 3%, wherein said stabilized nut paste can be stored for at least four weeks without displaying oil separation.

In another embodiment, the method further comprises the step of e) storing said oil stabilized nut paste for at least seven days, during which time no oil separation is evident in said oil stabilized nut paste.

In a preferred embodiment of the method, said two vegetable oils are cotton seed oil and rape seed oil.

In one embodiment, the concentration of oil stabilizer after said combining is

1.5%. In a preferred embodiment of the method, said ground nuts are ground

almonds.

In one embodiment of the method, said mixture of solid particles in oil without said stabilizer exhibits oil separation after 1-7 days.

In one embodiment, the invention provides an oil stabilized nut paste produced according to the method summarized immediately above.

In one embodiment, the invention further provides an oil stabilized nut paste comprising a combination of i) an oil stabilizer, said stabilizer comprising fatty acids and having a melting point between 130° and 160°F, and ii) a mixture of solid

particles in oil, said mixture produced from grinding nuts under conditions that

release oil from said nuts, wherein the concentration of said oil stabilizer in said

combination is between 1 and 3%, and wherein said oil stabilized nut paste can be stored for at least four weeks without displaying oil separation.

In one embodiment, the oil stabilized nut paste stabilizer comprises at least one vegetable oil. In another embodiment, said stabilizer comprises a mixture of two different vegetable oils. In a preferred embodiment, said two vegetable oils are cotton seed oil and rape seed oil. In one embodiment, the concentration of stabilizer in the oil stabilized nut paste is 1.5%. In preferred embodiments, said nuts are almonds. In one embodiment, the size of the majority of particles is between approximately 1 and 100 microns. In another embodiment, the size is between approximately 5 and 50 microns.

DEFINITIONS

The term "altering" and grammatical equivalents as used herein in reference to any entity and/or phenomenon refers to an increase and/or decrease in the quantity of the entity in a given space and/or the intensity, force, energy or power of the phenomenon, regardless of whether determined objectively, and/or subjectively.

The terms "increase," "elevate," "raise," "augment" and grammatical equivalents when used in reference to the quantity of an entity and/or the intensity, force, energy or power of a phenomenon in a first sample relative to a second sample, mean that the quantity of the entity and/or the intensity, force, energy or power of the phenomenon in the first sample is higher than in the second sample by any amount that is statistically significant using any art-accepted statistical method of analysis. In one embodiment, the increase may be determined subjectively, for example when a patient refers to their subjective perception of disease symptoms, such as pain, clarity of vision, etc. In another embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 10% greater than the quantity of the same substance and/or phenomenon in a second sample. In another embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 25% greater than the quantity of the same substance and/or phenomenon in a second sample. In yet another embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 50% greater than the quantity of the same substance and/or phenomenon in a second sample. In a further embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 75% greater than the quantity of the same substance and/or phenomenon in a second sample. In yet another embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 90% greater than the quantity of the same substance and/or phenomenon in a second sample. Alternatively, a difference may be expressed as an "n-fold" difference.

The terms "reduce," "inhibit," "diminish," "suppress," "decrease," and grammatical equivalents when used in reference to the quantity of an entity and/or the intensity, force, energy or power of a phenomenon in a first sample relative to a second sample, mean that the quantity of an entity and/or the intensity, force, energy or power of a phenomenon in the first sample is lower than in the second sample by any amount that is statistically significant using any art-accepted statistical method of analysis. In one embodiment, the reduction may be determined subjectively, for example when a patient refers to their subjective perception of disease symptoms, such as pain, weakness, etc. In another embodiment, the quantity of quantity of an entity and/or the intensity, force, energy or power of a phenomenoin the first sample is at least 10% lower than the quantity of the same substance and/or phenomenon in a second sample. In another embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 25% lower than the quantity of the same substance and/or phenomenon in a second sample. In yet another embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 50% lower than the quantity of the same substance and/or phenomenon in a second sample. In a further embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 75% lower than the quantity of the same substance and/or phenomenon in a second sample. In yet another embodiment, the quantity of the substance and/or phenomenon in the first sample is at least 90% lower than the quantity of the same substance and/or phenomenon in a second sample.

