Cheese topping for baked snacks suitable for application before baking

Abstract

A cheese slurry suitable for topical application to a snack product prior to baking is disclosed, the cheese slurry comprising: natural cheese powder solids, an emulsifier, oil, water, and pregelatinized starch in amounts effective to provide a crispy topping having the appearance of melted cheese uniformly adhered to the exterior surface of the baked dough product; and up to 1% reducing sugars, polyols, or a combination thereof, and essentially no enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, such that the cheese slurry composition resists undesirable browning and undesirable burning when baked.

Description

Technical Field

[0001] The present application relates generally to cheese toppings suitable for application to snack products prior to baking to provide a baked snack product with a crispy, crunchy, flavorful topping that simulates the appearance of melted cheese. Background Art

[0002] Baked snack products, such as cheese-flavored snack wafers, are extremely popular with consumers. Conventional seasoning techniques typically involve applying seasoning powder to the snack wafers after baking. However, this technique has certain drawbacks. For example, applying seasoning powder to already baked snack wafers results in limited adhesion of the seasoning to the wafers, which reduces flavor intensity and can cause the seasoning to stain consumers' hands during handling.

[0003] Applying seasoning powders to snack wafers before baking also has disadvantages. For example, applying seasoning powders before baking can result in poor adhesion and provide the snack wafers with a hard and undesirable topping texture. Additionally, conventional powders used to season snack wafers, such as cheese powder, have formulations that quickly brown when heated, imparting an undesirable burnt flavor and / or appearance to the snack product.

[0004] Snack products with multiple textures are also popular among consumers. However, conventional seasoning powders, which typically form a powder layer on the surface of the product, cannot provide snack products with a multiple texture appearance. Summary of the Invention

[0005] The present invention describes a cheese slurry composition suitable for topical application to the outer surface of a snack product prior to baking. Upon baking, the slurry composition forms a flavorful, crispy topping or coating that simulates the appearance of melted cheese on the outer surface of the snack product. The cheese slurry composition typically includes cheese powder solids, an emulsifier, oil, water, and pregelatinized starch in an amount effective to provide a generally uniform, crispy topping having the appearance of melted cheese adhered to the outer surface of the baked snack product. The cheese slurry composition includes minimal reducing sugars, polyols, and the like, and substantially no enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, such that the cheese slurry composition resists undesirable browning and undesirable burning when baked.

[0006] The slurries described herein typically include about 5% to about 60% cheese powder solids, about 0.1% to about 1.5% emulsifier, about 35% to about 65% oil, and about 0.25% to 5% pregelatinized starch. Suitable pregelatinized starches are starches that include amylopectin and substantially no amylose. In some methods, the pregelatinized starch can include 100% amylopectin and no amylose. In some methods, the pregelatinized starch is a pregelatinized waxy starch.

[0007] The slurry may also include up to about 5%, in some methods up to about 4%, in some methods up to about 3%, and in some methods up to about 2% added water. In some methods, the slurry may have a total moisture content of no more than about 5%, in some methods no more than about 4%, in some methods no more than about 3%, and in some methods no more than about 2% total moisture from all sources. If the slurry includes too much moisture, the starch in the slurry may gelatinize before the slurry is applied to the dough surface, which may lead to processing difficulties.

[0008] In some methods, the slurry may include 0.05% or less of an acid salt, and in some methods, substantially no food acid is included. The inventors have discovered that using an acid salt instead of conventionally used food acids (e.g., acetic acid, lactic acid) to enhance the full-bodied flavor of a product results in greater flavor enhancement at much lower usage levels. Exemplary acid salts may include, for example, calcium lactate, a crystalline hydrate of calcium lactate, calcium acetate, calcium butyrate, sodium citrate, and combinations thereof.

[0009] Also described herein are baked snack products having a flavorful topping or coating thereon that simulates the appearance of melted cheese. The baked snack product can be obtained by applying a cheese slurry composition as described herein to the outer surface of an unbaked dough component to form a coated unbaked dough component, and baking the coated unbaked dough component to a moisture content of about 5% or less, in some methods about 4% or less, and in some methods about 3% or less, by weight of the final product. In some methods, the cheese slurry composition can form at least about 5% by weight of the baked dough or baked snack product, at least about 10% in some methods, at least about 15% in some methods, and at least about 20% of the final baked snack product in some methods. In some methods, the baked cheese slurry on the surface of the snack product can form up to about 50% by weight of the final baked snack product.

[0010] Cheese slurry compositions are generally obtained by combining slurry ingredients to form a mixture and blending the mixture in a high shear mixer to reduce the particle size of the slurry and break up agglomerates. High shear mixing also improves the dispersion of solids in the slurry and reduces undesirable oil separation. In some methods, the slurry may be contained in a reservoir configured to continuously stir the slurry and maintain it at a suitable temperature to minimize separation and / or delamination prior to application to the outer surface of the dough component.

[0011] The dough component may comprise any dough suitable for application in snack products. In some methods, the dough component may be pancake dough or biscuit dough. In other methods, the dough component may be cookie dough. The dough component may be obtained by combining and mixing the dough ingredients in a mixer, feeding the dough through a sheeting machine into a metering section to form a thin sheet of dough, and feeding the sheet of dough through a rotating shearing blade to cut the dough sheet into individual pieces. A slurry is then applied uniformly to the outer surfaces of the dough pieces to form a coated, unbaked dough component. The slurry can be applied to the dough component using any suitable technique. The coated, unbaked dough component is then baked to a moisture content of approximately 5% or less.

[0012] The slurry, applied to the dough before baking, achieves excellent adhesion and uniform coverage on the exterior surface of the baked snack product. The slurry forms a crispy, flavorful topping layer that blends into the snack product, providing a unique appearance, texture, and flavor intensity. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a front perspective view of an exemplary multi-textured baked snack product having a flavorful topping or coating thereon that simulates the appearance of melted cheese.

[0014] Figure 2 is a front view of an exemplary multi-textured baked snack product having a flavorful topping or coating thereon that simulates the appearance of melted cheese.

