Extruded puffed high protein and high fiber food pieces and methods of making

Abstract

The present disclosure relates to low density, high protein, high fiber ready-to-eat food pieces, compositions including such food pieces, and methods of making such food pieces. The pieces include a plant-based protein ingredient in an amount of about 25% to about 55% by dry weight protein, where at least a portion of the protein ingredients include a protein with a PDCAAS greater of at least 60%, such as pea protein or soybean protein, a fiber ingredient contributing fiber in an amount of at least 20% by dry weight of the pieces, where the fiber ingredient comprises insoluble fiber in an amount of about 6% to about 35% by dry weight of the pieces, and about 5% to about 30% by dry weight low DE carbohydrate.

Description

EXTRUDED PUFFED HIGH PROTEIN AND HIGH FIBER FOOD PIECES AND METHODS OF MAKINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. ProvisionalApplication No. 63 / 625,499, filed January 26, 2024, which is incorporated herein by reference.TECHNOLOGY

[0002] The present disclosure generally relates to an extruded high protein, high fiber product with low density and methods of making such a product.BACKGROUND

[0003] High protein food products have found popularity among consumers as a way to eat nutritionally dense foods. In addition, high fiber foods can supplement fiber consumption. Consumers want diverse ways to get increased protein and fiber into their diets. Thus, there is a need for new high protein, high fiber food products to satisfy the increasing consumer desire for protein.SUMMARY

[0004] Low density, high protein, high fiber ready-to-eat (RTE) food pieces and methods of making such food pieces are provided herein.

[0005] Food pieces and compositions including such food pieces are provided herein. Food pieces can include at least 68% by dry weight of a combination of a plantbased protein ingredient, a fiber ingredient, and a low dextrose equivalent (DE) carbohydrate, where the plant-based protein ingredient is included in an amount of about 25% to about 55% by dry weight of the food pieces, the protein ingredient comprising pea protein, soybean protein, canola protein, fava bean protein, or chickpea protein andcontributing about 18% to about 35% protein content by dry weight of the food pieces; the food pieces have a total fiber content of about 25% to about 35% by dry weight of the food pieces, where the fiber ingredient contributes fiber in an amount of at least 20% by dry weight of the food pieces and comprises insoluble fiber in an amount of about 6% to about 35% by dry weight of the food pieces; the low DE carbohydrate is included in an amount of about 5% to about 30% by dry weight of the food pieces, the low DE carbohydrate having an average DE of from 1 to about 10; the food pieces have a moisture content of up to 5% by weight of the food pieces; and the food pieces have a bulk density range of from 110 to 200 grams per 100 cubic inches.

[0006] In some embodiments, the fiber ingredient can include bran. In some embodiments, the fiber ingredient can include psyllium, e.g., in an amount of up to about 18% by dry weight of the food pieces.

[0007] In some embodiments, the food pieces can include a grain flour in an amount of about 3% to about 30% by dry weight of the food pieces, where the combined amount of grain flour and low DE carbohydrate is about 18% to about 35% by dry weight of the food pieces, and where a combination of the plant-based protein ingredient, the fiber ingredient, the low DE carbohydrate, and the grain flour comprise at least 80% by dry weight of the food pieces. In some embodiments, at least a portion of the grain flour can be whole grain. In some embodiments, the grain flour can include com meal.

[0008] In some embodiments, the protein content and the total fiber content can be included at a ratio of about 1.5: 1 to about 1 : 1.5.

[0009] In some embodiments, the food pieces can have a total protein content of about 28% to about 32% by dry weight of the food pieces.

[0010] In some embodiments, the low DE carbohydrate can include maltodextrin in an amount of about 10% to about 25% by dry weight of the food pieces.

[0011] Some embodiments of food pieces provided herein can consist of: a plantbased protein ingredient in an amount sufficient to contribute soybean and / or pea protein in an amount of about 28% to about 32% by dry weight of the food pieces; a fiber ingredient, where the fiber ingredient contributes insoluble fiber in an amount of about 20% to about 25% by dry weight of the food pieces and psyllium in an amount of about 6% to about 10% by dry weight of the food pieces, and where the total fiber content is from about 28% to about 35% by dry weight of the food pieces; grain flour in an amountof about 4% to about 20% by dry weight of the food pieces, the grain flour comprising com meal; a low DE carbohydrate, where the low DE carbohydrate has an average DE of from 1 to about 6, and where the combined amount of the grain flour and the low DE carbohydrate is about 20% to about 35% by dry weight of the food pieces; and other ingredients in an amount of less than 10% by dry weight of the food pieces, where the moisture content is 4% or less by weight of the food pieces.

