Functional cheese sauce

Abstract

The invention provides a functional cheese sauce. The functional cheese sauce may be combined with various stuffing ingredients to form a self-supporting stuffing composition, which may be pressed or shaped such that it is self-supporting at a refrigerated or frozen temperature. The stuffing composition maintains its shape and is suitable for use in automated high throughput processing of food products such as roll-like food or Mexican rolls. Upon heating the stuffing composition, the self-supporting properties of the functional cheese sauce may disappear, such that the stuffing composition breaks down into a food product having desired organoleptic properties. Compositions of the functional cheese sauce, stuffing compositions, rolled food products, and methods of making are described.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 489,608, filed on March 10, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure relates to a functional cheese sauce and methods for incorporating the same into food products. More specifically, the present disclosure relates to a functional cheese sauce that can be used to make filling compositions and food products, such as wraps, burritos, rolls, and the like, and methods for making such food products. Background Art

[0004] Food products such as wrap-up food, burritos and roll-up food generally include a soft, flexible flour tortilla that is wrapped or wound around a filling composition. The existing method for preparing a wrap-up food product comprises manually distributing and placing various filling ingredients (such as one or more of meat, beans, vegetables, eggs, sausages, cooked rice, spices and cheese) and various condiments on the flour tortilla. The solid or semi-solid components of the filling are generally provided in small pieces, such as broken pieces, diced, sliced, bulky, diced, cereals, particles, shavings, cut into sections, peeled, ground meat, beans etc. The local flavor, shape, texture, outward appearance, smell and / or other qualities of the filling ingredients are very important, and contribute to the consumer's experience of the wrap-up food product. This existing method for providing the filling composition used in the wrap-up food product may be relatively slow and / or labor-intensive, and may not be convenient for automation.

[0005] When producing filling compositions for use in high-throughput automated processing for wrapping food products and for storage at refrigerated or frozen temperatures, various limitations exist using current techniques for bonding the ingredients together at refrigerated or frozen temperatures. Current techniques for bonding the ingredients during high-throughput processing and under refrigerated conditions can negatively impact lubricity during processing steps and can negatively impact the organoleptic properties of the product when consumed. Therefore, there is a need to provide a method for overcoming the limitations of existing methods and compositions. Summary of the Invention

[0006] The present disclosure relates to a functional cheese sauce, a filling composition containing the functional cheese sauce, and a food product made with the filling composition. The present disclosure also provides methods for preparing the functional cheese sauce, the filling composition, and the food product.

[0007] The functional cheese sauce compositions herein can be used to make food products such as wraps, burritos, rolled foods, and the like, all of which may be referred to herein as "wraps," "food products," or "wrap-up food products." The food products can include a soft, pliable dough wrapped or rolled around a filling composition. The filling composition can include various filling ingredients that are refrigerated or frozen prior to being heated and / or consumed.

[0008] A functional cheese sauce has been discovered that effectively mixes with refrigerated or frozen filling ingredients and acts as a binding agent to form a filling composition with the filling ingredients. The functional cheese sauce can impart self-supporting properties (e.g., bonding properties and / or shape-retaining properties) to the filling composition at refrigerated or frozen temperatures. The functional cheese sauce can also impart self-supporting properties to the filling composition during distribution or during high-throughput processing techniques, thereby producing portions of uniform size and shape that remain bonded together during processing at refrigerated or frozen temperatures. The functional cheese sauce can also provide lubricity to the filling composition at refrigerated or frozen temperatures, making them easier to handle and / or preventing them from clogging assembly line machinery during processing.

[0009] Although the functional cheese sauce composition herein imparts self-supporting properties to the filling composition at refrigerated or frozen temperatures, the functional cheese advantageously loses its ability to impart self-supporting properties to the filling composition upon heating, as the functional cheese sauce melts into the food product. For example, the filling ingredients mixed with the functional cheese sauce composition herein can be placed on the surface of a flatbread and then heated, whereby the filling composition can collapse or change shape. The resulting heated food product can have a filling composition with pleasant organoleptic properties that is not affected by the presence of the functional cheese sauce.

[0010] The filling composition herein may comprise a functional cheese sauce and one or more filling ingredients. The functional cheese sauce may be sufficiently fluid that, when combined with refrigerated or frozen filling ingredients, it may be easily mixed therewith to form a filling composition.

[0011] The present disclosure also provides a filling composition having self-supporting properties and containing functional cheese sauce and filling ingredients in a pre-made mixed portion, which filling composition can be frozen, stored and transported at refrigerated or frozen temperatures, and can also provide consumers with a sensory pleasing food product when heated.

[0012] Thus, the present disclosure provides a functional cheese sauce that, when combined to form a filling composition, can impart self-supporting properties, including cohesive properties and shape-retaining properties, to one or more filling ingredients. The functional cheese sauce composition herein can also be used to form a filling composition that is used as a component of a food product. The functional cheese sauce is further configured to lose its ability to impart self-supporting properties to the filling composition, such that the cohesive properties and shape-retaining properties are also lost when heated to a food-safe temperature above 145°F (about 63°C).

[0013] In one aspect, a method of preparing a food product is provided, wherein the method comprises: a) providing a functional cheese sauce, wherein the functional cheese sauce is flowable; b) providing a filling ingredient, wherein at least 50% of the filling ingredient has a longest dimension of 0.3 cm to 4.0 cm; c) mixing the functional cheese sauce with the filling ingredient to provide a filling composition, wherein the filling ingredient is at a temperature of about 20°F to about 34°F when mixed; and d) forming the filling composition into a predetermined shape to provide a shaped filling composition that is self-supporting at a refrigerated temperature of 40°F for at least two minutes, and wherein the shaped filling composition is not self-supporting at an internal temperature of at least 145°F.

[0014] In another aspect, a filling composition is provided, comprising a functional cheese sauce, wherein the functional cheese sauce is flowable at a temperature of 32°F to 40°F; and one or more filling ingredients mixed with the functional cheese sauce, wherein at least 50% of the filling ingredients have a longest dimension of 0.3 cm to 4 cm; and wherein the filling composition is self-supporting for at least two minutes at a refrigerated temperature of 40°F, and wherein the shaped filling composition is not self-supporting at an internal temperature of at least 145°F.

[0015] In another aspect, a food product is provided, comprising a dough; and a filling composition comprising a functional cheese sauce and one or more filling ingredients, wherein at least 50% of the one or more filling ingredients have a longest dimension of 0.3 cm to 4 cm; and wherein the filling composition is self-supporting at a refrigerated temperature of 40°F for at least two minutes, and wherein the shaped filling composition is not self-supporting at an internal temperature at a food-safe temperature of at least 145°F.

[0016] In another aspect, a method of making a heated food product is provided, comprising the steps of: a.) providing a filling composition; b.) placing the filling composition on a surface of a tortilla, wherein the tortilla may comprise a corn tortilla; c.) rolling the filling composition within the tortilla to provide a rolled food product; and d.) heating the rolled food product.

[0017] This summary is an overview of the present disclosure and is not meant to be exhaustive or exclusive of the description of this subject matter. Additional details are found in the detailed description and the appended claims herein. Other aspects of the present disclosure will be apparent to those skilled in the art after reading this disclosure and the subsequent claims. DETAILED DESCRIPTION

[0018] Reference will now be made in detail to certain aspects of the disclosed subject matter.While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the illustrated subject matter is not intended to limit the claims to the disclosed subject matter.

[0019] Use the edible binder additive that gives product bonding property to produce food product and may propose many challenges.Various edible food binders can comprise for example various types of starch and / or protein, modified carbohydrates such as cellulose, egg white etc.Produce the food product with the bonding property that can be used for the automated assembly line of high throughput and may further propose many challenges.In some cases, in the food product with high throughput speed processing, use food binders and may not provide bonding property for food product, make food product may spread out and may cause the loss of food product or the distribution of ingredients inconsistent.In some cases, use the filling composition of food binder to produce friction along the high throughput assembly line machinery, thereby when attempting to distribute this type of composition, cause additional problem, and can make production stop.In addition, although the combination of filling composition and this type of edible food binder can provide supporting property, when heating, many can not debond but keep rigid shape.