[0015] Figure 3 A flow chart of an exemplary method of making a multi-textured baked snack product having a flavorful topping or coating thereon that simulates the appearance of melted cheese.

[0016] Figure 4 is a block diagram of a system for preparing a cheese slurry composition suitable for topical application to an exterior surface of a snack product prior to baking.

[0017] Figure 5 is a block diagram of a system for preparing a multi-textured baked snack product having a flavorful topping or coating thereon that simulates the appearance of melted cheese.

[0018] Figure 6 is a graph illustrating the consistency of cheese solids in exemplary cheese slurry compositions.

[0019] Figure 7 Graph showing the homogeneity of an exemplary cheese slurry composition using NIR (near infrared spectroscopy).

[0020] Figure 8 Graphs comparing viscosity as a function of temperature for exemplary cheese slurries having 40% cheese solids.

[0021] Figure 9 The graphs compare the viscosity of cheese slurries with 40% cheese solids as a function of the addition of recipe water.

[0022] Figure 10 Shown is starch gelatinization of a cheese slurry having 40% cheese solids with the addition of 10% recipe water.

[0023] Figure 11 FIG2 is a graph comparing the viscosity of various exemplary cheese slurry compositions as a function of cheese solids at 113°F.

[0024] Figure 12 FIG2 is a graph comparing the viscosity of four exemplary cheese slurry compositions as a function of cheese powder solids and temperature.

[0025] Figure 13 Graphs comparing the viscosity of exemplary yellow cheddar cheese slurry compositions as a function of cheese powder solids and temperature.

[0026] Figure 14 Graphs comparing the viscosity of exemplary white cheddar cheese slurry compositions as a function of cheese powder solids and temperature.

[0027] Figure 15 FIG2 is a graph comparing the viscosity of exemplary yellow cheddar cheese slurry compositions as a function of cheese powder solids at 113°F. DETAILED DESCRIPTION

[0028] Reference will now be made to certain detailed aspects of the various embodiments of the present disclosure. It should be understood that the disclosed embodiments are merely illustrative of the present invention, which may be embodied in numerous forms and alternatives. Therefore, the specific details disclosed herein should not be construed as limiting, but rather merely as a representative basis for any aspect of the present invention and / or as a representative basis for teaching those skilled in the art to apply the present invention in various ways.

[0029] Except in the examples, or where otherwise expressly indicated, all quantities in this specification indicating amounts of material and / or amounts used are to be understood as modified by the word “about” when describing the broadest scope of the invention. It is generally preferred to practice within the numerical ranges recited.

[0030] It should also be understood that the present invention is not limited to the specific embodiments and methods described below, as specific components and / or conditions may of course vary. In addition, the terminology used herein is only used to describe specific embodiments of the present invention and is not intended to be limiting in any way.

[0031] It must also be noted that, as used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. For example, reference to an element in the singular is intended to include plural elements.

[0032] Unless otherwise indicated, percentages used herein are by weight.

[0033] The cheese slurry compositions described herein, suitable for topical application to the exterior surface of a snack product prior to baking, solve many of the problems associated with conventional seasonings applied topically to snack products. Food powders, such as seasoning powders, are typically applied to snacks after baking. When applied after baking, these conventional food powders often exhibit limited adhesion to the snack surface (e.g., less than 20% of the product weight) and inconsistent coatings, and have also been found to stick to processing equipment, hands, and the like. While in some cases, adhesion of food powders applied after baking can be improved by dispersing the food powder in a water-in-oil emulsion, this technique can alter the texture of the snack product and shorten its shelf life, and may require an additional drying step.

[0034] Applying conventional food powders before baking also presents challenges. For example, when topically applied to snack dough before baking, many food powders (such as dairy powder and cheese powder) fail due to burning, bubbling, and the formation of an undesirable hard topping texture and / or poor adhesion. Typical cheese powders used to season pancakes have recipe ingredients that quickly turn brown when heated, such as enzyme-modified cheese, buttermilk, whey, maltodextrin, yeast extract, lactose, and acid. Due to the large amount of reducing sugars in these powders, sweet food powders (such as fruit-based powders) can also experience undesirable browning and burning during baking.

[0035] To address the aforementioned challenges, the inventors have developed a cheese slurry composition suitable for topical application to the exterior surface of a snack product prior to baking. The cheese slurry composition generally includes cheese powder solids, an emulsifier, oil, water, and pregelatinized starch in amounts effective to provide a generally uniform, crispy topping with the appearance of melted cheese adhered to the exterior surface of the baked snack product. The cheese slurry composition enables excellent adhesion and uniform coverage of up to 50% weight / weight topping on the finished snack product. And because the slurry includes minimal amounts of reducing sugars, polyols, and the like and essentially no enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, the undesirable browning and burning often encountered when cheese powder is applied prior to baking can be avoided. The inventors also unexpectedly discovered that using acid salts instead of conventionally used food acids to enhance the product's rich cheese and dairy flavors results in greater flavor enhancement at much lower usage levels compared to food acids.

[0036] Cheese slurry compositions as described herein typically include about 30% to about 60% natural cheese powder solids, in some methods include about 35% to about 60% natural cheese powder solids, and in some methods include about 40% to about 55% natural cheese powder solids. Conventional cheese powder typically includes natural cheese, milk (e.g., buttermilk, skim milk powder), protein (e.g., whey), extender / carrier (e.g., maltodextrin, flour, gum, etc.), and flavoring (e.g., spices, acid, yeast extract, etc.). The inventors have found that using these conventional cheese powders to form a pre-baking slurry results in burnt milk protein and / or reducing sugars (e.g., lactose) during the baking process. Reducing sugars are sugars that include free aldehyde or ketone groups, which allow sugars to act as reducing agents. Examples of reducing sugars include, but are not limited to, glucose, fructose, lactose, galactose, ribose, xylose, maltose, and arabinose. The presence of reducing sugars in products intended for baking may pose a challenge. For example, heating reducing sugars during baking may result in undesirable caramelization of the sugar. Additionally, reducing sugars tend to interact with proteins and produce Maillard reaction products, which can lead to gradual browning and flavor development. It is also believed that ingredients such as yeast extract, enzyme-modified cheese, and flavor acids present in conventional cheese powder solids contribute to browning during baking.