[0012] Coated food pieces are described herein. Such coated food pieces include any of the herein described food pieces with a coating on at least a portion of a surface of at least a portion of the food pieces. In some embodiments, the coating can be about 10% to about 50% by weight of the coated food pieces. In some embodiments, coated food pieces can have a bulk density of about 150 to about 300 grams per 100 cubic inches.

[0013] Compositions that include a plurality of food pieces or coated food pieces according to any embodiment provided herein, and edible components other than the food pieces or coated food pieces, are also provided.

[0014] Methods of making food pieces are provided herein. A method of making a food pieces, can include: combining under extrusion conditions ingredients to form a dough having a moisture content of about 8% to about 40%, the ingredients comprising at least 68% by dry weight of a combination of a plant-based protein ingredient, a fiber ingredient, and a low DE carbohydrate; forming the dough from an extrusion die to form dough pieces; puffing and drying the dough pieces to form a plurality of food pieces having a bulk density of 110 to 200 grams per 100 cubic inches and a moisture content of 5% or less by weight to form the plurality of food pieces. The plant-based protein ingredient can be included in an amount of about 25% to about 55% by dry weight of the dough, the protein ingredient comprising pea protein, soybean protein, canola protein, fava bean protein, or chickpea protein, and contributing about 18% to about 35% protein by dry weight of the dough; the fiber ingredient is included in an amount sufficient to contribute fiber in an amount of at least 20% by dry weight of the dough, and comprises insoluble fiber in an amount of about 6% to about 35% by dry weight of the dough; the low DE carbohydrate is included in an amount of about 5% to about 30% by dry weight of the dough, the low DE carbohydrate having an average DE of 1 to about 10; and other ingredients are included in the dough, the combined other ingredients being included in an amount of up to 20% by dry weight of the dough. In some embodiments, the fiberingredient includes psyllium in an amount of about 5% to about 12% by dry weight of the dough, the combined psyllium and insoluble fiber ingredient contributing to a fiber content of about 25% to about 35% by dry weight of the dough, where a combination of a grain flour, the plant-based protein ingredient, the insoluble fiber ingredient, and the low DE carbohydrate comprise at least 80% by dry weight of the dough.

[0015] These and various other features and advantages will be apparent from a reading of the following detailed description.DETAILED DESCRIPTION

[0016] Consumers continually expect an even greater variety of nutrient dense, convenient foods that are suitable for different eating occasions, including foods that contain high concentrations of protein and fiber. However, protein ingredients, particularly non-animal derived protein ingredients, often suffer from bitter taste, astringency, and / or off-flavor / aroma, and have proven difficult to puff or to produce a product that resembles a traditional ready-to-eat (RTE) grain-based breakfast cereal. Fiber ingredients, especially insoluble fiber ingredients, often contribute to taste, astringency, and textural problems, and have proven difficult to puff when included at high levels to produce a product that resembles a traditional ready-to-eat (RTE) grain-based breakfast cereal. Thus, while grainbased RTE cereal products are available with supplemental protein content (i.e., protein content beyond that contributed by the grain-based component(s)) and / or supplemental fiber content (i.e., fiber content beyond that contributed by grain-based component(s)), such products leverage different formats (e.g., flakes, nugget-type pieces, or twigs) or have structures that are generally denser and often have a harder, crunchier, grittier, and / or glassier texture when attempting to replicate traditional puffed RTE cereal format than traditional RTE grain-based breakfast cereals. Such products also tend to suffer from off- flavors and / or bitterness. The present application describes the discovery of high protein, high fiber compositions that can be puffed into a low-density RTE food piece having a pleasant, crunchy texture resembling traditional grain-based RTE breakfast cereal, and having a pleasant or neutral flavor, even in the absence of flavorants or off-flavor maskers.