[0020] Using edible binder additives that impart bonding properties to food products to produce food products may further challenge the organoleptic properties of food products. Under inappropriate ratios, these binders can adversely affect the organoleptic properties of food products when edible. For example, some filling compositions can be made using binder additives that may have an undesirable sticky mouthfeel, and may otherwise impart undesirable bitterness or astringency or granular texture to the filling compositions. It has been found herein that functional cheese sauce compositions can serve as the binder of filling ingredients or filling compositions to provide self-supporting properties for filling compositions at refrigerated and frozen temperatures. Filling ingredients or filling compositions can also lose self-supporting properties when heated, so that the filling compositions no longer adhere together and no longer maintain a consistent shape. It has further been found that functional cheese sauce compositions herein can provide lubricity for food products or compositions, and they can not provide undesirable organoleptic properties for food products when heated. It has further been found that the functional cheese spreads herein do not detract from desirable organoleptic properties such as color, taste, aroma, and texture (e.g., no aroma taint, no change in color, no change in creamy flavor and mouthfeel, and no change in cheesy taste and texture).

[0021] definition

[0022] As used herein, the term "refrigeration temperature" refers to temperatures greater than 32°F and up to 40°F (ie, greater than 0°C and up to 4.5°C). It should be understood that the term "refrigerated" as used herein also refers to those items that are subjected to refrigeration temperatures.

[0023] As used herein, the term "freezing temperatures" refers to temperatures equal to or less than 32°F (ie, less than 0°C). It should be understood that the term "frozen," as used herein, also refers to those items that are subjected to freezing temperatures.

[0024] In the present disclosure, the functional cheese sauce composition can be described as being flowable. As used herein, the term "flowable" can be used to describe a functional cheese sauce that is capable of flowing from a starting point to an end point under its own weight at a given temperature for a given period of time, as measured by a Bostwick consistometer (described below).

[0025] As used herein, the term "self-supporting" refers to the properties that the functional cheese sauce can impart to the filling composition at refrigerated or frozen temperatures, including bonding properties and / or shape-retaining properties. The bonding properties and shape-retaining properties can be manifested by various physical properties, such as cohesion and adhesion contributed by the functional cheese sauce. The functional cheese sauce is configured to impart self-supporting properties to the filling composition so that once dispensed, it is able to prevent any collapse or other shape change of the filling composition, such that the height, width, and length of the filling composition do not change by more than 5% relative to the starting shape at refrigerated temperature.

[0026] As used herein, the term "processed cheese" refers to a food product prepared with the aid of heat and one or more types of cheese or two or more types of cheese, as further defined in 21 CFR §133.169 and as amended January 6, 1993.

[0027] As used herein, the term "cheddar cheese" refers to cheese made from one or more dairy ingredients, and as further defined in 21 CFR §133.113, as amended on January 6, 1993. Cheddar cheese may also include ingredients that comply with the requirements of 21 CFR §133.113, such as coloring agents, calcium chloride, enzymes, etc.

[0028] As used herein, the term "food product" may refer to a food item that includes a soft, pliable dough wrapped or rolled around a filling composition, such as a wrap, burrito, rolled food, etc. The term food product as used herein may include the singular or plural terms "wrap" or "wrap food products," with the understanding that these terms are used interchangeably herein.

[0029] As used herein, the term "tortilla" may refer to ingredients including, but not limited to, tortillas made from flours such as wheat, corn, or sorghum; pita bread; naan; chapati; injera; Moroccan flatbread; etc. Soft and / or pliable tortillas are preferred because they may be more suitable for use in wrapped food products.

[0030] As used herein, the term "wrap" refers to a food product made by rolling, wrapping, or otherwise folding a dough around a filling composition. An example of a wrap is a burrito. Unless otherwise indicated, the term "wrap" is used interchangeably herein with the term "food product" or "wrapped food product."

[0031] Functional cheese sauce

[0032] The functional cheese sauce as described herein can be combined and / or mixed with filling ingredients to provide a filling composition as described elsewhere. The filling composition can be placed on a dough and rolled and / or wrapped within the dough to provide a food product.

[0033] The functional cheese sauce can be made from one or more ingredients, including but not limited to water; processed cheese; cheddar cheese; salted or unsalted butter; milk or milk products, such as skim milk powder, whey, curd, milk fat, etc.; sodium chloride; one or more gums, such as xanthan gum, carrageenan, etc.; one or more alginates, including sodium alginate, potassium alginate, calcium alginate, etc.; one or more starches isolated from waxy corn, cassava, potato or rice; one or more phosphates, such as sodium phosphate, potassium phosphate or calcium phosphate; one or more additional seasonings, flavors or coloring agents, including annatto, apocarotene and paprika.

[0034] The water present in the functional cheese sauce herein can include the amount of the added water of 30 wt % to 70 wt % (wt.%). In various aspects, the functional cheese sauce herein can include the water of the addition of 30 wt % to 70 wt % or 40 wt % to 60 wt % or 45 wt % to 50 wt %. It should be understood that the water of the addition present in the functional cheese sauce herein can include 30 wt %, 35 wt %, 40 wt %, 45 wt %, 50 wt %, 55 wt %, 60 wt %, 65 wt % or 70 wt %, or the amount within any aforementioned weight percentage range. It should be understood that water is added to the functional cheese sauce to allow the sauce to flow at refrigerated or frozen temperatures, wherein the functional cheese sauce and filling ingredients are mixed together. It has been found herein that the insufficient amount of water in the functional cheese sauce can cause the sauce to be unable to flow, and causes the filling composition to be unable to maintain shape, and shows unfavorable rupture in the filling ingredient particles.

[0035] The processed American cheese present in the functional cheese sauce herein can include the amount of the processed American cheese of 10 % by weight to 25 % by weight (wt.%). In various aspects, the functional cheese sauce herein can include the processed American cheese of the amount of 10 % by weight to 25 % by weight, or 12 % by weight to 22 % by weight, or 16 % by weight to 21 % by weight. It should be understood that the processed American cheese present in the functional cheese sauce herein can include 10 % by weight, 11 % by weight, 12 % by weight, 13 % by weight, 14 % by weight, 15 % by weight, 16 % by weight, 17 % by weight, 18 % by weight, 19 % by weight, 20 % by weight, 21 % by weight, 22 % by weight, 23 % by weight, 24 % by weight or 25 % by weight, or the amount in any aforementioned weight percentage range. Processed cheese can include one or more of processed cheese, processed cheese food product or processed cheese spread, such as for example processed American cheese or processed American cheese spread, or any combination thereof. Processed cheeses suitable for use herein are further defined by 21 CFR §133.169.

[0036] For example, the processed cheese suitable for this paper can include fermented milk, skim milk, cream, cheddar cheese, cheese culture solution, lemon juice concentrate, sodium phosphate, salt enzyme and one or more coloring agents. Without wishing to be bound by any particular theory, it is believed that the processed cheese with higher protein content and higher fat content is excellent for producing emulsion in functional cheese sauce, which is understood to provide cohesiveness and lubricity to the functional cheese sauce. Having higher protein and higher fat content can be suitable for providing self-supporting properties for the filling composition when forming and when undergoing high throughput processing. Higher protein content can include a protein content of 15 weight % to 25 weight %, or more specifically 19 weight % to 22 weight % processed cheese. Higher fat content can include a fat content of 25 weight % to 35 weight %, or more specifically 28 weight % to 33 weight % processed cheese.

[0037] Exemplary processed cheeses may include Yellow American cheese (Bongards Creameries, Chanhassen, MN, USA), Land Processed American cheese (Land Inc., Arden Hills, MN, USA) or Ornua Pasteurized Blended Aged White American Cheese (Ornua Ingredients North American, Hilbert, WI, USA) or any processed cheese having similar properties thereto.