[0037] The natural cheese powder solids used to form the cheese slurry composition described herein have 1% or less reducing sugars, polyols, etc., and substantially no enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, resulting in a baked snack having a desired cheese flavor after baking without undesirable browning or burning. The natural cheese included in the natural cheese powder solids can be derived from any natural cheese or combination thereof, including but not limited to yellow cheddar, white cheddar, four-flavor cheese, Gouda, Muenster, Parmesan, Romano, and combinations thereof. In some methods, the natural cheese powder solids can include cream cheese solids.

[0038] The amount of cheese powder solids in the slurry is selected to provide a desired non-powdery texture while also providing the slurry with a viscosity suitable for processing and applying to the dough component. In some cases, a slurry with a lower amount of cheese solids may have a faster settling rate, which may result in the slurry having a powdery texture. Although a slurry with a higher amount of cheese solids may have a slower settling rate, the viscosity of the slurry also increases as the solids content increases, which may cause processing problems. In some methods, the temperature of the slurry with a higher solids content may be increased to reduce the viscosity to a viscosity suitable for processing. In some methods, the optimal solids content for slowing down the settling and controlling the viscosity may be different for different types of cheese powder solids. For example, as shown in Example 5, cheese slurry compositions comprising different types of natural cheese powder solids (yellow cheddar, white cheddar, four-flavor cheese) have different viscosities at a given temperature.

[0039] Food acids such as, for example, acetic acid and lactic acid can also cause undesirable browning and burning. Therefore, in some methods, the cheese slurry compositions described herein may be substantially free of food acids. The slurry may include 0.05% or less of an acid salt to enhance the rich and / or acidic flavor that may be lost by reducing the use of food acids. Exemplary acid salts may include, but are not limited to, calcium lactate, crystalline hydrates of calcium lactate, calcium acetate, calcium butyrate, sodium citrate, and combinations thereof. The inventors have discovered that using acid salts instead of conventionally used food acids to enhance the rich and acidic flavor of the product results in more flavor enhancement at much lower usage levels without affecting the appearance or rheology of the slurry, while also reducing the risk of undesirable browning and burning. The inventors have also discovered that the addition of acid salts acts to replace some of the acidic flavor intensity that may be lost due to excluding and / or removing ingredients such as enzyme-modified cheese from the cheese powder or slurry composition.

[0040] The cheese slurry composition also includes one or more vegetable oils. Exemplary oils may include, for example, coconut oil, palm kernel oil, soybean oil, palm oil, sunflower oil, corn oil, canola oil, high oleic canola oil, cottonseed oil, peanut oil, and combinations thereof. The slurry may include from about 35% to about 65% oil, in some methods from about 40% to about 60% oil, and in some methods from about 42% to about 58% oil. The oil serves as a carrier to deliver the suspended cheese powder solids to the surface of the dough component.

[0041] The cheese slurry composition may include a small amount of water. The slurry composition may include up to about 5%, in some methods up to about 4%, in some methods up to about 3%, and in some methods up to about 2% added water. The amount of added water may be based on, for example, the amount of moisture provided by one or more slurry ingredients. For example, if a higher moisture ingredient is added to the slurry, the amount of added water may be reduced to ensure a suitable slurry moisture content. In some methods, the slurry may not include added water, for example, when other slurry ingredients provide sufficient moisture. In some methods, the slurry may have a total moisture content of no more than about 5%, in some methods no more than about 4%, in some methods no more than about 3%, and in some methods no more than about 2% of the total moisture from all sources.

[0042] As shown in Example 4 below, increasing the water content of the recipe above 5% was found to increase slurry viscosity due to starch gelatinization. The inventors also discovered that the water content of the slurry can affect the browning rate of the slurry and the baking rate of the snack product. Specifically, the inventors found that for every 1% of added water, the final moisture content of the final product increased by approximately 0.36%, requiring longer baking times and / or higher baking temperatures to achieve a target moisture content of 5% or less. Therefore, the amount of water added to the slurry is carefully selected to avoid gelatinization during processing and minimize baking time to avoid undesirable textures and flavors in the final baked product.

[0043] The starch included in the cheese slurry composition is pregelatinized starch. The slurry includes about 0.25% to about 5% pregelatinized starch. Adding too much starch to the cheese slurry can undesirably reduce the flavor intensity of the slurry in the final baked product. During the early baking stages of a snack product, when the cheese slurry including pregelatinized starch is topically applied to the dough component, moisture escaping the dough "activates" or expands the pregelatinized starch into an elastic matrix, resulting in a crispy, textured topping in which the cheese powder is retained in a generally uniform, crispy, flavorful topping that adheres to the baked snack. Pregelatinized starches are ideal for this purpose because they require less water to gel and support shorter baking times, thereby reducing the risk of undesirable browning. Preferably, the pregelatinized starch has a low hydration capacity, allowing available water to boil off during baking, thereby providing the baked slurry with a bubbly texture similar to melted cheese on the surface of the snack. Suitable pregelatinized starches preferably include amylopectin and are substantially free of amylose. In some methods, the pregelatinized starch can include 100% amylopectin and no amylose. In some methods, the pregelatinized starch is a waxy starch.

[0044] The cheese slurry composition may also include one or more emulsifiers in a total amount of about 0.1% to about 1.5%. Suitable emulsifiers may include, but are not limited to, lecithin, monoglycerides, diglycerides, polyglycerol esters (PGE), calcium stearoyl lactylate, and combinations thereof.

[0045] The slurries described herein may include additional ingredients such as flavorings, spices, herbs, seasonings, gums, fillers, and the like, provided that the cheese slurry maintains minimal amounts of reducing sugars, polyols, and the like, and does not substantially include enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, such that the cheese slurry composition resists browning and scorching when baked.