[0017] A food piece provided herein is a high protein, high fiber, low density, and ready-to-eat grain-based food piece. As used herein, the term “high protein” refers to a food piece that includes protein in an amount of about 25% to about 40% by dry weight ofthe piece (e.g., about 28% to about 35%) by dry weight of the food piece. The term “high fiber” refers to a food piece that includes a total fiber content of about 25% to about 35% (e.g., about 28% to about 32%) by dry weight of the food piece. In some embodiments, a food piece described herein can have a total fiber content and a protein content that are similar (e.g., included at a ratio of about 1.5: 1 to about 1 : 1.5, or about 1 : 1).

[0018] The term “low density” refers to a plurality of food pieces that have a bulk density of about 80 to about 200 (e.g., about 90 to about 200, about 110 to about 200, or about 140 to about 190) g / 100 cubic inches. A low density food piece may also be referred to as “puffed.” Low density food pieces resembling RTE breakfast cereal pieces can, for example, have a bulk density of about 110 to about 200 (e.g., about 140 to about 180) g / 100 cubic inches. Low density food pieces resembling cheese puff snack pieces can, for example, have a bulk density of less than 110 (e.g., about 80 to about 100, or about 90 to about 100) g / 100 cubic inches.

[0019] As used herein, the term “ready-to-eat” (“RTE”) refers to a food that does not require further cooking or preparation to be suitable and safe for consumption. A food piece provided herein is typically also shelf stable at room temperature for at least 6 months (e.g., at least 8 months, or 12 months to 18 months) without significant negative impact on texture, structure, or flavor when stored in appropriate packaging. A food piece provided herein typically has dimensions that are suitable for a RTE breakfast cereal or a bite sized snack food. A food piece provided herein can also be suitably coated, or it can be used in other products, such as dry snacks, inclusions to be mixed in other products (e.g., yogurt or pudding), snack blends, cold-formed or baked snack bars or clusters.

[0020] A food piece provided herein comprises at least 68% (e.g., at least 70%) by dry weight of a combination of a plant-based protein ingredient, a fiber ingredient, and a low dextrose equivalent (DE) carbohydrate.

[0021] A food piece provided herein includes a plant-based protein ingredient in an amount of about 25% to about 55% by dry weight. A suitable plant-based protein ingredient has at least a portion (e.g., at least 60%, at least 70%, or at least 90%) of its protein content comprising a protein source that has a protein digestibility-corrected amino acid score (PDCAAS) of at least 60%. Examples of such proteins include, without limitation, soybean protein, which typically has a PDCAAS of about 90% to about 100%, pea protein, which typically has a PDCAAS of at least 60%, chickpea protein, whichtypically has a PDCAAS of at least 70%, quinoa protein, which typically has a PDCAAS of at least 60%, and rapeseed protein, which typically has a PDCAAS of at least 80%. PDCAAS of a protein is calculated according to the Food and Agriculture Organization of the United Nations (Joint FAO / WHO Expert Consultation (1990), Protein Quality Evaluation. Report of a Joint FAO / WO Expert Consultation held in Bethesda, MD, USA, 4-8 December 1989. Food and Agriculture Organization, Rome. Section 8. ISBN 92-5- 103097-9).

[0022] In some embodiments, a plant-based protein ingredient comprises a legume protein (e.g., soybean protein, pea protein, chickpea protein, fava bean protein, lentil protein, and the like). In some embodiments, a plant-based protein ingredient can include protein from a non-legume plant source, such as wheat, rice, corn, canola, and the like.

[0023] In some embodiments, a plant-based protein ingredient can have a protein content of at least 60% (e.g., at least 65%) by dry weight of the protein ingredient. In some embodiments, a plant-based protein ingredient can have a protein content that consists of soybean protein, pea protein, canola protein, chickpea protein, fava bean protein, or any combination thereof. A plant-based protein ingredient can comprise, for example, legume flours (e.g., soybean flour or the like), protein concentrates (e.g., soybean protein concentrate, pea protein concentrate, fava bean protein concentrate, canola protein concentrate, chickpea protein concentrate, or the like), protein isolates (e.g., soybean protein isolate, pea protein isolate, chickpea protein isolate, or the like), and the like, or any combination thereof.

[0024] A protein ingredient having at least a portion of the protein content comprising a legume protein can contribute to a texture that closely resembles a traditional grain-based RTE cereal. In contrast, a similarly formulated food piece that includes wheat protein and no legume protein can result in a texture that is harder, more brittle, grittier, and / or glassier than a food piece described herein.