[0038] The cheddar cheese present in the functional cheese sauce herein can include the amount of the cheddar cheese of 10 % by weight to 20 % by weight (wt.%). In various aspects, the functional cheese sauce herein can include the cheddar cheese of the amount of 10 % by weight to 20 % by weight, or 12 % by weight to 18 % by weight, or 14 % by weight to 17 % by weight. It should be understood that the cheddar cheese present in the functional cheese sauce herein can include 10 % by weight, 11 % by weight, 12 % by weight, 13 % by weight, 14 % by weight, 15 % by weight, 16 % by weight, 17 % by weight, 18 % by weight, 19 % by weight or 20 % by weight, or the amount in any aforementioned weight percentage range. Cheddar cheese can include one or more of white cheddar cheese, super intense cheddar cheese, intense cheddar cheese, mild cheddar cheese, medium cheddar cheese, mature cheddar cheese, aged cheddar cheese etc., or any combination thereof. Cheddar cheese can be made from sterilized and / or pasteurized milk and one or more enzymes. Cheddar cheese suitable for use herein is further defined by 21 CFR § 133.113. In various aspects, processed cheese and cheddar cheese suitable for use herein may also contain one or more flavoring agents, spices, or coloring agents.

[0039] It should be understood that while the exemplary functional cheese sauces described herein incorporate cheddar cheese in their formulations, other cheeses having similar water content, hardness, mouthfeel, and other properties of cheddar cheese may also be used to produce functional cheese sauces similar to those described herein. Cheeses similar to cheddar cheese may include one or more varieties of Gouda cheese, Muenster cheese, Colby cheese, Swiss cheese, brick cheese, Monterey Jack cheese, Edam cheese, Gloucester cheese, Gruyere cheese, or combinations thereof.

[0040] The ratio of processed cheese to cheddar cheese also helps provide cohesion and lubricity to the functional cheese sauce. The ratios are discussed in more detail below.

[0041] The butter present in the functional cheese sauce of this paper can comprise the amount of the butter of 5 % by weight to 12 % by weight (wt.%). In various fields, the functional cheese sauce of this paper can comprise the butter of the amount of 5 % by weight to 12 % by weight, or 7 % by weight to 11 % by weight, or 8 % by weight to 10 % by weight. It should be understood that the butter present in the functional cheese sauce of this paper can comprise 5 % by weight, 6 % by weight, 7 % by weight, 8 % by weight, 9 % by weight, 10 % by weight, 11 % by weight or 12 % by weight, or the amount in any aforementioned weight percentage range. The butter can comprise salted butter or unsalted butter, or any combination thereof.

[0042] The milk product present in the functional cheese sauce herein can include the amount of the milk product of 1 wt % to 8 wt % (wt.%). In various aspects, the functional cheese sauce herein can include the milk product of 1 wt % to 8 wt %, or 2 wt % to 7 wt %, or 3 wt % to 6 wt %. It should be understood that the milk product present in the functional cheese sauce herein can include 1 wt %, 2 wt %, 3 wt %, 4 wt %, 5 wt %, 6 wt %, 7 wt % or 8 wt %, or the amount within any aforementioned weight percentage range. The milk product can include one or more of milk, skim milk powder, whey, curd or butterfat, or any combination thereof.

[0043] The starch present in the functional cheese sauce herein can include the amount of 0.5 wt % to 6 wt % (wt.%) starch. In various aspects, the functional cheese sauce herein can include the starch in an amount of 0.5 wt % to 6 wt %, or 1 wt % to 5 wt %, or 1.5 wt % to 3.5 wt %. It should be understood that the starch present in the functional cheese sauce herein can include 0.5 wt %, 0.6 wt %, 0.7 wt %, 0.8 wt %, 0.9 wt %, 1 wt %, 1.5 wt %, 2 wt %, 2.5 wt %, 3 wt %, 3.5 wt %, 4 wt %, 5 wt % or 5 wt %, or an amount within any of the aforementioned weight percentage ranges. Starch can include one or more starches isolated from corn, waxy corn, potato, cassava or rice, and can include modified, functionalized or non-functionalized starch, or any combination thereof. Exemplary starch can include Cassava starch (Ingredion, Westchester, IL, USA); 2100 modified potato starch (Ingredion, Westchester, IL, USA) 47 modified potato starch (Ingredion, Westchester, IL, USA), NOVATION 600 waxy corn starch (Ingredion, Westchester, IL, USA), Modified waxy corn starch (Ingredion, Westchester, IL, USA), Modified waxy corn starch (Tate & Lyle, Hoffman Estates, IL, USA) or starch with similar properties.

[0044] The phosphate present in the functional cheese sauce of this paper can comprise the amount of the phosphate of 0.1 % by weight to 5 % by weight (wt.%).In various fields, the functional cheese sauce of this paper can comprise the phosphate of the amount of 0.1 % by weight to 5 % by weight or 0.3 % by weight to 3 % by weight or 0.5 % by weight to 1.5 % by weight.Should be understood that the phosphate present in the functional cheese sauce of this paper can comprise 0.1 % by weight, 0.2 % by weight, 0.3 % by weight, 0.4 % by weight, 0.5 % by weight, 0.6 % by weight, 0.7 % by weight, 0.8 % by weight, 0.9 % by weight, 1 % by weight, 1.5 % by weight, 2 % by weight, 2.5 % by weight, 3 % by weight, 4 % by weight or 5 % by weight, or the amount in any aforementioned weight percent range.Phosphate can comprise one or more phosphates such as sodium phosphate, potassium phosphate or calcium phosphate, or their any combination.

[0045] The gums present in the functional cheese sauce herein can include an amount of 0.01% to 3% by weight (wt.%) of gums. In various aspects, the functional cheese sauce herein can include gums in an amount of 0.01% to 3% by weight, or 0.03% to 1% by weight, or 0.05% to 0.5% by weight. It should be understood that the gums present in the functional cheese sauce herein may include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.5%, 2%, 2.5% or 3% by weight, or an amount within any range of the foregoing weight percentages. The gums may include carrageenan, xanthan gum, guar gum, gum arabic, agar, arrowroot gum, locust bean gum, collagen, carrageenan, sodium alginate, alginic acid, gum arabic, gum ghatti, gum tragacanth, beta-glucan, gum karaya, gum dammar, glucomannan, tara gum, gellan gum, or any combination thereof.

[0046] The alginate present in the functional cheese sauce herein can include the amount of 0.01 wt % to 3 wt % (wt.%) alginate. In various aspects, the functional cheese sauce herein can include the alginate in an amount of 0.01 wt % to 3 wt %, or 0.02 wt % to 1 wt %, or 0.05 wt % to 0.5 wt %. It should be understood that the alginate present in the functional cheese sauce herein can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.5%, 2%, 2.5% or 3% by weight, or an amount within any of the aforementioned weight percentage ranges. The alginate can include sodium alginate, potassium alginate, calcium alginate or any combination thereof.

[0047] The salt present in the functional cheese sauce of this paper can comprise the amount of the salt of 0.1 % by weight to 5 % by weight (wt.%). In various fields, the functional cheese sauce of this paper can comprise the salt of the amount of 0.1 % by weight to 5 % by weight or 0.2 % by weight to 3 % by weight or 0.3 % by weight to 1.5 % by weight. It should be understood that the salt present in the functional cheese sauce of this paper can comprise 0.1 % by weight, 0.2 % by weight, 0.3 % by weight, 0.4 % by weight, 0.5 % by weight, 0.6 % by weight, 0.7 % by weight, 0.8 % by weight, 0.9 % by weight, 1 % by weight, 1.5 % by weight, 2 % by weight, 2.5 % by weight, 3 % by weight, 4 % by weight or 5 % by weight, or the amount in any aforementioned weight percentage range. Salt can comprise sodium chloride.

[0048] In one aspect, a functional cheese sauce is provided, wherein the functional cheese sauce comprises 30 to 70 wt % of water, 10 to 25 wt % of processed American cheese, 10 to 20 wt % of white cheddar cheese, 5 to 12 wt % of salted butter, 1 to 8 wt % of skim milk powder, 0.5 to 6 wt % of starch from waxy corn, 0.1 to 5 wt % of sodium phosphate, 0.01 to 3 wt % of xanthan gum, 0.01 to 3 wt % of sodium alginate, and 0.1 to 5 wt % of sodium chloride.