[0046] In some methods, the cheese slurry composition may include a fruit or vegetable component. The fruit or vegetable component may include any ingredient suitable for baking based on fruit or vegetables. For example, the fruit or vegetable component may include fruit or vegetable powder, dried fruit or vegetables, reconstituted fruit or vegetables, concentrates, crumbs, purees, pastes, fruit or vegetable fibers, fillers, and combinations thereof. Suitable fruit or vegetable components are resistant to browning and scorching when baking, and preferably include less than 1% reducing sugars. In some methods, the fruit component may be a low-moisture, baking-stable fruit filler that is resistant to browning and scorching when baking. The baking-stable fruit filler may include other ingredients so that they have baking stability, such as starch, modified starch, flour, pectin, fruit solids, sugar solids, and other hydrophilic colloids, including but not limited to xanthan gum and alginate, etc. In some methods, the baking-stable filler may include one or more fruit acids, such as, for example, citric acid and / or malic acid, which, compared with, for example, tartaric acid, have a lower tendency to scorch during baking. The fruit acid included in the fruit filling is generally located within the matrix of the fruit filling, thereby further reducing the risk of undesirable browning due to the fruit acid. In some methods, the fruit or vegetable component can be incorporated into the cheese slurry composition. In some methods, the fruit or vegetable component can be separately dripped or swirled onto the surface of the slurry applied to the dough component before baking.

[0047] The slurries described herein can have a variety of flavor profiles, making them suitable for a wide variety of savory, non-sweet, and sweet baked snack products. For example, the slurries can have a savory, cheesy flavor profile consistent with the flavor of natural cheeses, such as cheddar cheese. Such cheese slurries can be used as a coating or topping on wafers to form baked cheese snacks.

[0048] In another example, the cheese slurry can have a flavor profile similar to cream cheese. The cream cheese slurry can be used as a topping or coating on pancakes, crackers, cookies, cereal bars, or other baked products. In some methods, the cream cheese slurry can include a bake-stable fruit component. In one method, the bake-stable fruit component can be a bake-stable low-moisture filler as described above. The filler can be, for example, a blueberry or strawberry filler. The cream cheese slurry that includes the fruit component can have a sweeter flavor profile than a similar cream cheese slurry that does not include the fruit component, and therefore can be particularly suitable for sweet baked snack products such as cookies or cereal bars.

[0049] The cheese slurry compositions described herein are generally obtained by combining slurry ingredients to form a mixture, and blending the mixture in a high shear mixer to reduce the particle size of the slurry and break up agglomerates. Exemplary ingredient ranges for cheese slurry compositions suitable for topical application to baked snack products prior to baking are provided in Table 1.

[0050] Table 1

[0051] Element Formulation % (Range 1) Formulation % (Range 1) Formulation % (Range 1) Natural cheese powder solid 30-60 35-60 40-55 vegetable oil 35-65 40-60 42-58 water 0-5 0.1-3 0.25-2 Pregelatinized starch 0.25-5 0.25-4 0.25-3 emulsifiers 0.1-1.5 0.1-1.5 0.1-1.5 acid salt 0-0.05 0-0.05 0-0.05

[0052] An exemplary formulation for a cheese slurry composition having approximately 40% cheese powder solids is provided in Table 2.

[0053] Table 2

[0054] Element Dry weight basis % formula% Pregelatinized starch 1.19 2.46 water 0.00 1.07 calcium lactate 0.02 0.05 vegetable oil 29.40 56.02 Lecithin 0.36 0.69 Cheese powder 20.01 39.71

[0055] An exemplary formulation for a cheese slurry composition having approximately 48% cheese powder solids is provided in Table 3.

[0056] Table 3

[0057] Element Dry weight basis % formula% Pregelatinized starch 1.19 2.46 water 0.00 1.07 calcium lactate 0.02 0.05 vegetable oil 25.03 47.69 Lecithin 0.36 0.69 Cheese powder 24.20 48.04

[0058] Because cheese slurry compositions resist undesirable browning and undesirable burning when baked, they can be applied to the exterior surfaces of dough components prior to baking to form baked snack products having a flavorful topping or coating that simulates the appearance of melted cheese.

[0059] The dough component can include any dough composition suitable for baking. The dough component's formulation is not particularly limited, provided that the dough component contains sufficient moisture to "activate" or expand the pregelatinized starch in the slurry as the moisture in the dough evaporates into the slurry on the dough. The activated starch in the slurry forms an elastic matrix, in which the cheese powder is retained in a uniform, crispy, and flavorful topping that adheres to the baked snack. In some methods, the dough component can be a non-sweet or savory dough, such as, for example, a pancake dough. In other methods, the dough component can be a sweet dough, such as, for example, a cookie dough.

[0060] In some embodiments, the baked snack product can have a sweet dough component, and the cheese slurry applied to the outer surface of the dough component prior to baking can include cream cheese solids and an optional fruit component.

[0061] Figure 1 and Figure 2An exemplary, non-limiting example of a baked snack product 100 is shown, in which a baked cheese slurry composition forms a multi-textured topping 110 on the surface of a dough component 120. As discussed, the moisture in the dough component activates the starch in the slurry during baking to form a topping having an air bubble texture 130 that simulates the appearance of melted cheese on the surface of the snack product. In some methods, the baked cheese slurry on the surface of the snack product comprises at least about 5% by weight of the final baked snack product, in some methods at least about 10% by weight, in some methods at least about 15% by weight, and in some methods at least about 20% by weight of the final baked snack product. In some methods, the baked cheese slurry on the surface of the snack product may comprise up to about 50% by weight of the final baked snack product. Baked snack products generally have a final moisture content of about 5% or less, in some methods about 4% or less, and in some methods about 3% or less, by weight of the final product.

[0062] The final baked snack product can have any suitable thickness or shape, depending on, for example, the nature of the product, the desired texture and / or mouthfeel, the formulation of the dough components, the intended use of the product, process and / or machine limitations, etc.