Alternatively, a difference may be expressed as an "n-fold" difference. As used herein, the term "nut" relates to foodstuffs referred to generally as "culinary nuts." Conventional botanical terms and classifications apply only loosely to culinary nuts, which include certain seeds and fruits that may not conform to the botanical description but that are characterized by having an edible kernel or core surrounded, at least partially, by a relatively hard wall. In general, the kernel is relatively dry (or can be dried). It therefore can be "ground," or divided into a plurality of similarly shaped and sized particles. Culinary nuts cany fats (i.e., fatty acids mostly esterified to glycerol) and oils (fats that are commonly encountered in liquid form) that the grinding process releases. Grinding therefore does not yield a "dry" powder or granular material but a "paste." The released oils tend to separate into an oily liquid layer disposed above a sediment of solid particles. The sedimented particles tend to pack together more and more tightly as time passes, until the sedimentary layer loses its character as a fluid or even a "semi-solid," and becomes, effectively, a solid. In general, the smaller the size of the particles, the more tightly packed they can become.

The term "mixture," as used herein relates to combinations of substances broadly, without inferring any chemical combining or any particular ratio of the components with respect to one another in the mixture, i.e., the substances retain their identities. Mixtures include systems, the components of which are distributed uniformly (homogeneously), and systems whose components are distributed non- uniformly. In the former, the proportions of the components tend not to vary from sample to sample or from place to place within a sample (at sufficiently long ranges).

As used herein, the term "suspension" and cognates thereof relate to mixtures wherein uniformity decays over time absent the application of a "re-mixing" energy. A "solution," in contrast, is a mixture of particles that remain homogeneously distributed indefinitely.

A "colloid" or "colloidal suspension" relates herein to a mixture comprising at least two immiscible components which, although immiscible, occupy (for a time) a single phase (gas, liquid, solid), each comprising particles of microscopic or sub- microscopic size, distributed uniformly (at sufficiently long ranges). The "dispersed" phase comprises particles dispersed (but not dissolved in solution) in a "continuous" medium. Apart from "gas-in-gas" mixtures, which are always miscible, all combinations can be colloids. The stability of such mixtures is influenced by many agents, all of which reduce the tendency of the dispersed particles to aggregate. As used herein, the term "derived from" relates to a product made from a raw or partially processed material.

As used herein, the term "particle" relates to any object having at least supramolecular dimensions, up to about 1 ,000 μιη in mean diameter, which object is discrete under conditions that are relevant to embodiments of the invention. A "solid particle" herein refers to any such particle, provided only that it can be separated from fats and fatty acids.

As used herein, the terms "pour" and cognates thereof relate to a fluid in bulk flow. In general, fluids are either gases or liquids but, herein, as the context so admits, the terms "fluid" and "flow" may refer to particles and granules (e.g., sand) that are solids as ind dual objects but flow or "pour" in bulk. It is not intended that to pour out of a container, the container must empty completely or at any particular rate.

As used herein, the term "soy lecithin" relates to any of a number of fatty substances derived from the soy plant and characterized in that it typically contains phosphoric acid, choline, fatty acids, glycerol, glycolipids, triglycerides and phospholipids such as phophatidylcholine, phophatidylethanolamine and

phophatidylino sitol .

As used herein, the term "carrageenan gum" relates to a product derived from seaweed and used widely as a thickening agent in cooking.

As used herein, the term "oil" relates to edible oils, and in particular to vegetable oils comprising fats which, at or near room temperature, are liquids. It will be understood that each oil referred to herein comprises various species of lipid molecules, including but not limited to free and esterified fatty acids, mixed together in varying proportions. "Edible oils" herein are oils, known or unknown, that can be eaten by humans without being generally offensive to the sense of taste, and without doing acute harm to the sense of well-being.

As used herein, the terms "melt" and "melting point" relate particularly to the melting of fats. In general, the distribution of molecules in a solid confers a rigidity that is lost when applied heat raises the temperature of the solid to a characteristic point at which the molecules redistribute (melt) and flow as a liquid.

As used herein, the term "fatty acid" relates to a (usually) single chain of carbon atoms bonded together variously with a double bond (all valences occupied by carbon electrons, i.e, "unsaturated") or a bond wherein valences are occupied by carbon electrons and hydrogen electrons ("saturated"), and terminated by a carboxylic acid residue. The hydrogen atoms may appear "side-by- side" (i.e., on the same side of the carbon-carbon bond) or across from one another (i.e., "transversely"). The former bond is "cis-unsaturated," the latter "trans-unsaturated." References to "fatty acids" herein may refer to fatty acids esterified to glycerol or not (i.e., free fatty acids) as the context so admits.