[0049] In one aspect, a functional cheese sauce is provided, wherein the functional cheese sauce comprises 45 to 50 wt % water, 16 to 21 wt % processed American cheese, 14 to 17 wt % white cheddar cheese, 8 to 10 wt % salted butter, 3 to 6 wt % skim milk powder, 1.5 to 3.5 wt % starch from waxy corn, 0.5 to 1.5 wt % sodium phosphate, 0.05 to 0.5 wt % xanthan gum, 0.05 to 0.5 wt % sodium alginate, and 0.3 to 1.5 wt % sodium chloride. Exemplary functional cheese sauces are summarized in Table 1.

[0050] Table 1. Exemplary functional cheese sauce formulations

[0051]

[0052] The advantage of the functional cheese sauce of this paper is that phosphate, gum, starch and alginate can be used, and the organoleptic properties of filling composition and the food product made therefrom can not be negatively impacted. Providing this type of composition separately is not enough to be bonded to the filling composition of adhesion, for high throughput processing provides lubricity, and contributes to the organoleptic properties of the expectation in the food product. Therefore, without wishing to be bound by any particular theory, it is believed that phosphate, gum, starch and alginate can contribute to the self-supporting properties of functional cheese sauce. In various aspects, functional cheese sauce comprises one or more of the following items less than 3 % by weight: xanthan gum, sodium alginate, phosphate or starch. In various aspects, functional cheese sauce comprises one or more of the following items less than 5 % by weight: xanthan gum, sodium alginate, phosphate or starch.

[0053] It should be understood that any of the phosphates, gums, starches, and alginates are added to the filling compositions herein as part of a functional cheese spread, rather than as a single ingredient added directly to the filling composition.

[0054] In the present disclosure, the functional cheese sauce composition can be described as being able to flow. As described above, the term "able to flow" can be used to describe a functional cheese sauce that can flow from a starting point to an end point under its own weight at a given temperature for a given period of time, as measured by a Bostwick consistency meter. The Bostwick consistency meter can be used to determine the consistency of a sample, which can be reported as the distance traveled at a given temperature in a given amount of time. The consistency of the functional cheese sauce can be measured in the following manner: fill the gated reservoir portion of the Bostwick consistency meter with the functional cheese sauce, maintain the temperature of the consistency meter within a 2°F range, release the gate of the reservoir portion, and time how long it takes for the functional cheese sauce to travel a distance from a starting point to an end point in a given amount of time. The consistency can be measured at any temperature using the Bostwick consistency meter, as long as all measurements are performed at the same temperature for comparison purposes.

[0055] When measured using a Bostwick consistency meter, the functional cheese sauce herein is considered to be able to flow when it is able to traverse a distance of 5 cm to 12 cm or 5 cm to 10 cm from the starting point to the end point within 10 seconds at any temperature of about 155 ° F to about 165 ° F (e.g., about 68 ° C to 74 ° C). In various aspects, the functional cheese sauce herein can traverse a distance of 5 cm, 6 cm, 7 cm, 8 cm, 9 cm, 10 cm, 11 cm or 12 cm or any range of the foregoing within 10 seconds at a temperature of 155 ° F to about 165 ° F. In one aspect, the functional cheese sauce herein is considered to be able to flow when it is able to traverse a distance of 8 cm from the starting point to the end point within 10 seconds at a temperature of 160 ° F (e.g., about 71 ° C).

[0056] On the other hand, the functional cheese sauce is considered to be flowable at a temperature of 32°F to 40°F. For example, the functional cheese sauce can be flowable when it can traverse a distance of 1 cm to 5 cm from the starting point to the end point within 10 seconds at a temperature of 34°F to 36°F (about 1°C to about 2°C). In various aspects, the functional cheese sauce herein can traverse a distance of 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, or 6 cm, or any range thereof, from the starting point to the end point within 10 seconds at a temperature of 34°F to 36°F. For example, the functional cheese sauce can traverse a distance of about 0 cm to about 6 cm, or about 1 cm to about 6 cm, or about 1 cm to about 5 cm, or about 1 cm to about 4 cm, or about 2 cm to about 5 cm, or about 2 cm to about 7 cm from a start point to an end point in about 5 seconds to about 15 seconds, or about 7 seconds to about 13 seconds, or about 8 seconds to about 12 seconds, or about 10 seconds at a temperature of about 28°F to about 40°F (about -2°C to about 4.4°C), or about 30°F to about 38°F (about -1°C to about 3.3°C), or about 32°F to about 37°F (about 0°C to about 2.8°C), or about 34°F to about 36°F (about 1°C to about 2°C).

[0057] When measuring using a Bostwick consistometer, the temperature is maintained within 2°F of the desired temperature for the measurement. For example, when the desired temperature for the measurement is 160°F, the Bostwick consistometer is maintained at 159°F to about 161°F for 10 seconds. In another example, when the desired temperature for the measurement is 35°F, the Bostwick consistometer is maintained at 34°F to about 36°F for 10 seconds.

[0058] The functional cheese sauce can be flowable as defined herein at a temperature of about 26°F to about 41°F (about -3°C to about 5°C), or about 26°F to about 39°F (about -3°C to about 4°C), or about 26°F to about 37°F (about -3°C to about 3°C), or about 26°F to about 36°F (about -3°C to about 2°C), or about 27°F to about 35°F (about -3°C to about 1.7°C), or about 27°F to about 34°F (about -3°C to about 1.1°C), or about 28°F (about -2°C).

[0059] In one aspect, the functional cheese sauce disclosed herein can be fully fluid at refrigerated temperatures so that when mixed with a filling ingredient, the functional cheese sauce bonds the filling ingredients together to form a cohesive filling composition. Before mixing, the functional cheese sauce can be tempered to a temperature of about 35°F so that it can flow and can be fully blended with the filling ingredient. The filling ingredient can include one or more edible ingredients in the form of discrete blocks as described herein. In order to bond the filling ingredient, the functional cheese sauce can flow between and around any block and / or portion of the filling ingredient and act to bond the blocks and / or portions together to form a self-supporting filling composition. The filling ingredient can be mixed with the functional cheese sauce at refrigerated or frozen temperatures, so in preferred aspects, the functional cheese sauce fully flows at refrigerated or frozen temperatures and has enough viscosity or cohesiveness so that the functional cheese sauce is mixed with the filling ingredient and bonds them together to form a filling composition.

[0060] In one aspect, the functional cheese sauce comprises cheese and added water. In this context, the added water is water that binds to the total cheese, including cheddar cheese and processed cheese, and does not include water inherently present in the cheese. The weight ratio of the total cheese to the added water in the functional cheese sauce can be 1:3 to 1:1, or 1:2 to 1:1, or 1:1.5 to 1:1; or 0.5:1, or 1:1 to about 3:2, relative to the functional cheese sauce. The weight ratio of the total cheese to the added water in the functional cheese sauce can be 0.5:1, 1:1, 1:1.5, 1:2, 2:3, 3:4, or 3:2, relative to the functional cheese sauce. In various aspects, the weight ratio of the total cheese to the added water in the functional cheese sauce can be 1:1.40 to 1:1.20, relative to the functional cheese sauce. In one aspect, the weight ratio of the total cheese to the added water in the functional cheese sauce can be 1:1.35.

[0061] The ratio of processed cheese to cheddar cheese in the functional cheese sauce can affect the binding properties and lubricity of the functional cheese sauce. Therefore, the weight ratio of processed cheese to cheddar cheese in the functional cheese sauce can be 1:3 to 1:1, or 1:2 to 1:1, or 2:1 to 3:4, or 2:1 to 1:1, or 3:2 to 1:1, or 13:10 to 12:10. In one aspect, the weight ratio of processed cheese to cheddar cheese in the functional cheese sauce can be 1.22:1.

[0062] As described above, the functional cheese sauce described herein can be used to bind filling ingredients in the absence of additional binders within the filling composition. Another advantage of the functional cheese sauce is that when heated to serving temperatures (such as an internal temperature above 145°F), the binding properties of the functional cheese sauce decrease, and the filling composition can debond, collapse, and no longer remain bound together, and can contribute to an organoleptically pleasing filling composition for a food product.