[0063] An exemplary method 200 for preparing a baked snack product having a flavorful topping or coating is shown in FIG. Figure 3In step 210, the slurry composition comprising natural cheese powder solids, emulsifier, oil, water and pregelatinized starch (together with any other ingredients) is combined. In some methods, dry ingredients (e.g., natural cheese powder solids, pregelatinized starch, etc.) can be dry mixed, and water, oil and emulsifier can be premixed separately before being combined with the dry mixed mixture. In step 220, the combined ingredients are mixed in a high shear mixer. High shear mixing is used to reduce the particle size of the slurry mixture and to break up the agglomerates, and also improves the dispersibility of the solids in the slurry and reduces undesirable oil separation. Suitable high shear mixing devices include, for example, high-speed rotor mixers, mixers with serrated disperser blades, and other mixing devices that can effectively reduce the particle size of the slurry mixture and to break up the agglomerates, improve the dispersibility of the solids in the slurry and reduce undesirable oil separation. After high shear mixing, the slurry is usually pumped into a holding tank associated with the slurry application unit. In some methods, the mixed slurry can be contained in a slurry reservoir tank that is configured to continuously stir the slurry and maintain it at a suitable temperature to minimize separation and / or delamination prior to application to the outer surface of the dough components. For example, in some methods, the slurry can be maintained at a temperature of about 100°F to about 125°F, and in some methods, the slurry can be maintained at a temperature of about 110°F. In some methods, the cheese slurry can have a water content (Aw) of 0.30 to about 0.50 prior to application.

[0064] A dough component is provided in step 230. The dough component is typically an unbaked dough component that may be cut and / or formed into individual pieces. In step 240, a slurry is applied to the outer surface of the dough component. The slurry may be applied to the dough component using any topping or liquid application system or technique that effectively achieves the desired coverage, adhesion, appearance, texture, etc., such as, but not limited to, roller coating, throwing, spraying, dripping, waterfall applicators, and the like.

[0065] In some methods, the slurry can be applied to the dough components using, for example, a rotating disk or dispersing drum to create a wide spray pattern oriented perpendicular to the direction of travel of the dough components. The slurry is applied to achieve, for example, a suitable dough coverage of between about 5% and about 55% by weight of the unbaked dough-slurry combination. In some methods, the slurry has a temperature of about 100°F to about 125°F during application to the outer surface of the dough piece, and in some methods, a temperature of about 110°F. Preferably, the dough piece is maintained at a temperature between 75°F and 105°F during application of the slurry to facilitate uniform slurry coverage and so that the slurry will be able to migrate smoothly onto the surface of the dough piece.

[0066] In step 250, the coated dough component is baked to a moisture content of 5% or less. In some methods, the coated dough component is baked to a moisture content of about 4% or less, and in some methods, about 3% or less. In some methods, the coated dough pieces can be baked at a temperature of about 375°F for about 5 minutes to achieve the desired final moisture content.

[0067] Applying the cheese slurry composition to the dough before baking achieves excellent adhesion and uniform coverage on the outer surface of the baked snack product. In some methods, the baked cheese slurry on the surface of the snack product comprises at least about 5% by weight of the finished baked snack product, in some methods at least about 10% by weight, in some methods at least about 15% by weight, and in some methods at least about 20% by weight of the finished baked snack product. In some methods, the baked cheese slurry on the surface of the snack product may comprise up to about 50% by weight of the finished baked snack product.

[0068] This article also combines Figure 4 and Figure 5 A system 300 is described for preparing a baked snack product having a flavorful topping or coating that simulates the appearance of melted cheese. Figure 4 As shown, a slurry can be formed by combining effective amounts of natural cheese powder solids, an emulsifier, oil, water, and pregelatinized starch. In one method, as Figure 4 As shown, natural cheese powder solids and pregelatinized starch (along with optional additional dry ingredients) can be dry mixed in a first premixer (301a), while water, oil, and emulsifier can be premixed in a second premixer (301b) and then combined in a high shear mixer 302, where the combined ingredients are further mixed under high shear. High shear mixing serves to reduce the particle size of the slurry mixture and break up agglomerates, and also improves the dispersion of solids in the slurry and reduces undesirable oil separation. After high shear mixing, the slurry is transferred to a slurry application unit 303 for application to the outer surface of the dough component.

[0069] The cheese slurry is generally pumped from the mixing tank to the holding tank associated with the slurry application unit on the pipeline by pump feeding, which may be challenging for higher solids / higher viscosity slurries. The inventors have found that some cheese slurry formulations (especially those with higher solids content) have higher viscosities, which can clog the processing lines of the system. Therefore, the slurry can be heated to achieve a viscosity suitable for processing and application. For example, a cheese slurry with a cheese solids content of about 40% to about 55% can be heated or otherwise maintained at a temperature of about 75°F to 131°F to achieve, for example, a viscosity of about 200 cP to about 5000 cP. In some methods, it is preferred that the cheese slurry have a viscosity of about 2000 cP or less. In order to balance solid sedimentation but achieve easy flowability, in some methods, a cheese slurry with a higher solids content can be heated at a temperature sufficient to achieve a viscosity of about 1200 cP to about 2000 cP. In some methods, the slurry may be heated to a temperature of about 100° F. to about 125° F. during processing and / or application to facilitate a balance between low solids settling and viscosity, and in some methods, the temperature is about 110° F. In other methods, the slurry may have a suitable viscosity at ambient or room temperature such that heating of the slurry during processing and / or application is not required.

[0070] refer to Figure 4 The dough components can be obtained by combining and mixing dough ingredients 304 in a dough mixer 305. Any suitable dough mixer can be used. The dough mixture is then fed through a sheeter 306 to form a thin, sheeted dough. In some methods, the sheeted dough may optionally be fed through a laminator 307 and may undergo multiple laminations (e.g., up to six laminations). The dough sheet is fed through one or more metering rollers 308, and when it reaches the desired thinness, it is fed to a rotating shear 309 to cut the dough sheet into individual pieces. In some methods, the dough components may have a thickness of, for example, approximately 25 mm before the slurry is applied. The dough pieces are then conveyed to the inlet of a slurry application unit 303, where the slurry is applied to the dough pieces in a uniform manner to achieve a desired dough coverage, for example, between about 5% and about 55% by weight of the unbaked dough-slurry combination. Preferably, the dough pieces are maintained at a temperature between 75°F and 105°F during slurry application to facilitate even slurry coverage, and so the slurry will be able to migrate smoothly onto the surface of the dough pieces.