[0025] A plant-based protein ingredient can contribute protein in an amount of about 15% to about 40% (e.g., about 25% to about 35%) by dry weight of the food piece. In some embodiments a plant-based protein ingredient can be selected to arrive at a total protein content that delivers high quality protein in an amount of at least 10% (e.g., at least 11%, or about 11% to about 15%) by dry weight of a food piece. As used herein, the amount of high quality protein in a food piece can be calculated by multiplying the amountof protein contributed by a protein ingredient by the PDCAAS value. For example, if a protein ingredient contributes a protein content of 20% by weight to a food piece, and the PDCAAS value is 60%, then the amount of high quality protein is about 12% (0.2 x 0.6 = 0.12, or 12%). Total protein in a food piece provided herein ranges from about 28% to about 40% (e.g., about 28% to about 38%, or about 28% to about 36%) by dry weight of the food piece, and includes protein content combined from all of the included ingredients (e.g., protein ingredient and grain flour).

[0026] A food piece provided herein includes a fiber ingredient. Although a food piece can contain other sources of fiber, such as fiber from a grain ingredient or a low DE carbohydrate described below, a fiber ingredient, as used herein, consists of an insoluble fiber source (e.g., bran, cellulose, oat hull fiber, sugar cane fiber, and the like) and, optionally, psyllium. A fiber ingredient can contribute fiber to a food piece described herein in an amount of at least 20% by dry weight of the food piece. A fiber ingredient typically contributes insoluble fiber to a food piece in an amount of about 6% to about 35% (e.g., about 20% to about 28%, or about 20% to about 25%) by dry weight of the food piece.

[0027] Bran is a particularly suitable source of insoluble fiber. As used herein the term “bran” refers to the combined aleurone and pericarp of a cereal grain (e.g., com, wheat, rice, barley, rye, oat, and the like). Insoluble fiber content of a bran suitable for use herein can range from about 40% to about 85% by dry weight. In some embodiments, bran in a food piece can have an average insoluble fiber content of greater than 50% by dry weight of the bran. In some embodiments, bran in a food piece can include bran from a combination of sources. For example, in some embodiments, a bran with an insoluble fiber content of 50% or less by weight (e.g., wheat bran, oat bran, rice bran) and a bran with an insoluble fiber content of greater than 50% (e.g., corn bran, rye bran, barley bran), can be combined at a ratio suitable to achieve an average insoluble fiber content of greater than 50%. For example, com bran and wheat bran can suitably be used at a ratio of about 1 : 1 to about 1 :3 (e.g., about 1 :2). Other components of a bran can include, for example, starch, soluble fiber, protein, and fat.

[0028] In some embodiments, a fiber ingredient can contribute psyllium to a food piece in an amount of up to about 18% (e.g., about 5% to about 18%, or about 6% to about10%) by dry weight of the food piece. Although optional, psyllium can contribute to puffing of a food piece provided herein while also contributing fiber.

[0029] In some embodiments, a food piece provided herein can include a grain flour in an amount of from about 3% to about 30% (e.g., about 4% to about 20%) by dry weight of the food piece. As used herein, a grain flour refers to a food ingredient obtained by grinding a grain (e.g., wheat, com, rice, oat, barley, and the like). In some embodiments, a grain flour alternative can be substituted in-part or fully for a grain flour. Examples of grain flour alternatives can include seed and / or pseudo grain flour (e.g., sunflower, millet, buckwheat, sorghum), tuber flour (e.g., tapioca flour, potato flour, or the like), or the like, or combinations thereof. A grain flour is not limited to finely ground flours, and can include coarse flours such as corn meal and / or com cones. In some embodiments, a suitable grain flour has a particle size where at least 80% of the particles pass through a U.S mesh #40. In some embodiments, a grain flour has a particle size where at least 50% of the particles pass through a U.S. mesh #60. A grain flour referred to herein can be a whole grain flour or a refined flour, however, a grain flour referred to herein does not refer to isolated and / or extracted starches. In some embodiments, at least a portion of a grain flour (e.g., at least 20%, at least 50%, or at least 80% by weight of the grain flour) included in a food piece can comprise a whole grain flour.