[0063] In one aspect, the functional cheese sauce can provide lubricity to the filling composition and various surfaces of automated assembly line machinery at refrigerated or frozen temperatures, making the filling composition easier to handle and / or preventing it from spreading and clogging the assembly line machinery during processing. For example, on an assembly line, particularly an automated assembly line, this property is particularly advantageous because it can prevent undesirable obstructions in the transport of the filling composition within the assembly line.

[0064] The present disclosure provides a method for forming a functional cheese sauce of this article using various technologies for mixing and heating food ingredients. The functional cheese sauce can include the water, processed American cheese, white cheddar cheese, salted butter, skim milk powder, starch from waxy corn, sodium phosphate, xanthan gum, sodium alginate and sodium chloride added. The method can include mixing together each of the water, skim milk powder, starch from waxy corn, sodium phosphate, xanthan gum, sodium alginate and sodium chloride added by a determined amount to form a slurry to produce a slurry. The method can also include heating salted butter until melted, and then adding the slurry to the melted butter, while mixing and heating to about 110 ° F. The method can also include adding processed American cheese and white cheddar cheese to a butter slurry mixture, and mixing and heating cheese, butter and slurry ingredients to about 185 ° F.

[0065] Filling ingredients

[0066] Filling ingredients suitable for use in the filling compositions herein may include one or more edible ingredients in the form of discrete pieces. The discrete pieces may be in the form of food materials themselves (e.g., rice grains, seeds, nuts, etc.), or may be separated into discrete pieces by methods such as chopping, grinding, slicing, crushing, peeling, or any other method of reducing the size of the food materials. The food materials of the filling ingredients are not particularly limited. Filling ingredients may include ingredients such as: cooked meats (such as ham, pork, steak, beef, chicken, fish, sausage, bacon, etc., and combinations thereof); mushrooms; vegetables (such as asparagus, broccoli, beans, peppers, onions, potatoes, lettuce, cabbage, etc., and combinations thereof); cooked grains and / or legumes (such as quinoa, beans, chickpeas, lentils and pulses); seeds, such as sesame seeds; whole, split or chopped nuts, such as peanuts, cashews, Brazil nuts; cheese (such as blue cheese, cheddar cheese, Colby cheese, Gouda cheese, Gouda, Swiss cheese, etc.); fruit, such as tomatoes, grapes, apples, and any combinations thereof; and hard-boiled eggs, hard-boiled egg ingredients (such as hard-boiled egg yolks and / or hard-boiled egg whites), or any combination thereof.

[0067] As mentioned above, at least a portion of the filling ingredients can be in the form of blocks or particles. In one aspect, at least 30% by weight, or at least 40% by weight, or at least 50% by weight, or at least 60% by weight, or at least 70% by weight, or at least 80% by weight, or at least 90% by weight of the filling ingredient blocks or particles have a diameter of about 0.1 cm to about 10 cm, or about 0.1 cm to about 5 cm, or about 0.2 cm to about 5 cm, or about 0.3 cm to about 5 cm, or about 0.4 cm to about 5 cm, or about 0.01 cm to about 4 cm, or about 0.05 cm to about 5 cm, or about 0.4 cm to about 5 cm. The longest dimension is from about 0.1 cm to about 4 cm, or from about 0.2 cm to about 4 cm, or from about 0.3 cm to about 4 cm, or from about 0.1 cm to about 3 cm, or from about 0.1 cm to about 2 cm, or from about 0.2 cm to about 5 cm, or from about 0.2 cm to about 3 cm, or from about 0.2 cm to about 2 cm, or from about 0.3 cm to about 3 cm, or from about 0.2 cm to about 2.5 cm, or from about 0.2 cm to about 2 cm, or from about 1 cm to about 4 cm, or from about 1 cm to about 5 cm.

[0068] The filling ingredients are stored frozen prior to use, and when mixed with the functional cheese sauce, the filling ingredients are kept frozen at a temperature of 26°F to 30°F or 26°F to 28°F, inclusive, during mixing.

[0069] In one aspect, the filling ingredients can include ingredients that are not discrete pieces, such as salsa, salsa, guacamole, crema, sour cream, one or more types of vegetable oils such as olive oil, honey, vinegar, lemon juice, yeast, citric acid, fruit juices, and any combination thereof.

[0070] Filling composition

[0071] Functional cheese sauce and filling ingredients as described herein can be combined and / or mixed to provide a filling composition. The filling ingredients and functional cheese sauce can be mixed in any order to provide a filling composition. Mixing can be done manually, with a mixer, or a combination thereof. Functional cheese sauce and filling ingredients can be mixed together to produce a filling composition at a refrigerated temperature or a frozen temperature. Functional cheese sauce can maintain the bonding between the filling ingredients in the filling composition at a refrigerated temperature or a frozen temperature. In one aspect, the functional cheese sauce can maintain the bonding between the filling ingredients in the filling composition at a frozen temperature, a refrigerated temperature, or both a refrigerated temperature and a frozen temperature. It should be understood that the refrigerated temperature as defined herein includes those temperatures greater than 32°F and at most 40°F (i.e., greater than 0°C and at most 4.5°C). It should be understood that the frozen temperature as defined herein includes those temperatures equal to or less than 32°F (i.e., less than 0°C).

[0072] In one aspect, the functional cheese sauce and the filling ingredients are mixed together at a temperature of 27°F to 30°F. In one aspect, the functional cheese sauce and the filling ingredients are mixed together at a temperature of 27°F to 30°F, wherein the filling ingredients and the functional cheese sauce are all stored at a refrigerated temperature prior to mixing. The functional cheese sauce is tempered to a temperature of about 35°F so that it can flow and can be fully blended with the filling ingredients. In one aspect, mixing can be performed when the filling ingredients are stored at a temperature of less than 35°F, or less than 34°F, or less than 33°F, or less than 32°F, or less than 31°F, or less than 30°F, or less than 29°F, or less than 28°F. In various aspects, the filling ingredients can be stored at a temperature of about 14°F to about 36°F, or about 17°F to about 34°F, or about 19°F to about 34°F, or about 20°F to about 41°F, or about 20°F to about 34°F, or about 25°F to about 36°F, or about 25°F to about 34°F, or about 27°F to about 36°F, or about 26°F to about 30°F, or about 28°F. It should be understood that when mixed with the functional cheese sauce to form the filling composition, the filling ingredients can be present at a temperature of 24°F to 40°F.

[0073] By applying a force, such as by pressure, the filling composition can be shaped and / or compressed into a self-supporting adhesive filling composition to enhance the bonding properties of the functional cheese sauce. Suppression, compression and / or shaping can be completed manually or by machine. The filling composition can be shaped and / or pressed into a shape, such as a predetermined shape, by hand or machine. The shape formed by the compression filling composition is not particularly limited. For example, the filling composition can be shaped into a roughly rectangular or cubic piece for subsequently placing on or in a flour tortilla (such as a tortilla) to make a burrito. In one aspect, the filling composition can be pressed into an irregular shape by hand or by machine. The shaped filling composition is self-supporting as defined above. It should be understood that the filling composition can be pre-distributed ingredients, which can be shaped into a pie, a cylinder, a cube, a cuboid, etc.

[0074] The shaped filling composition can be self-supporting at refrigerated temperature or freezing temperature or both. This self-supporting shaped filling composition can be distributed and handled easily, for further processing, freezing, storage, transportation and / or being included in the food product. For example, the filling composition can be placed on the surface of the bread, and wrapped or wound in the bread to provide food product, such as can be refrigerated, frozen and / or stored for future use.

[0075] In one aspect, the presence of the functional cheese sauce within the filling composition provides robustness through the binding and lubricating properties it provides to the filling composition, such that the filling ingredients are not broken down by the forces of processing, handling, transporting, etc., compared to filling compositions lacking the functional cheese sauce.