[0071] The slurry application unit 303 may include any application system that effectively achieves the desired coverage, adhesion, appearance, texture, etc., such as, but not limited to, a roller coater, a throw coater, a spray coater, a drip coater, a waterfall applicator, and the like. In some methods, the slurry application unit 303 utilizes a rotating disk or a dispersing drum to produce a wide spray pattern oriented perpendicular to the direction of travel of the dough components. The rotating disk or dispersing drum atomizes the slurry solution by using the mechanical energy of a motor to rotate the disk or drum, thereby generating centrifugal force to apply the slurry to the product. It should be understood that other application techniques may also be used.

[0072] In some methods, the slurry application unit 303 may include a reservoir tank that holds the slurry and has a small agitator to prevent slurry separation and / or minimize stratification. The slurry application unit may be jacketed to maintain the slurry solution at an appropriate temperature to minimize the risk of clogging the slurry applicator and the lines draining the surface. For example, in some methods, the slurry may be maintained at a temperature of about 100°F to about 125°F, and in some methods at a temperature of about 110°F. The slurry pump should be of a suitable configuration and have a sufficient flow rate to keep the solids in suspension, facilitate uniform slurry application, and prevent slurry carbonization and agglomeration. Additional factors that may affect slurry application include the percentage of solids in the slurry, the particle size of the solids, the amount of fat and / or sugar in the slurry, the glass transition temperature of the various components, and the temperature of the slurry.

[0073] The slurry application unit 303 applies slurry to the dough pieces in a uniform manner to achieve suitable dough coverage, for example, between about 5% to about 55% by weight of the unbaked dough-slurry combination.

[0074] After the slurry is applied to the dough pieces, the coated dough pieces are baked in a suitable oven 310 to a moisture content of about 5% or less, in some methods about 4% or less, and in some methods about 3% or less. In some methods, the coated dough pieces can be baked at a temperature of about 375°F for about 5 minutes to achieve the desired final moisture content. The baked snack product is then cooled to a desired temperature using any suitable technique, such as, for example, ambient cooling or refrigerated cooling 311.

[0075] The cheese slurry composition described herein, which includes minimal reducing sugars, polyols, and the like, and essentially excludes enzyme-modified cheese, buttermilk, whey, maltodextrin, and yeast extract, enables the topical application of natural cheese powder solids to snack products before baking, while minimizing the risk of undesirable browning and burning often encountered with cheese powder applied before baking. The ability to apply the cheese slurry before baking is of significant importance. During baking, moisture in the dough interacts with the pregelatinized starch in the slurry to form an elastic matrix comprising the cheese powder solids. After baking, the elastic matrix comprising the cheese powder solids fuses to the surface of the dough, resulting in increased adhesion and coverage of the cheese solids on the snack product. The interaction between the moisture in the dough and the pregelatinized starch in the slurry also results in a topping with the appearance of melted cheese. Furthermore, reducing the use of food acids, which are prone to browning and burning, in the slurry and replacing them with much lower levels of acid salts can provide greater flavor intensity. The result is a baked snack product with a crispy, flavorful topping layer that fuses into the snack product, providing a unique appearance, texture, and flavor intensity.

[0076] A better understanding of the present disclosure and its many advantages can be illustrated by the following examples. The following examples are illustrative and are not limiting in scope or substance. Those skilled in the art will readily appreciate that variations of the components, methods, steps, and apparatus described in these examples may be used. Unless otherwise indicated, all percentages, ratios, and parts mentioned in this disclosure are by weight.

[0077] Example

[0078] Example 1: Cheese Slurry Solids Consistency

[0079] On the bench top, cheese slurry compositions were formed by combining oil, lecithin, water, cheddar cheese powder solids, and pregelatinized starch in the amounts listed in Table 5 below in a spackl mixer and then mixing in a high shear mixer (OLSA, Breddo Likwifier).

[0080] Table 5

[0081] Element Dry weight basis % formula% Pregelatinized starch 2.48 2.64 water 0.00 0.26 lactic acid 0.01 0.014 vegetable oil 53.96 52.77 Lecithin 0.72 0.7 Cheese powder 42.82 43.62

[0082] The slurry also included 1.250% sodium and 7.5% protein to assess slurry solids consistency.The slurry was transferred to a slurry application unit equipped with a dispersion drum (General Oil Equipment, Variable Profile Liquid Spray System).

[0083] The cheese slurry solids consistency provided by the slurry application unit was evaluated by analyzing the sodium and protein concentrations in the slurry. Samples were collected over a one hour period. The results are shown in Figure 6 The sodium and protein concentrations were initially lower (1030 mg / 100 g; 6.38%) compared to the fresh mixed slurry (1250 mg / 100 g; 7.5%). Subsequent samples had higher sodium and protein contents. The sodium of these samples ranged from 1350 mg / 100 g to 1940 mg / 100 g, and the protein ranged from 8.55% to 9.26%. The inventors found that the sodium and protein contents were initially lower due to insufficient circulation after the pump was clogged. Figure 6 As shown in Table 6, the protein concentration then stabilized to an average of 8.9% + / - 0.3%. Similar to the protein, the sodium concentration was initially low due to insufficient recirculation after the pump clogged. After the initial point, the sodium stabilized to an average of 1.7% + / - 0.250%. The inventors have found that, preferably, the slurry application unit sprayer should pump / recirculate for at least 20 minutes after a significant pump clog to resuspend the solids and ensure consistent solids coverage.