[0030] Although a combination of a plant-based protein ingredient and a fiber ingredient can provide nutritional content that some consumers prefer, the combination was found to be difficult to puff to a desired density and texture resembling a traditional grain-based RTE cereal. It was discovered that including a low dextrose equivalent (DE) carbohydrate (e.g., a DE of less than 20, DE of 18 or less, DE of 16 or less, DE of 11 or less, or DE 1 to about 10) in an amount of about 5% to about 30% (e.g., about 6% to about 26%, or about 6% to about 25%) by dry weight of a food piece resulted in the food piece having not only had a desired low density, but a texture and shape that closely resembled traditional grain-based RTE cereals. That is, a food piece provided herein could be made to resemble traditional puffed grain-based RTE cereals, such as a round puff, a rounded “o” shape, a puffed square, and the like, rather than being limited to formats more generally available in high protein RTE cereals (e.g., nuggets, twigs, flakes, and the like). A suitable low DE carbohydrate can include, for example, maltodextrin or a soluble fiber having an average DE of from 1 to 10 (e.g., 1 to about 9, or 1 to about 6). Surprisingly,although starch typically contributes to puffing in traditional low-density grain-based RTE cereals, isolated / extracted starch ingredient could not replace low DE carbohydrate and, when included with insufficient low DE carbohydrate (e.g., less than 5%), resulted in poor puffing, irregular shapes, and / or sharp edges rather than the preferred rounded edges.

[0031] If a grain flour is included in a food piece provided herein, preferably, the combined amount of low DE carbohydrate and grain flour comprises about 18% to about 35% by dry weight of the food piece. If a grain flour is included in a food piece, such a food piece typically comprises at least 80% (e.g., at least 85%, at least 90%, or at least 93%) by dry weight of a combination of a plant-based protein ingredient, a fiber ingredient, a low DE carbohydrate, and the grain flour.

[0032] Density can be adjusted by adjusting the ratios of plant-based protein ingredient, fiber ingredient, and low DE carbohydrate relative to each other. Generally, density can be decreased by increasing the content of low DE carbohydrate. Density of food pieces also generally increased as protein ingredient content increased.

[0033] Additional other ingredients can optionally be included in a combined amount of up to 20% (e.g., up to 18%, less than 10%, or up to 7%) by dry weight of a food piece. For example, a sweetener (e.g., sugar, sugar alcohol, high potency sweetener, or the like) can be included to contribute to flavor / sweetness and / or structure or texture; colorants and / or flavorants (e.g., salt, vanilla, cocoa, cinnamon, natural and / or artificial coloring, or the like) to provide a desired appearance or flavor; oil (e.g., canola oil, corn oil, olive oil, soy oil, sunflower oil, and the like, or any combination thereof) to provide texture and flavor benefits; animal-derived protein ingredients (e.g., casein or caseinate, whey protein, milk powder, egg, and the like) to provide flavor, texture, and / or nutritional benefits; starch (e.g., corn starch, potato starch, tapioca starch, and the like); and / or minors, such as vitamins, minerals, calcium carbonate, processing aids, and the like.

[0034] Food pieces provided herein typically have a moisture content of 5% or less (e.g., about 1% to about 4%, or about 2% to about 3.5%) by weight.

[0035] In addition to a texture very similar to traditional grain-based RTE cereals, the described puffed food pieces can be made to closely visually resemble traditional grain-based RTE cereals, with rounded appearance rather than sharp edges from cutting or irregular shapes due to irregular expansion.

[0036] In some embodiments, a food piece provided herein can have a coating on at least a portion of a surface of the food piece. For example, a sugar-based, sugar alcohol- based, fruit- and / or vegetable-based, or fat-based coating can be applied on at least a surface of a food piece to modify the taste, texture, bowl life (e.g., in a bowl of milk), nutritional profile, and / or appearance of the food piece. In another example, a food piece can be sprayed with oil and a dry seasoning (e.g., cinnamon, sugar, chili, oregano, cocoa powder, or the like, or any combination thereof) can be dusted onto the surface.

[0037] Also provided herein are compositions comprising a plurality of food pieces provided herein. In some embodiments, a composition can contain edible components other than the food pieces provided herein. For example, a composition can comprise dried fruit, nuts, confectionery pieces, grain-based pieces, protein-based pieces, or the like. In some embodiments, a composition can comprise coated food pieces provided herein. A composition comprising coated food pieces can contain pieces that are partially or entirely coated and, in some cases, uncoated pieces as well as coated pieces. A coating in a composition of coated food pieces provided herein can typically comprise about 10% to about 50% (e.g., about 20% to about 40%) by weight of the composition. In some embodiments, a composition comprising coated food pieces can have a bulk density of about 100 to about 300 (e.g., about 120 to about 300, about 150 to about 300, or about 180 to about 280) grams per 100 cubic inches.