[0076] When the filling composition herein is heated to a food-safe temperature of at least 145°F, the functional cheese sauce can melt or blend into the filling ingredients such that the functional cheese sauce no longer imparts self-supporting properties to the filling composition (i.e., the functional cheese sauce no longer binds the filling ingredients together). As a result, the filling composition can collapse and / or otherwise debond. The functional cheese sauce can be incorporated into the heated food product to contribute to the desired organoleptic properties in the final product, as compared to a filling composition lacking the functional cheese sauce. Thus, when heated at the point of sale, for example as a breakfast burrito, the consumer will not notice a difference in texture or taste when using the functional cheese sauce composition herein compared to a food product that does not incorporate the functional cheese sauce composition.

[0077] It should be understood that as the functional cheese sauce transitions from refrigerated or frozen temperatures, the functional cheese sauce may begin to lose the ability to impart self-supporting properties to the filling composition at temperatures above 40°F for a period of more than 1 minute or more than 2 minutes. It should also be understood that when heated to above 40°F, the functional cheese sauce may lose the ability to impart self-supporting properties to the filling composition. For example, when the filling composition has an internal temperature of greater than 40°F to 150°F, or 80°F to 140°F, or 100°F to 145°F, the functional cheese sauce is no longer self-supporting as defined elsewhere herein. However, from a food safety perspective, it should be understood that heating to a food safety temperature above 145°F is preferred for consumer safety and satisfaction.

[0078] Surprisingly, it has been discovered herein that the functional cheese sauce imparts self-supporting properties to the filling composition at refrigerated or frozen temperatures, but upon heating, the self-supporting properties cease to exist. Thus, upon heating a food product containing the functional cheese sauce, the filling composition may collapse and / or debond, thereby providing a food product having pleasing organoleptic properties and meeting consumer expectations.

[0079] In one aspect, the filling composition can account for a larger proportion or even major part of the filling composition. The filling composition can comprise 40 % by weight to 98 % by weight (wt.% or w / w%) of the filling composition (that is, the weight of the filling composition divided by the gross weight of the filling composition that comprises the filling composition, then multiplied by 100). The filling composition can comprise 40 % by weight to 98 % by weight, or 50 % by weight to 98 % by weight, or 60 % by weight to 98 % by weight, or 70 % by weight to 98 % by weight, or 80 % by weight to 98 % by weight, or 85 % by weight to 98 % by weight, or 60 % by weight to 80 % by weight, or 50 % by weight to 80 % by weight of the filling composition. The filling composition can comprise a larger proportion of the food block, which must be bonded to realize the advantage of functional cheese sauce. Therefore, when the filling composition accounted for a larger proportion of the filling composition, the bonding properties of the functional cheese sauce must be effective especially because the functional cheese sauce of the filling composition bonding a given amount is less. When the filling composition comprises less than 3 wt % functional cheese sauce relative to the weight of the filling composition or less than 3.1 wt % functional cheese sauce relative to the filling ingredients, the functional cheese sauce may become ineffective in binding the filling ingredients in the filling composition.

[0080] In one aspect, the filling composition can comprise 3% to 50% by weight of the functional cheese sauce, or 3% to 40% by weight, or 3% to 30% by weight, or 3% to 20% by weight, or 5% to 50% by weight, or 5% to 40% by weight, or 5% to 30% by weight, or 5% to 20% by weight, or 5% to 10% by weight, or 10% to 50% by weight, or 10% to 40% by weight, or 10% to 30% by weight, or 10% to 20% by weight, or 20% to 50% by weight, or 30% to 50% by weight, or 40% to 50% by weight, or 20% to 40% by weight of the functional cheese sauce.

[0081] As described above, the functional cheese sauces described herein can act as a binder for filling ingredients without the need to add additional binders to the filling composition. Thus, in various aspects, the filling composition as described herein can contain less than 5% by weight, or less than 4% by weight, or less than 3% by weight, or less than 2% by weight, or less than 1% by weight of a protein-based binder, such as egg, egg white, soy protein, or whey protein. In various aspects, the functional cheese sauces herein do not contain any additional binders.

[0082] After shaping, the filling composition is self-supporting as defined herein at about 35 ° F, or about 34.5 ° F to about 36 ° F, or about 32 ° F to about 36 ° F for at least one minute, or at least two minutes, or at least three minutes, or at least four minutes, or at least five minutes, or at least six minutes, or at least 10 minutes, or at least 20 minutes. The temperature range and specific temperature specified above have specified the minimum temperature range or temperature of the filling composition self-supporting. However, the filling can also be self-supporting outside these scopes. Therefore, the self-supporting of the filling composition allows the filling composition to maintain shape, composition and / or quality for a period of time at a specified temperature before the next step of assembling the food product (such as when wrapping the food product in production). This is advantageous for the manual assembly of food products, and is particularly advantageous for the automated assembly of wrapping the food product because it provides the advantage of being easy to handle and process, has commensurate benefits, such as productivity and consistency (such as product portion size, taste and other organoleptic properties) of the product. The consistency of the product can contribute to final consumer satisfaction because the product always meets the expectation of the client.

[0083] The filling composition itself can be a ready-to-eat or ready-to-heat food product without the need for the addition of other components. However, the filling composition can be placed on a dough and wrapped in the dough alone or with other ingredients to provide a rolled food product. The rolled food product can be assembled manually or automatically, refrigerated and / or frozen, and shipped refrigerated or frozen to the point of sale, where a simple heating step can provide a heated rolled food product for supply to customers, thereby achieving the favorable organoleptic properties of the rolled food and the filling composition.

[0084] Thus, the filling compositions herein can be formed into pre-portioned portions that can be immediately frozen or can be distributed onto the surface of a dough to form a food product, such as a roll-up food product. In one aspect, a method of preparing a formed ready-to-heat or ready-to-eat food product can include: a) providing any functional cheese sauce described herein, wherein the functional cheese sauce is flowable; b) providing any filling ingredient as described herein; c) combining and / or mixing the functional cheese sauce with the filling ingredient to provide any filling composition described herein; and d) forming the filling composition into a shape to provide a shaped filling composition that is self-supporting at refrigerated or frozen temperatures; and wherein the shaped filling composition is not self-supporting at an internal temperature of at least 145°F (50°C).

[0085] International patent application publication WO 2022 / 087105 A1 (the entire text of which is incorporated herein by reference) describes an automated burrito making machine. The filling composition can be formed into discrete patties or blocks that can be used as a filling for a burrito or part of a filling for a burrito. The process can be accomplished in a variety of ways, such as feeding the loose ingredients and functional cheese sauce into a hopper or other input device, dispensing the mixture into metered doses, and compressing the doses to form solid or semi-solid patties or blocks. The functional cheese sauce and filling composition described in this application can be used in an automated burrito making method and an automated burrito making machine as described in International patent application publication WO 2022 / 087105 A1, which is incorporated herein in its entirety and for all purposes.

[0086] Food products

[0087] Contained herein are various food products comprising the functional cheese sauce and filling compositions. The food product herein can comprise any type of roll-up food, burritos and rolled food, which generally comprise a soft, pliable flour cake that is wrapped or wound around the filling composition. In one aspect, the food product comprises flour cake and any filling composition as herein described. In one aspect, the food product comprises flour cake and filling composition, wherein the flour cake is wound around the filling composition or is wrapped to form a roll-up food product. In various fields, the food product herein can be considered to be instant or hot.

[0088] The food product can be formed using pre-portioned filling compositions. As discussed elsewhere herein, frozen or partially frozen filling ingredients can be used to form the filling compositions and stored for future use. The assembled food product can be refrigerated and / or frozen for transport to a point of sale, such as a fast food restaurant, where the food product can be further frozen or stored refrigerated before being heated for consumption by customers.

[0089] In one aspect, the filling composition can be placed on the surface of the dough, and the dough and filling composition form a food product that can be refrigerated or frozen before use. In one aspect, the food product can be heated together to an internal temperature of the filling composition of 145°F to 195°F, or heated as described elsewhere herein, to maintain food safety for the consumer.

[0090] Example

[0091] Various aspects of the present disclosure may be better understood by reference to the following examples which are provided by way of illustration.The present disclosure is not limited to the examples given herein.