As used herein, the term "hydrogenated," used in connection with a fatty acid, relates to fatty acids derived synthetically by converting fatty acids having relatively many unsaturated bonds to fatty acids having relatively more saturated bonds.

As used herein, the term "fractionated palm oil stearine," relates to a product derived from palm oil in a process that separates the stearins from the oleins in palm oil.

The "fractionation process" typically involves crystallizing a species of the fats comprising an oil and isolating the crystals, crystallizing and isolating another species, etc., to create "crystallization fractions."

As used herein, the term "almond oil" relates to an oil, or a fraction thereof, derived from the seeds of the almond tree. Unfractionated almond oil comprises, predominantly, unsaturated fatty acids.

As used herein, the term "cottonseed oil" relates to an oil, or a fraction thereof, derived from the seeds of cotton plants. Unfractionated cottonseed oil consists of about 70% unsaturated fatty acids, but the approximately 20% that is saturated is comprised largely of long-chains such as stearin.

As used herein, the term "rapeseed oil" relates to an oil, or a fraction thereof, derived from rapeseed by crushing.

As used herein, the term "palm oil" relates to an oil, or a fraction thereof, derived from the fruit (specifically, the fruit pulp surrounding the kernel or seed) of the oil palm. The fatty acid content comprises, disproportionately, saturated fats.

As used herein, the term "palm kernel oil" relates to an oil, or a fraction thereof, derived from the kernel (seed) portion of the fruit of the oil palm. The proportion of saturated fats is higher in palm kernel oil extracts than it is in oil extracted from the fruit pulp.

As used herein, the term "coconut oil" relates to an oil, or a fraction thereof, derived from the fruit of the coconut palm, including the pulp or "meat," and the kernel. As used herein, the term "almond" relates to a seed derived from the fruit of an almond tree. The seed is extracted from the fruit by removing, first, the outer hull and, next, a hard shell to reveal the seed within.

As used herein, the term "cashew" relates to a seed derived from the fruit of a cashew tree.

As used herein, the term "hazelnut" relates to a nut from the hazel tree. One variety of the hazelnut is the filbert.

As used herein, the term "macadamia" relates to a seed derived from the fruit of the Macadamia genus of a large evergreen plant.

As used herein, the term "pecan" relates to a seed derived from the fruit of a pecan tree.

As used herein, the term "pistachio" relates to a seed derived from the fruit of the pistachio bush (or tree).

As used herein, the term "viscosity" and cognates thereof relates to a property of fluids characterized by resistance of the fluid to an applied stress on the fluid, i.e., resistance to flow.

As used herein, the term "dry roasted" relates to a process wherein the moisture content of a nut or other foodstuff is reduced by transporting heat to the foodstuff without using a liquid heat transfer medium, oil in particular.

As used herein, the term "blanching" and cognates thereof relates to a process wherein applied heat, usually by means of boiling water or steam, partially "cooks" a foodstuff, nuts in particular. For almonds, blanching assists in removing the skin or seedcoat.

As used herein, the term "beverage" relates to any liquid prepared for human consumption. The terms "nut milk" and the like refer to a beverage containing particles derived from nuts and prepared to simulate dairy milk in color, "mouth-feel," pourability, texture, etc.

As used herein, the term "phase separation," relates to the separation of components of a mixture into separate phases. Depending upon the context, the phases may relate to the states of matter (gas, liquid, solid) or to miscibility (e.g, water and oil).

The terms "hard," "hardness" and cognates thereof may be used in at least two different ways herein. The context will distinguish between the two concepts.