[0038] Methods of making food pieces are also provided. Generally, food pieces are produced by combining ingredients under extrusion conditions to form a dough. As used herein, the term “extrusion conditions” refers to subjecting a composition to heat, pressure, and shear in an extruder (e.g., single screw extruder, twin screw extruder, triple screw extruder, ring extruder, or the like). For example, a co-rotating, intermeshing, twin screw extruder can be used in a method provided herein. Manufacturers for co-rotating twin screw extruders include, for example, Coperion, Wenger, Clextral, Berstorff, APV, Baker Perkins, Buhler, and Leistritz.

[0039] In some embodiments, food pieces provided herein can be extruded in a twin screw extruder with a barrel temperature of at least 180° F (e.g., about 220° F to about 350° F). As used herein, the term “barrel temperature” refers to the maximum temperature of a heated barrel of an extruder. In some embodiments, extrusion conditions can comprise a specific mechanical energy (SME) of about 60 to about 150 Wh / kg. Insome embodiments, extrusion conditions can comprise a die pressure of about 720 to about 2200 (e.g., about 1000 to about 1500) psi.

[0040] A dough is typically made in a continuous fashion by feeding ingredients into an extruder during an extrusion process. In some embodiments, dry ingredients can be combined to produce a dry mix prior to being combined with water or other aqueous ingredients and, optionally, oil to produce a composition suitable for extrusion. In some embodiments, dry ingredients and a portion of water can be combined in a preconditioner prior to being fed into an extruder.

[0041] The dough generally contains the ingredients described above with regard to the food pieces. That is, the dough comprises at least 68% by dry weight of a combination of a plant-based protein ingredient, a fiber ingredient, and a low DE carbohydrate. A plant-based protein ingredient is typically included in a dough in an amount of about 25% to about 55% by dry weight of the dough. A fiber ingredient is typically included in a dough in an amount sufficient to contribute fiber in an amount of at least 20% by dry weight of the dough, and contribute insoluble fiber in an amount of about 6% to about 35% by dry weight of the dough. A fiber ingredient can optionally include psyllium in an amount of up to 18% by dry weight of the dough. A low DE carbohydrate is typically included in a dough in an amount of about 5% to about 30% by dry weight of the dough. A dough can optionally include other ingredient in a combined amount of up to 20% by dry weight of the dough.

[0042] A dough produced in a method provided herein includes a moisture content of from about 8% to about 40% (e.g., about 20% to about 40%, or about 25% to about 35%) by weight of the composition.

[0043] The dough can then be extruded from an extrusion die to form dough pieces. In some embodiments, the dough can puff directly upon extrusion from the extrusion die and portioned (e.g., cut) to form puffed dough pieces, and the puffed dough pieces can be dried to a final density of 110 to 200 g per 100 cubic inches. However, in some embodiments, the dough can be indirectly puffed and dried after the dough pieces are formed (e.g., using a fluid bed drier or a puffing gun) to achieve the desired final density and moisture content.

[0044] In some embodiments, food pieces provided herein can have average diameter of from about 8 mm to about 20 mm (e.g., from about 10 mm to about 15 mm).However, the size of a food piece can be adjusted for the desired use of the food piece or to provide a manufacturing advantage. For example, the size of a food piece can be adjusted to provide a desired size for eating as a stand-alone RTE breakfast cereal or snack, or for use as a component in a snack bar or snack mix. In another example, the size of a food piece can be adjusted to result in a desired drying time during manufacturing. Piece size can be adjusted using known methods, such as die opening size and / or die opening shape selection, rate of extrusion, and / or cutter speed. For example, cutter speed can be reduced to form elongated puffed pieces, such as pieces resembling churros or snack straws or sticks.

[0045] In some embodiments, a food piece can be dried to a moisture content of less than 8% (e.g., about 1% to about 7%, less than 6%, or about 2% to about 4%) to produce dried food pieces. Drying can be performed using any suitable method and equipment, such as a belt dryer.