[0092] Example 1: Comparative Example: Analysis of the Binding Properties of Various Starch Compositions in Breakfast Burrito Fillings

[0093] In this example, various starch-based binder ingredients were analyzed for their ability to bind various filling ingredients to form a breakfast burrito composition. The starch ingredients used in this example are listed in Table 2.

[0094] Table 2: Various starches used for analysis of bonding properties

[0095]

[0096]

[0097] The filling ingredients used in the breakfast burrito compositions analyzed in this example included a mixture of scrambled eggs, sausage, onions, and red peppers. The filling ingredients were warmed to either 29°F or 32°F and mixed with each starch ingredient according to the recipe for each experimental condition outlined in Table 3.

[0098] Table 3: Experimental conditions used to analyze the bonding properties of various starches

[0099]

[0100] As used herein, the term "rewarmed" or "rewarming" refers to the process of moderating the temperature of food to allow it to gradually rise from a temperature below 21° F to any temperature within the range of 22° F to 40° F. Rewarming can be safely performed by moving frozen food into a refrigerator below 40° F to allow it to slowly and safely reach the desired temperature before cooking.

[0101] Each of the modified starch and native starch was blended at a 1:1.3 water to starch ratio and mixed with the filling composition at 29°F or 32°F with <7% by weight starch binder and as shown in Table 3. The starch-filling ingredient mixture was pressed into a 1 / 8 flat baking pan (dimensions measuring approximately 6.5 inches by 9 inches). The mixture was placed in a blast freezer set at -35°F for 10 to 15 minutes. The breakfast burrito composition was removed from the blast freezer, removed from the baking pan, and separated using a kitchen knife to analyze the binding properties of each starch during handling and portioning.

[0102] The results showed that the mixtures of Tests 1 to 5 did not contain sufficient moisture and the vegetables did not release any additional moisture during the test period. Thus, many of these combinations were fragile at refrigerated and frozen temperatures and did not hold together during transport to the rolls for rolling into food products at these temperatures.

[0103] The mixture was thoroughly blended at 32°F and was thicker than that blended at 29°F. The mixture held together slightly better. Further observation showed that as the temperature increased, the egg curd began to soften slightly, however, the vegetables remained solid and did not release additional moisture. While the direct addition of starch produced a breakfast burrito composition that allowed for portioning with limited breakage, each of the starches used contributed undesirable organoleptic properties to the breakfast burrito composition. For example, upon heating, none of the starches melted into the remaining ingredients, and upon consumption, undesirable organoleptic properties were detectable in both taste and texture.

[0104] Example 2: Analysis of the Binding Properties of Various Cheese Sauce Compositions in Breakfast Burrito Fillings

[0105] In this example, various functional cheese sauce compositions were analyzed for their ability to bind filling ingredients to form a breakfast burrito composition, as well as their ability to contribute to desirable sensory properties in the breakfast burrito composition. Various processed cheeses were analyzed, including Yellow American cheese (Bongards Creameries, Chanhassen, MN, USA), Land Processed American cheese (Land Inc., Arden Hills, MN, USA), Ornua Pasteurized Blend Aged White American Cheese (Ornua Ingredients North American, Hilbert, WI, USA), Glanbia Better Melting Cheddar Cheese (Glanbia Nutritionals, Fitchburg, WI, USA), and Pasteurized reprocessed American cheese spread (Kraft Heinz, Co., Chicago, IL, USA) The functional cheese spread compositions analyzed in this example are listed in Table 4.

[0106]

[0107]

[0108] The cheese sauce was mixed, cooked, and frozen until use. Each cheese sauce was mixed with filling ingredients (e.g., scrambled eggs, sausage, onions, and red peppers) at a 9:1 cheese sauce to filling ingredient blend ratio to form a breakfast burrito composition. The breakfast burrito composition was pressed into a 1 / 8 flat baking pan (approximately 6.5 inches by 9 inches in size) and frozen in a blast freezer set at -35°F for 10 to 15 minutes. The breakfast burrito composition was removed from the blast freezer, removed from the baking pan, and separated using a kitchen knife.

[0109] Formed breakfast burrito compositions containing each tested functional cheese sauce were analyzed for their ability to maintain their shape and minimize loss during handling. The formed portion of the breakfast burrito composition was placed on a dough tortilla and rolled with an added outer paper wrapper. The rolled food products were microwaved to 145°F and subjected to taste testing and analysis for their ability to maintain or release their shape. The results are listed in Table 5.

[0110] Table 5. Binding properties of various functional cheese sauce compositions

[0111] cheese sauce Observation results 1 Can bind filler ingredients. Undesirable organoleptic properties. 2 Cohesion is affected, manifesting as breaking of filling ingredient particles upon cutting. Undesirable flavor impact. 3 The formula is too dry and cannot be adequately dispersed throughout the filling ingredients to impart binding properties. 5 The formula is too dry and cannot be adequately dispersed throughout the filling ingredients to impart binding properties. 6 The bonding properties were suboptimal, exhibiting chipping and cracking upon forming. 7 Exhibits prolonged melting properties and undesirable flavor impact. 8 Exhibits favorable flow properties, enhanced bonding and desirable sensory properties. 9 --- 12 Exhibits favorable flow properties, enhanced bonding and desirable sensory properties.

[0112] Cheese sauce 1 contributed to the best binding properties for the breakfast burrito composition, but had an undesirable effect on flavor. Cheese sauce 2 did not maintain the binding properties of the breakfast burrito composition during dispensing and handling, and had an undesirable effect on flavor. Cheese sauces 3 and 5 were too dry and failed to disperse throughout the filling ingredients, thereby failing to impart any significant binding properties to the filling ingredients. Cheese sauce 6 exhibited suboptimal binding properties and failed to maintain shape. Cheese sauce 7 exhibited prolonged melting during mixing, taking over 20 minutes to melt to produce cheese sauce, and had an undesirable effect on the flavor profile. Cheese sauce 8 exhibited the best flowability as described herein and was able to maintain shape in the filling composition. When heated as a component of the filling composition, cheese sauce 8 melted into the ingredients, as observed when the filling composition spread out as if it had been dispensed into the tortilla using a spoonful of filling, and the sensory properties were excellent and desirable. Cheese sauce 12 exhibited similar properties to cheese sauce 8. Both cheese sauce 8 and cheese sauce 12 provide enhanced self-supporting properties to the filling composition and help achieve desired organoleptic properties when heated to food-safe temperatures. It should be understood that cheese sauce 8 and cheese sauce 12 produce a final filling composition that is indistinguishable from a frozen product and is similar to a filling composition that is manually scooped onto a tortilla using a measuring spoon.

[0113] The methods and compositions described herein provide special benefits. In one aspect, by providing a functional cheese sauce that can flow at refrigerated or frozen temperatures but still has adhesiveness. This functional cheese sauce can be fully mixed with the filling ingredients and provide enough bonding functions for the filling ingredients to give it self-supporting properties before the filling composition is heated. This filling composition can be reproducible and clearly defined in quantity and shape. This filling composition can easily be conveyed with automation or manual processes without prematurely separating the filling ingredients. This filling composition can be placed on the surface of the dough quickly and assembled into consistent wrapping food products. If you do not intend to use the wrapping food product immediately, it can be frozen for subsequent storage and / or transportation to another location, such as a point of sale, such as a fast food restaurant, a convenience store, etc.

[0114] Benefits of the functional cheese sauce and filling compositions described herein include enhanced productivity, increased product consistency, the ability to mass-produce filling compositions and / or wrap food products off-site, and finished wraps or other food products containing the functional cheese sauce that do not impart undesirable organoleptic food properties to the final product.

[0115] It should be understood that the definitions set forth herein apply to all aspects described unless otherwise stated.

[0116] In this document, unless the context clearly dictates otherwise, the terms "a," "an," or "the" are used to include one or more than one. Unless otherwise indicated, the term "or" is used to refer to a non-exclusive "or." All publications, patents, and patent documents cited in this document are incorporated herein by reference in their entirety, as if individually incorporated by reference. In the event of any inconsistency between the usages of this document and those documents so incorporated by reference, the usage in the incorporated references should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.