However, in both cases, "hardness" is a term of art. In one context, the term refers to a property of a plurality of particles packed together so tightly as to create a body having at least some properties of a solid (resistance to changes of shape or volume). In the other context, the term derives from its use in food science and related fields as a reference to oils that are not liquid at room temperature, i.e., "hard" oils. Indeed, the physical properties of "hard oils" are consistent with the existence of a crystalline structure as is typical of solids generally. Although the applicants do not intend to be bound by any theory that seeks to explain how embodiments of the present invention work, it is widely accepted in the art that stabilizing oils (i.e., "hard" oils) added to solid-in-oil suspensions work because they "crystallize" in the suspension or, at least, form networks of fatty acid chains around the solid particles, trapping the particles in a deformable matrix. In the art (and herein), the term "texture" may refer to the "hardness" of an oil or a mixture comprising an oil. In some contexts, the term may relate to the viscosity or "thickness" of a fluid. This usage merges in other contexts with the concept of "mouth feel," another art-specific term.

DETAILED DESCRIPTION OF THE INVENTION

Almond Breeze^®, a non-dairy beverage derived from almonds, has received strong market acceptance since its introduction. The beverage may be made from a concentrate comprising, in addition to finely ground almonds and the almond oil expressed in the grinding process, soy lecithin, carrageenan gum and citrate. These additives facilitate the production and performance of the final product. Citrate, for example, contributes antioxidant properties to almond milk, and probably participates in the buffering of the product. The water added to the concentrate to make the milk product will tend to separate into oil and water phases. Emulsifiers, including but not limited to lecithins, tend to keep the oil dispersed in the added water. Carrageenan also has emulsifying properties and tends to "thicken" the almond milk product to improve its "mouth feel." However, different additives might be selected in other countries or by other packagers of the final product, depending on regulations, availability, market acceptance, intended use, mode of packaging, storage, and distribution of the product, etc. To facilitate these choices, a "base" product containing no additives (essentially, finely ground almonds in expressed oil) needs to be available. Such a preparation, however, does not lend itself to storage and transport.

The inventor has found that an effective base product can be produced from a paste prepared by finely grinding almonds and adding to it an appropriate stabilizing oil. By way of illustration, one may select one or more varieties of nuts depending upon the features desired for the final beverage product. Raw material may be provided at any stage of processing (from the harvested fruit or "drupe") and processed until a nut suitable for grinding is obtained. For products similar to Almond Breeze^®, almonds would be selected. The selected nuts may be dry-roasted or oil-roasted until they contain, preferably, less than 4% moisture. The method of moisture-reduction is not intended to be limiting. Alternative methods may include vacuum dehydration, sun-drying and freeze-drying, for example.

Preferably, the almonds are blanched to prepare the fibrous "skin" for removal from the nut. One may simply "squeeze" the blanched nut from its skin.

Commercially, the process may employ a hot water/steam scalder to loosen the brown skin of the almond, after which the almond is passed through a series of rollers that "pinch" or squeeze the almond, removing the loose skin. The almonds are then subjected to dewatering (draining) and drying.

A suitable method of dry-roasting blanched nuts comprises providing an oven such as a gas-fired Proctor™ Oven, distributing the blanched nuts in a layer, typically 2 to 4 inches thick, and maintaining an oven temperature of about 265-285°F. for about 30-50 min.

Grinding maybe performed in two steps. First, the (preferably) moisture- reduced nuts may be ground (or "milled") in a Bauer-type grinding mill such as a peanut butter mill with adjustable grinding plate gap at a feed-rate of about 1000-5000 lb/hr. The product of the Bauer-type milling process may next be fed to an Urschel Comitrol™ Model #1500 for the final grinding step. The fineness of the grind at this step depends upon the blades chosen. If smaller particles are preferable in the preparation of final products, finer-cutting blades maybe selected, consistent with allowable production times. For particles comprising submicron diameters, a high- pressure "medialess" mill or homogenizer may be used in addition to or as an alternative to a "rotor-stator" type mill such as the Urschel Comitrol™ mill.

In a non-limiting example, nut particles prepared in a Bauer-type mill may be fed into the Urschel Comitrol™ comminutor at a rate of about 3000 lb/hr when the comminutor is equipped with Urschel Comitrol¹" blade #206. It may be convenient to introduce the stabilizer into the Bauer-type mill in the form of beads or flakes along with the whole nuts in the grinding process, especially if the stabilizer is a solid at room temperature. In this case, the almonds-stabilizer blend is ground to a minimum temperature of ~140 - 160°F. (to the point where the blend becomes fluid and can be pumped to the Urschel Mill). The heat of grinding ensures that the stabilizer will melt during the grinding process, thus yielding a homogeneous, deformable mixture. Alternatively, stabilizer may be mixed into a cooled nut grind, and the mixture heated in a stirred kettle until a temperature in excess of the stabilizer melt point is obtained, resulting in a homogeneous, deformable mixture.