[0046] In some embodiments, food pieces provided herein can be packaged and sold as a food product without any other components. Such packaged food pieces can be intended to be eaten as a food product alone or in combination with other food products. For example, food pieces can be packaged and sold as a stand-alone snack, alone or as part of a RTE breakfast cereal. In some embodiments, a food piece can be adhered with one or more edible components, such as another food piece, nut pieces, fresh or dried fruit pieces, seeds, coconut, grain, and the like, to form a cluster or bar. A food piece and one or more edible components can be adhered to each other using any appropriate method and ingredients (e.g., edible binders and the like). For example, a cluster can be produced using a combination of a food piece and rolled oats adhered using a honey-based binder or slurry. Clusters can be provided as a food product alone or as part of a food product, such as a snack mix, ready to eat cereal, or oatmeal mix.

[0047] It is to be understood that food pieces provided herein can be used for either sweet or savory applications in food. Food pieces disclosed herein can provide a benefit of being a high protein, high fiber stand-alone food product or provide added protein and fiber in combination with other components in food products while also providing an improved texture and flavor over other known high protein, high fiber pieces.EXAMPLESExample 1

[0048] Samples were prepared according to Table 1. Minors included salt, calcium carbonate, sodium bicarbonate, and flavor. The formulations were extruded on a twin screw extruder, to make a dough with a moisture content of about 12% to about 20%, and puffs were made by direct expansion of the dough from the extruder. The moisture of the puffs directly from the extruder (prior to further drying or processing) was about 6% to about 8%. Conditions included a screw speed of about 220 rpm, a barrel temperature of about 250° F, a specific mechanical energy of about 95-110 Wh / kg, and a die pressure of about 1300-2000 psi. The maltodextrin had an average DE of 1. Each formulation was formed using a round die to make sphere-shaped puffs. Formulation 1 produced uniform, regular, rounded pieces. Formulation 2 also produced puffed pieces that were uniform, regular, and consistently rounded on the surfaces. Formulations 1 and 2 had acceptable flavor and texture with a pleasant, clean taste, a crunchy / crispy texture with little to no toothpacking, with Formulation 2 having a softer texture than Formulation 1. Formulations 1 and 2 closely resembled traditional grain-based RTE cereal in appearance and eating experience. Formulation 3 included a lower grain content, higher protein content, including pea protein instead of soy protein. Formulation 3 produced product with a slightly higher density relative to Formulation 1 and exhibited some sharp edges, but remained acceptable in appearance, taste, and texture. Formulation 4 was similar to Formulation 3 but contained higher com meal content and no maltodextrin. Formulation 4 had much higher density and was ragged and irregular in appearance. Formulation 5 was similar to Formulation 1 but contained higher corn meal content and no maltodextrin. Formulation 5 was unacceptably ragged and irregular in appearance. Formulation 6 was similar to Formulation 1, except that it included pea protein instead of soy protein, and contained more maltodextrin. Formulation 6 was slightly higher density, but otherwise similar to Formulation 1 in appearance, taste, and texture.Table 1

[0049] The implementations described above and other implementations are within the scope of the following claims. One skilled in the art will appreciate that the present disclosure can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation.

Claims

What is claimed is:

1. A composition comprising a plurality of food pieces, the food pieces comprising at least 68% by dry weight of a combination of a plant-based protein ingredient, a fiber ingredient, and a low dextrose equivalent (DE) carbohydrate, wherein: a. the plant-based protein ingredient is included in an amount of about 25% to about 55% by dry weight of the food pieces, the protein ingredient comprising pea protein, soybean protein, canola protein, fava bean protein, or chickpea protein and contributing about 18% to about 35% protein content by dry weight of the food pieces; b. the food pieces have a total fiber content of about 25% to about 35% by dry weight of the food pieces, wherein the fiber ingredient contributes fiber in an amount of at least 20% by dry weight of the food pieces and comprises insoluble fiber in an amount of about 6% to about 35% by dry weight of the food pieces; c. the low DE carbohydrate is included in an amount of about 5% to about 30% by dry weight of the food pieces, the low DE carbohydrate having an average DE of from 1 to about 10; d. the food pieces have a moisture content of up to 5% by weight of the food pieces; and e. the food pieces have a bulk density range of from 110 to 200 grams per 100 cubic inches.