[0084] Table 6

[0085] time Sodium (mg / 100g) protein(%) Average sodium Average protein Standard Deviation Fresh mixture 1250.00 7.50 11:00 AM 1030.00 6.38 11:10 AM 1780.00 9.26 1700.00 250 11:25 AM 1940.00 8.92 8.91 0.29 11:40 AM 1730.00 8.55 12:00 PM 1350.00 8.89

[0086] In addition, near infrared spectroscopy (NIR) measurement of protein was used as an "online" tool to measure the homogeneity of cheese slurry solids. Six slurry samples were scanned by NIR in the wavelength range of 1400nm to 1650nm to ensure that the amide bands were collected. The absorbance values ​​of the six slurry samples collected correlated with the analytical protein values ​​with Rsq = 0.993 and SECV of + / - 0.163, as shown in Figure 2. Figure 7 shown.

[0087] The data presented herein demonstrate that the use of a slurry application unit equipped with a dispersing drum can advantageously maintain a homogeneous dispersion of cheese solids in the slurry.

[0088] Example 2: Slurry Coverage Consistency

[0089] The slurry from Example 1 was collected on a tray below the applicator, and the slurry weight was recorded. Samples were collected over a one-hour period. As shown in Table 7, the slurry delivery weight was consistent over the one-hour test period, with a standard deviation in the delivered weight ranging from 2% to 6%, depending on the spray pattern setting.

[0090] Table 7

[0091]

[0092]

[0093] Example 3: Changes in cheese slurry viscosity with temperature

[0094] According to the recipe provided in Table 5 above, a cheese slurry composition having 40% cheese solids was prepared. 25 ml of the cheese slurry sample was stirred at 160 rpm and equilibrated at 35°C (95°F), 46°C (115°F), and 56°C (133°F) before viscosity testing using a rapid viscometer (Perten, Model 4500). The viscosity results, reported in cP, are provided in Tables 8 and 9 below. Figure 8 A 5,000 cP (25°C) silicone viscosity standard solution was also tested for reference.

[0095] Table 8

[0096]

[0097] These data illustrate that increasing the temperature of a cheese slurry having 40% cheese solids to temperatures as high as 133°F reduces the slurry viscosity.

[0098] Example 4: Changes in starch gelatinization with formula water

[0099] In this example, a cheese slurry composition having the recipe provided in Table 9 was prepared.

[0100] Table 9

[0101] Element formula% Pregelatinized starch 2.46 water 1.07 calcium lactate 0.05 vegetable oil 56.02 Lecithin 0.69 Cheese powder 39.71

[0102] Water was added to a cheese slurry composition having approximately 40% cheese solids at 1%, 2%, 3%, 11.7%, and 19.5% of the formula weight. The viscosity of a 25 ml sample of the slurry composition was measured at 35° C. using a rapid viscometer (Perten, Model 4500) while stirring continuously at 160 rpm at a constant temperature. Figure 9 As shown in Figure 2, as the water content of the slurry increases from 1% to 5%, the slurry viscosity increases from 380 cP to 400 cP, and when the water content exceeds 5%, the slurry viscosity increases significantly. Increasing the water content from 3% to 10% increases the viscosity from 320 cP to as much as 580 cP and starch gelatinization occurs, as shown in Figure 2. Figure 10 shown.

[0103] Example 5: Viscosity Variation with Cheese Powder Solids and Temperature

[0104] According to the recipes provided in Table 10 below, cheese slurries comprising yellow cheddar, white cheddar, and one of four cheese powder solids were prepared at 40% cheese powder solids. According to the recipes in Tables 11, 12, and 13 below, cheese slurries comprising yellow cheddar, white cheddar, and one of four cheese powder solids were prepared at 46.4% cheese powder solids, 49.2% cheese powder solids, or 53.2% cheese powder solids by removing the oil from the recipe in Table 10 and adding additional cheese powder. All other ingredient compositions remained unchanged.

[0105] Table 10

[0106] Cheese slurry with 39.7% cheese powder solids

[0107] Element formula% Pregelatinized starch 2.46 water 1.07 calcium lactate 0.05 vegetable oil 56.02 Lecithin 0.69 Cheese powder 39.71

[0108] Table 11

[0109] Cheese slurry with 46.4% cheese powder solids

[0110] Element formula% Pregelatinized starch 2.46 water 1.07 calcium lactate 0.05 vegetable oil 49.30 Lecithin 0.69 Cheese powder 46.43

[0111] Table 12

[0112] Cheese slurry with 49.6% cheese powder solids

[0113] Element formula% Pregelatinized starch 2.46 water 1.07 calcium lactate 0.05 vegetable oil 46.17 Lecithin 0.69 Cheese powder 49.55

[0114] Table 13

[0115] Cheese slurry with 53.7% cheese powder solids

[0116] Element formula% Pregelatinized starch 2.46 water 1.07 calcium lactate 0.05 vegetable oil 42.02 Lecithin 0.69 Cheese powder 53.70

[0117] The viscosity of the cheese slurry was tested using a rapid viscoanalyzer (Perten, Model 4500) while stirring continuously at 160 rpm at a constant temperature. Three temperatures were tested: 35°C (95°F), 45°C (113°F), and 55°C (131°F).

[0118] Figure 11 As shown, 46.4% cheese solids resulted in a yellow cheddar viscosity of 525 cP at 113°F, a four-flavor cheese viscosity of 1000 cP at 113°F, and a white cheddar viscosity of 1500 cP at 113°F.

[0119] The viscosity of each of the three cheese powders at each of the three test temperatures is shown in Figure 12 (Four Cheeses), Figure 13 (yellow cheddar) and Figure 14 (white cheddar) in.

[0120] Figure 15 Shown are typical profiles of yellow cheddar cheese slurries tested at 35°C, 45°C, and 55°C.

[0121] The present inventors have discovered that while cheese slurries with higher solids content generally have slower settling rates, they may not flow well at ambient temperatures, which can cause problems during processing and application. Therefore, in order to reduce the viscosity of the high solids slurry to a viscosity acceptable for slurry processing and application while also maintaining a slow settling rate, the slurry temperature can be increased to, for example, 113°F. The type of cheese powder solids used in the slurry should also be considered when balancing settling rate and viscosity, as the viscosity can vary between cheese powder solid types at a given temperature, such as Figure 11 shown.