As noted above, a range of particle sizes is within the control of the operator, and it is not intended that embodiments of the invention be limited to any particular particle size or distribution of particle sizes. A suitable base can be prepared as outlined herein with statistically spherical, solid particles having a median diameter (determined by Mie light-scattering) of about 8 μπι (standard deviation about 9 μηι). Several suitable means of making size determinations are known in the art, and may be obtained from contractors such as Medallion Labs, 9000 Plymouth Avenue North, Minneapolis, MN 55427, a division of General Mills, Inc.

The temperature to be reached in melting the stabilizer is not critical as long as its heat effectively melts the added stabilizer if the stabilizer is "hard" at room temperature. It may be preferable, however, to avoid temperatures that could denature proteins. A maximum temperature of about 190°F. is preferred.

Cooling the mixture after the melted stabilizer is mixed in does require particular attention. The artisan is advised to cool the mixture under refrigeration to a temperature below the melting point of the stabilizer, preferably about 120°F. but lower than about 75°F. for coconut oil, for example, and then maintain the mixture at that temperature long enough to effect a crystallization of the stabilizer, that is, to "set" the mixture. It will be understood that the exact temperature to be reached at this step depends on several variables, including but not limited to the nut selected (and therefore the species of nut oil that is present) and the stabilizer selected (and therefore the temperature that optimally promotes the assembly of stabilizer molecules into networks or "crystals"). The time required to effect crystallization of the stabilizer varies based on stabilizer concentration and hot fill temperature. Typically, an initial set takes place within 10 to 30 minutes of filling. Crystallization may continue on a micro level for days after the initial set.

Whatever the optimal setting temperature, it is advisable to reach it quickly and uniformly throughout the batch of nut base. To reduce the temperature of large batches of the notably heat-retaining nut base, one may advantageously employ a scraped surface heat exchanger such as a Votator™. The device deposits the hot mixture on a refrigerated metal surface that withdraws enough heat from the deposited layer to "harden" or "set" it. The device simultaneously scrapes set material off of the refrigerated surface and takes in more of the hot mixture. The effect of the process is to create a product that behaves as a homogeneous solid or semi-solid and does not separate into distinct oil and solid phases over time. If sufficient shear stress is applied to the set product, however, it becomes deformable, i.e., more liquid-like. This behavior is advantageous in final processing, which typically involves resuspending the nut base in a diluted condition.

Optionally, substances may be added to the stabilized nut base to address a variety of purposes and concerns, including but not limited to preservation, health and nutrition, and further processing of the base to aid in the production of end-products such as nut-based milk, other beverages, bakery products, pastries, candies, and other confections. Additives recited herein by way of example and not of limitation include potassium or sodium citrate, and soy lecithin, preferably non-hydroxylated.

In one embodiment, said stabilizer comprises an oil having a melting point less than about 160°F. and more than about 130°F., preferably less than about 150°F. and more than about 140°F. and, most preferably, less than about 145°F. and more than about 135°F.

In general, stabilizing oils having a high melting point are preferable to oils having lower melting points. To that extent, therefore, saturated oils are preferable to unsaturated oils, and maximizing the degree of saturation by hydrogenation is also preferred. However, persons having ordinary skill in the art will recognize that lower melt point stabilizers may be chosen if relatively high concentrations of stabilizer are used. Regardless of melt point considerations, relatively high concentrations of stabilizer may also be preferred if a nut base having a relatively high oil-to-solids ratio is an advantage, perhaps to enhance the "creaminess" of the final product, for example. Persons of skill in the art will also recognize that the selection of type and amount of stabilizer has fewer constraints in a product that will be diluted or otherwise modified to create final products.