2. The composition of claim 1, wherein the fiber ingredient comprises bran.

3. The composition of claim 1 or 2, wherein the food pieces comprise a grain flour in an amount of about 3% to about 30% by dry weight of the food pieces, wherein the combined amount of grain flour and low DE carbohydrate is about 18% to about 35% by dry weight of the food pieces, and wherein a combination of the plantbased protein ingredient, the fiber ingredient, the low DE carbohydrate, and the grain flour comprise at least 80% by dry weight of the food pieces.

4. The composition of claim 3, wherein at least a portion of the grain flour is whole grain.

5. The composition of any one of claims 3-4, wherein the grain flour comprises corn meal.

6. The composition of any one of claims 1-5, wherein the fiber ingredient comprises psyllium in an amount of up to about 18% by dry weight of the food pieces.

7. The composition of any one of claims 1-6, wherein the protein content and the total fiber content are included at a ratio of about 1.5: 1 to about 1 : 1.5.

8. The composition of any of claims 1-7, wherein the food pieces have a total protein content of about 28% to about 32% by dry weight of the food pieces.

9. The composition of any one of claims 1-8, wherein the low DE carbohydrate comprises maltodextrin in an amount of about 10% to about 25% by dry weight of the food pieces.

10. The composition of any one of claims 1-9, wherein the food pieces consist of: a. the plant-based protein ingredient in an amount sufficient to contribute soybean and / or pea protein in an amount of about 28% to about 32% by dry weight of the food pieces; b. the fiber ingredient, wherein the fiber ingredient contributes insoluble fiber in an amount of about 20% to about 25% by dry weight of the food pieces and psyllium in an amount of about 6% to about 10% by dry weight of the food pieces, and wherein the total fiber content is from about 28% to about 32% by dry weight of the food pieces; c. grain flour in an amount of about 4% to about 20% by dry weight of the food pieces, the grain flour comprising com meal; d. the low DE carbohydrate, wherein the low DE carbohydrate has an average DE of from 1 to about 6, and wherein the combined amount of the grainflour and the low DE carbohydrate is about 20% to about 35% by dry weight of the food pieces; and e. other ingredients in an amount of less than 10% by dry weight of the food pieces, wherein the moisture content is 4% or less by weight of the food pieces.

11. A composition, comprising a plurality of coated food pieces, the coated food pieces comprising: a. the plurality of food pieces according to any one of claims 1-10; and b. a coating on at least a portion of a surface of at least a portion of the food pieces.

12. The composition of claim 11, wherein the coating comprises about 10% to about 50% by weight of the coated food pieces.

13. The composition of claim 12, wherein the coated food pieces have a bulk density of about 150 to about 300 grams per 100 cubic inches.

14. The composition, comprising a plurality of food pieces or coated food pieces according to any one of claims 1-13, and edible components other than the food pieces or coated food pieces.

15. A method of making a plurality of food pieces, comprising: a. combining under extrusion conditions ingredients to form a dough having a moisture content of about 8% to about 40%, the ingredients comprising at least 68% by dry weight of a combination of a plant-based protein ingredient, a fiber ingredient, and a low DE carbohydrate, wherein: i. the plant-based protein ingredient is included in an amount of about 25% to about 55% by dry weight of the dough, the protein ingredient comprising pea protein, soybean protein, canola protein,fava bean protein, or chickpea protein, and contributing about 18% to about 35% protein by dry weight of the dough; ii. the fiber ingredient is included in an amount sufficient to contribute fiber in an amount of at least 20% by dry weight of the dough, and comprises insoluble fiber in an amount of about 6% to about 35% by dry weight of the dough; iii. the low DE carbohydrate is included in an amount of about 5% to about 30% by dry weight of the dough, the low DE carbohydrate having an average DE of 1 to about 10; and iv. other ingredients are included in the dough, the combined other ingredients being included in an amount of up to 20% by dry weight of the dough; b. forming the dough from an extrusion die to form dough pieces; c. puffing and drying the dough pieces to form a plurality of food pieces having a bulk density of 110 to 200 grams per 100 cubic inches and a moisture content of 5% or less by weight to form the plurality of food pieces.

16. The method of claim 14, wherein the fiber ingredient comprises psyllium in an amount of up to about 12% by dry weight of the dough, the combined psyllium and insoluble fiber ingredient contributing to a fiber content of about 25% to about 35% by dry weight of the dough, wherein a combination of a grain flour, the plantbased protein ingredient, the insoluble fiber ingredient, and the low DE carbohydrate comprise at least 80% by dry weight of the dough.