[0122] The matters described in the foregoing description and accompanying drawings are provided by way of example only and are not intended to be limiting. While specific embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of protection sought is defined in the claims, which are properly defined based on the prior art.

Claims

1. A cheese slurry composition for application to an outer surface of a baked dough product prior to partial baking, the cheese slurry composition comprising: about 30% to about 60% by weight natural cheese powder solids, about 0.1% to about 1.5% by weight emulsifier, about 35% to about 65% by weight oil, up to about 5% by weight water, and about 0.25% to about 5% by weight pregelatinized starch effective to provide a crisp topping having a bubbly appearance uniformly adhered to the exterior surface of the baked dough product; as well as Up to 1% by weight of reducing sugars, polyols, or combinations thereof, and substantially no enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, such that the cheese slurry composition resists browning and scorching when baked, wherein the cheese slurry composition has a total moisture content of 5% or less; and wherein the cheese slurry composition is flowable and the natural cheese powder solids are suspended in the oil.

2. The cheese slurry composition of claim 1, wherein the pregelatinized starch comprises amylopectin and substantially no amylose.

3. The cheese slurry composition of claim 1, further comprising 0.05% or less by weight of an acid salt and substantially no food acid.

4. The cheese slurry composition of claim 3, wherein the acid salt comprises at least one of calcium lactate, a crystalline hydrate of calcium lactate, calcium acetate, calcium butyrate, sodium citrate, and combinations thereof.

5. The cheese slurry composition of claim 1, wherein the natural cheese powder solids comprise cream cheese solids.

6. The cheese slurry composition of claim 1 , further comprising a bake-stable fruit or vegetable component.

7. A cheese-flavored multi-textured baked snack product, comprising: a baked dough component; as well as A co-baked cheese topping formed from a cheese slurry having a moisture content of 5% or less and applied to the exterior surfaces of the dough components prior to baking, the cheese slurry comprising, by weight of the slurry: about 30% to about 60% natural cheese powder solids, about 0.1% to about 1.5% emulsifier, about 35% to about 65% oil, up to about 5% water, and about 0.25% to about 5% pregelatinized starch effective to uniformly adhere the cheese slurry to the exterior surface of the dough component to form the cheese topping upon baking and to provide a crisp texture and bubbly appearance to the cheese topping, wherein the cheese slurry is flowable and the natural cheese powder solids are suspended in the oil; and Up to 1% by weight reducing sugars, polyols, or combinations thereof, and substantially no enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, such that the cheese slurry resists browning and scorching when baked.

8. The baked snack product of claim 7, wherein the cheese slurry comprises cream cheese solids, a bake-stable fruit component, and / or a bake-stable vegetable component.

9. The baked snack product of claim 7, wherein the cheese topping forms at least about 20% by weight of the baked dough product.

10. The baked snack product of claim 7, having a moisture content of about 5% or less.

11. The baked snack product of claim 7, wherein the pregelatinized starch comprises amylopectin and substantially no amylose.

12. The baked snack product of claim 7, further comprising 0.05% or less of acid salts and substantially no food acid.

13. The baked snack product of claim 12, wherein the acid salt comprises at least one of calcium lactate, a crystalline hydrate of calcium lactate, calcium acetate, calcium butyrate, sodium citrate, and combinations thereof.

14. A method for preparing a cheese-flavored multi-textured baked snack product, the method comprising: providing an unbaked dough component; applying a cheese slurry having a total moisture content of 5% or less to an outer surface of the unbaked dough component to form a coated unbaked dough component; baking the coated unbaked dough component to a moisture content of about 5% or less, wherein the cheese slurry comprises, by weight of the cheese slurry, about 30% to about 60% natural cheese powder solids, about 0.1% to about 1.5% emulsifier, about 35% to about 65% oil, up to about 5% water, and about 0.25% to about 5% pregelatinized starch effective to uniformly adhere the cheese slurry to the exterior surface of the dough product upon baking and to provide a crisp topping having a bubbly appearance, wherein the cheese slurry is flowable and the natural cheese powder solids are suspended in the oil; and Up to 1% by weight reducing sugars, polyols, or combinations thereof, and substantially no enzyme-modified cheese, buttermilk, whey, maltodextrin, or yeast extract, such that the cheese topping resists browning and scorching when baked.

15. The method of claim 14, wherein the cheese slurry is applied to the outer surface of the unbaked dough component by at least one of rolling, throwing, spraying, dripping, and cascading.

16. The method of claim 14, wherein the cheese slurry has a temperature of about 100°F to about 125°F during application of the cheese slurry to the exterior surface of the unbaked dough component.

17. The method of claim 14, wherein the dough components are maintained at a temperature of about 75°F to about 105°F during application of the cheese slurry to facilitate uniform coverage and smooth migration of the cheese slurry over the dough components.

18. The method of claim 14, wherein the coated unbaked dough component comprises from about 5% to about 55% of the cheese slurry, by weight of the coated unbaked dough component.

19. The method of claim 14, wherein the cheese slurry is obtained by combining the natural cheese powder solids, an emulsifier, oil, water, and pregelatinized starch to form a slurry mixture, and mixing the slurry mixture in a high shear mixer to reduce the particle size of the slurry mixture and break up agglomerates.

20. The method of claim 19, wherein the cheese slurry is continuously stirred and maintained at a temperature effective to minimize separation and / or demixing prior to application to the dough component.

21. The method of claim 14, wherein the cheese slurry comprises cream cheese solids, a bake-stable fruit component, and / or a bake-stable vegetable component.

22. The method of claim 14, wherein the pregelatinized starch comprises amylopectin and substantially no amylose.

23. The method of claim 14, the cheese slurry further comprising 0.05% or less, by weight of the cheese slurry, of an acid salt and substantially no food acid.

24. The method of claim 23, wherein the acid salt comprises at least one of calcium lactate, a crystalline hydrate of calcium lactate, calcium acetate, calcium butyrate, sodium citrate, and combinations thereof.

Images