It is not intended that the melting point, fatty acid chain length, the extent or nature (cis- or trans-) of saturation or the concentration of the stabilizing oil(s) in the various embodiments of the invention be limiting. Suitable stabilizing oils and their concentrations are determined empirically by a simple test: The finished base exhibits substantially no oil-solid phase separation over periods consistent with international surface transportation. One may readily detect the earliest stage of oil separation by determining when the surface of the mixture first develops an "oily sheen." At this stage, a film of oil only a few molecules thick will have formed. The thickness of the oil layer at any time approximates the thickness of the sedimentary layer. The inventor has had under observation for approximately six weeks (as of the date of filing of this application) samples prepared as provided herein and stored at room temperature. No sheen has appeared and no bulk layer of oil has formed. It follows that no sediment has accumulated and, certainly, no "packing" of solid particles has occurred. The presence of an "oily sheen," if present, may readily be detected by eye. Its thickness (>2μηι, up to 500 μηι) may be determined with precision by means of reflectance measurements made, for example, with a Filmetrics, Inc. Model #F20 spectral reflectometer.

EXPERIMENTAL

These examples present representative protocols used in describing the invention disclosed herein. These protocols are not to be considered limiting as any analogous or comparable protocol measuring the same end-points within the skill of an ordinary artisan would also be sufficient.

Various amounts of oil stabilizers (Table 1) were added to pure almond base.

Five different oil stabilizers were evaluated at 1.5%, 3.0%, and 4.5% by weight in almond base. Samples of almond base with stabilizer were prepared by adding the stabilizer to almond base, heating to ~160°F to melt the stabilizer, mixing until homogeneous, cooling over ice to 120°F, and then filling into 26 fl oz clear PET jars.

The filled jars were then allowed to cool at room temperature undisturbed overnight.

Filled jars were subsequently stored at room temperature (75°F), at refrigerated temperature (40°F), and oven temperature (104°F). Periodically the jars of stabilized almond base were tested for hardness using a Brookfield Texture Analyzer model CT3 1000. The analyzer was equipped with a conical probe (TA15/1000) and the force in grams required to penetrate the almond base to a depth of 15.0 mm was recorded. Higher values of force indicate a harder or firmer texture of almond base, which is preferred within the time- frame of these experiments, during which settling of solids into a hard-packed sediment does not occur. At the end of four weeks of storage the mm depth of separated oil in each jar was measured.

TABLE 1 - OIL STABILIZERS

TRADE NAME COMPOSITION MELT POINT oF

Revel A Fractionated Palm Oil Stearine >_140°F

Dritex C Hydrogenated Cottonseed Oil >_1 8°F

Hydrogenated Rapeseed, Cottonseed,

Sta-Set RCSTM and Soybean Oil 140-148

Hydrogenated Rapeseed and

Sta-Set RCTM Cottonseed Oil 142-151 °F

27 STEARINETM Hydrogenated Palm Oil 136- 44° F

Test Results

TABLE 7

3.0% OIL STABILIZER

COLD TEMPERATURE STORAGE

HARDNESS PENETRATION FORCE IN GRAMS

STA-SET STA-SET 27

DAY REVEL A DRITEX C RCS RC STEARINE

0 9.7 4.3 274.5 203.2 166.3

7 9.5 10.4 253.2 201.8 79.4

14 - - - - -

28 10.5 9.2 245.5 21 1.1 186.0

TABLE 10

4.5% OIL STABILIZER

COLD TEMPERATURE STORAGE

HARDNESS PENETRATION FORCE IN GRAMS

STA-SET STA-SET 27

DAY REVEL A DRITEX C RCS RC STEARIN E

0 31.5 195.4 512.4 496.8 333.7

7 21.6 181.2 449.9 450.2 328.1

14 - - - - -

28 21.0 169.8 463.8 426.5 342.8

Discussion and Conclusions

Revel A at all concentrations showed the least amount of oil stabilization with the least amount of hardness compared to all other oil stabilizers. Oil separation was noted at all concentrations and storage conditions with the exception of 4.5% in cold temperature storage. Oil separation increased with storage temperature. Revel A was judged to be a poor oil stabilizer in this application. It is noted, however, that where concentrations higher than 4.5% are acceptable, stabilization with Revel A may be acceptable.

Dritex C showed inconsistent oil stabilization and hardness with oil separation evident at 1.5 and 3.0% use levels. Dritex appears to be only effective at the higher 4.5% concentration.

Sta-Set RCS™ showed increasing hardness with usage rate and no oil separation at all concentrations and storage temperatures.

Sta-Set RC™ showed increasing hardness with usage rate and no oil separation at all concentrations and storage temperatures. Performance was very similar to the Sta-Set RCS .