[0117] Values ​​expressed in range format should be interpreted in a flexible manner to include not only the values ​​explicitly listed as the limits of the range, but also all individual values ​​or subranges encompassed within the range, as if each value and subrange were explicitly listed. For example, a range of "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted to include not only about 0.1% to about 5%, but also individual values ​​(e.g., 1%, 2%, 3%, and 4%) and subranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the specified range. Unless otherwise indicated, the statement "about X to Y" has the same meaning as "about X to about Y." Similarly, unless otherwise indicated, the statement "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z."

[0118] Unless expressly indicated, ppm (parts per million), percentages and ratios are on a weight basis. Percentage on a weight basis (w / w %) is used interchangeably herein with percent by weight (wt %) or percent by weight (% wt.).

Claims

1. A method of preparing a food product, the method comprising: a. Providing a functional cheese sauce, wherein the functional cheese sauce is capable of flowing; b. Providing a filling component, wherein at least 50% by weight of the filling component has a longest dimension of 0.3 cm to 4 cm; c. mixing the functional cheese sauce with the filling ingredients to provide a filling composition; as well as d. forming the filling composition into a predetermined shape to provide a shaped filling composition that is self-supporting at a refrigerated temperature of 40°F for at least two minutes, and wherein the shaped filling composition is not self-supporting at an internal temperature of at least 145°F at a food-safe temperature.

2. The method of claim 1, wherein the weight ratio of cheese to added water in the functional cheese sauce is from about 1:3 to about 1:

1.

3. The method of claim 1 or claim 2, wherein the functional cheese sauce is flowable when it is capable of traversing a distance of 5 cm to 10 cm from a starting point to an end point within 10 seconds at a temperature of 159°F to about 161°F.

4. The method according to any one of claims 1 to 3, wherein the functional cheese sauce is flowable when it is able to traverse a distance of 2 cm to 7 cm from a starting point to an end point within 10 seconds at a temperature of 34°F to 36°F.

5. The method according to any one of claims 1 to 4, wherein the functional cheese comprises processed cheese and cheddar cheese.

6. The method according to any one of claims 1 to 5, wherein the filling composition comprises 70% to 98% by weight of the filling ingredients.

7. The method according to any one of claims 1 to 6, wherein the functional cheese sauce further comprises one or more of butter, skimmed milk powder or salt.

8. The method according to any one of claims 1 to 7, wherein the functional cheese sauce further comprises one or more of xanthan gum, sodium alginate, phosphate or starch.

9. The method of any one of claims 1 to 7, wherein the functional cheese sauce comprises less than 5% by weight of any combination of one or more of the following: xanthan gum, sodium alginate, phosphates, or starch.

10. The method of any one of claims 1 to 9, wherein the filling ingredients comprise one or more of eggs, sausage, meat, beans or vegetables.

11. The method according to any one of claims 1 to 10, further comprising freezing the shaped filling composition.

12. The method according to any one of claims 1 to 11, further comprising placing the shaped filling composition on a surface of a dough to produce a rolled food product.

13. The method of any one of claims 1 to 12, further comprising placing the shaped filling composition on a tortilla.

14. A shaped filling composition, the shaped filling composition being made by the method according to any one of claims 1 to 13.

15. A food product made by the method according to any one of claims 1 to 14.

16. A filling composition, comprising: A functional cheese sauce, wherein the functional cheese sauce is flowable; and one or more filling ingredients mixed with the functional cheese sauce; wherein at least 50% by weight of the filling ingredients have a longest dimension of 0.3 cm to 4 cm; and wherein the filling composition is self-supporting at a refrigerated temperature of 40°F for at least two minutes, and wherein the shaped filling composition is not self-supporting at an internal temperature of at least 145°F, a food-safe temperature. 17 . The filling composition of claim 16 , wherein the weight ratio of the functional cheese to the added water in the functional cheese sauce is from about 1:3 to about 1:

1.

18. The filling composition of any one of claims 16 or 17, wherein the functional cheese spread is flowable when it is capable of traversing a distance of 5 cm to 10 cm from a starting point to an end point within 10 seconds at a temperature of 159°F to about 161°F.

19. The filling composition of any one of claims 16 or 17, wherein the functional cheese spread is flowable when it is capable of traversing a distance of 2 cm to 7 cm from a starting point to an end point within 10 seconds at a temperature of 34°F to 36°F.

20. The filling composition according to any one of claims 16 to 19, wherein the functional cheese comprises processed cheese and cheddar cheese.

21. The filling composition according to any one of claims 16 to 20, wherein the filling composition comprises 70% to 98% by weight of the filling ingredients.

22. The filling composition according to any one of claims 16 to 21, wherein the functional cheese sauce further comprises one or more of butter, skimmed milk powder or salt.

23. The filling composition according to any one of claims 16 to 21, wherein the functional cheese sauce further comprises one or more of xanthan gum, sodium alginate, phosphate or starch.

24. The filling composition of any one of claims 16 to 23, wherein the functional cheese sauce comprises less than 5% by weight of any combination of one or more of the following: xanthan gum, sodium alginate, phosphate, or starch.

25. A filling composition according to any one of claims 16 to 24, wherein the filling ingredients comprise one or more of eggs, sausage, meat, beans or vegetables.

26. A food product comprising a dough and a filling composition according to any one of claims 16 to 25.

27. A functional cheese sauce, comprising: 10% to 25% by weight of processed cheese; 10% to 20% by weight of cheddar cheese; 30% to 70% by weight of added water; 5% to 12% by weight of salted butter; 1 to 8% by weight of skimmed milk powder; 0.5 to 6 wt% starch from waxy corn; 0.1 to 5 wt% sodium phosphate; 0.01 to 3 wt% xanthan gum; 0.01 to 3 wt% sodium alginate; as well as 0.1% to 5% by weight of sodium chloride.

28. The functional cheese sauce of claim 27, wherein the processed cheese is 16 to 21 wt %; the cheddar cheese is 14 to 17 wt %; the added water is 45 to 50 wt %; the salted butter is 8 to 10 wt %; the skim milk powder is 3 to 6 wt %; the starch from waxy corn is 1.5 to 3.5 wt %; the sodium phosphate is 0.5 to 1.5 wt %; the xanthan gum is 0.05 to 0.5 wt %, the sodium alginate is 0.05 to 0.5 wt %, and the sodium chloride is 0.3 to 1.5 wt %.

29. The functional cheese sauce of claim 27, wherein the functional cheese sauce is flowable when it is capable of traversing a distance of 2 cm to 7 cm from a starting point to an end point within 10 seconds at a temperature of 34°F to 36°F.

30. The functional cheese sauce of claim 27 or 28, wherein the weight ratio of total cheese in the functional cheese sauce to the added water is from about 1:3 to about 1:

1.

31. The functional cheese sauce of any one of claims 27 to 30, wherein the functional cheese sauce comprises less than 5% by weight of any combination of one or more of the following: xanthan gum, sodium alginate, phosphates, or starch.

32. The functional cheese spread of any one of claims 27 to 31, wherein the filling ingredient comprises one or more of eggs, sausage, meat, beans or vegetables.

33. A food product comprising: Flatbread; and A filling composition comprising the functional cheese sauce according to any one of claims 27 to 32 and one or more filling ingredients, wherein at least 50% of the one or more filling ingredients have a longest dimension of 0.3 cm to 4 cm; and wherein the filling composition is self-supporting at a refrigerated temperature of 40°F for at least two minutes, and wherein the shaped filling composition is not self-supporting at an internal temperature of at least 145°F, a food-safe temperature.

34. The food product of claim 33, wherein the flatbread is selected from a tortilla, a pita, a naan, a chapati, an injera, or a Moroccan flatbread.

35. A method of making a heated food product, the method comprising: a.) providing a filling composition according to any one of claims 16 to 26; b.) placing the filling composition on the surface of the dough; c.) wrapping the filling composition in the dough to provide a wrapped food product; as well as d.) heating the wrapped food product.

36. The method of claim 35, wherein in step d.), the internal temperature of the filling composition reaches a temperature of at least 145°F.

Images