27 Stearine™ showed increasing hardness with usage rate with no oil separation at the 3.0 and 4.5% rates under all storage conditions.

Refrigeration of almond base retards oil separation.

The use of an oil stabilizer changes the texture of almond base from a pourable paste to a soft semisolid non-pourable paste.

Lower hardness levels of almond base are more desirable as being easier to work with in production as long as oil stabilization is achieved.

Claims

CLAIMS I claim:

1. A method of making an oil stabilized nut paste, the method comprising the steps of:

c) cooling said mixture to a temperature between 90° and 125°F so as to make an oil stabilized nut paste, wherein the concentration of said stabilizer in said oil stabilized nut paste is between 1 and 3%, wherein said stabilized nut paste can be stored for at least four weeks without displaying oil separation.

2. The method of Claim 1 , wherein the heat from said grinding raises the temperature of said oil stabilizer above 160°F.

3. The method of Claim 1, further comprising the step of d) storing said oil stabilized nut paste for at least seven days, during which time no oil separation is evident in said oil stabilized nut paste.

4. The method of Claim 1 , wherein said oil stabilizer comprises at least one vegetable oil.

5. The method of Claim 1, wherein said oil stabilizer comprises a mixture of two different vegetable oils.

6. The method of Claim 5, wherein said two vegetable oils are cotton seed oil and rape seed oil.

7. The method of Claim 1, wherein the concentration of said oil stabilizer in said oil stabilized nut paste is 1.5%.

8. The method of Claim 1 , wherein said grinding is performed in a mill.

9. The method of Claim 1, wherein said plurality of nuts are almonds.

10. The method of Claim 8, wherein the oil stabilizer and the nuts are fed into the mill.

11. The method of Claim 10, wherein the nuts are fed into the mill on a separate feed.

12. The method of Claim 1, wherein said oil stabilizer is in the form of a flake or bead.

13. The method of Claim 1, wherein said cooling is to a temperature between 100° and 120°F.

14. The method of Claim 1, wherein said oil stabilized nut paste after said cooling is poured into a plurality of containers.

15. The oil stabilized nut paste produced according to Claim 1.

16. A method of making an oil stabilized nut paste from ground nuts, the method comprising the steps of:

b) heating said oil stabilizer above said melting point;

17. The method of Claim 16, further comprising the step of e) storing said oil stabilized nut paste for at least seven days, during which time no oil separation is evident in said oil stabilized nut paste.

18. The method of Claim 16, wherein said oil stabilizer comprises at least one vegetable oil.

19. The method of Claim 16, wherein said oil stabilizer comprises a mixture of two different vegetable oils.

20. The method of Claim 19, wherein said two vegetable oils are cotton seed oil and rape seed oil.

21. The method of Claim 16, wherein the concentration of oil stabilizer after said combining is 1.5%.

22. The method of Claim 16, wherein said ground nuts are ground almonds.

23. The method of Claim 16, wherein said mixture of solid particles in oil without said stabilizer exhibits oil separation after 1-7 days.

24. The oil stabilized nut paste produced according to Claim 16.

25. An oil stabilized nut paste comprising a combination of i) an oil stabilizer, said stabilizer comprising fatty acids and having a melting point between 130° and 160°F, and ii) a mixture of solid particles in oil, said mixture produced from grinding nuts under conditions that release oil from said nuts, wherein the concentration of said oil stabilizer in said combination is between 1 and 3%, and wherein said oil stabilized nut paste can be stored for at least four weeks without displaying oil separation.

26. The oil stabilized nut paste of Claim 25, wherein said stabilizer comprises at least one vegetable oil.

27. The oil stabilized nut paste of Claim 25, wherein said stabilizer comprises a mixture of two different vegetable oils.

28. The oil stabilized nut paste of Claim 27, wherein said two vegetable oils are cotton seed oil and rape seed oil.

29. The oil stabilized nut paste of Claim 25, wherein the concentration of stabilizer is 1.5%.

30. The oil stabilized nut paste of Claim 25, wherein said nuts are almonds.

31. The oil stabilized nut paste of Claim 25, wherein the size of the majority of particles is between approximately 1 and 100 microns.

32. The oil stabilized nut paste of Claim 31 , wherein the size of the majority of particles is between approximately 5 and 50 microns.