Puffed snack product and preparation method thereof

Abstract

A puffed snack product comprising a hard matrix defining a pore structure, and a batter for making a puffed snack product, the batter comprising a substrate, an emulsifier, and starch. Methods of preparation and kits are also disclosed.

Description

Technical Field

[0001] The present invention relates to an expanded snack and a method for preparing the expanded snack. In particular, the present invention relates to an edible substrate that is mixed with starch and an emulsifier to form a batter and then dehydrated using microwaves to produce a non-fried, non-extruded expanded snack product. The substrate may include minimally processed fruits, vegetables, nuts, seeds, fungi and / or legumes that are mixed with starch and an emulsifier to form a batter and then dehydrated using microwaves to produce a non-fried, non-extruded expanded snack product. Background Art

[0002] Snack products are expected to have an attractive appearance and provide a pleasant mouthfeel, including a crisp texture, which can be achieved through the puffed nature of the product. Such snacks are typically made from a cereal-based and / or potato-based dough, the puffed nature of which is achieved by extrusion followed by frying. Despite the desire for innovative snack products, the use of alternative ingredients as the base or substrate for puffed snack products is limited by factors such as moisture content: substrates with high moisture content can hinder or make the forming and / or dehydration processes economically unfeasible. Examples of puffed snack products include and They are a cornmeal-based snack and a potato-based snack, respectively, made by extrusion and then deep-frying.

[0003] However, people are gradually realizing the necessity of eating healthy foods. Given the calorie content of fried foods, snack products that are produced without frying are desirable. In addition, due to the increased concern of consumers about health and well-being, snacks with "clear labels" are becoming more and more popular; that is, snacks that contain ingredients that consumers consider to be natural, familiar, simple, easy to identify, understand and pronounce, and that are not artificial ingredients or synthetic chemicals, and minimally processed ingredients. In addition, snacks that contain vegetables and / or fruits are becoming more and more popular for health and well-being reasons.

[0004] Conventional manufacturing processes face multiple challenges in forming and / or dehydrating processed snacks made from vegetables and fruits. The use of fruits and vegetables in the preparation of processed snacks is often limited due to the inherently high moisture content of these ingredients, which, as mentioned above, can hinder or make the forming and / or dehydration process economically unfeasible. This problem is often addressed by controlling the overall moisture content of the mix by using dehydrated materials (most commonly powders, followed by flakes) or by limiting the amount of fruit or vegetable. The latter approach does not allow for the preparation of snacks with fruit or vegetables as the primary ingredient in the ingredient statement.

[0005] Therefore, snacks containing plant-based substrates are usually made from powders. For example, plant-based snack products that are extruded and then fried usually contain 3% to 15% of plant-based materials derived from plant-based powders. However, dehydration of plant substrates usually leads to loss of heat-labile nutrients, color changes, altered rehydration characteristics, reduced antioxidant activity, and substandard sensory attributes. Therefore, the use of plant-based powders to make snack products can negatively affect the visual, nutritional, and sensory properties of the snacks, resulting in products with a limited range of texture attributes (usually quite high density), reduced flavor, and dull color.

[0006] Alternatively, fruit-based or vegetable-based snacks can be prepared by freeze-drying or otherwise dehydrating the fruit or vegetable pieces. This technique can help retain the flavor of the base material, but the resulting product may not expand in the way that is desired for a snack.

[0007] Foam drying (whipping a liquid or semi-liquid into a stable foam and then dehydrating it by heat) can be used to produce aerated products, but this foam requires the addition of a foaming agent and a foam stabilizer. For example, Ozcelik et al. (J. Food Eng. 2019. 240: 83-98) discloses a foam made of puffed food, which includes highly whipped fruit with a potato protease inhibitor as a foaming agent and maltodextrin and pectin as a foam stabilizer. Additional ingredients are essential for the generation and stability of foam, so that the puffed structure of the foam can be retained. If the foam stability is not ideal, the pore foam structure will collapse, which seriously damages the drying process and reduces product quality (Dachmann et al. Food & Bioprocess Tech (2018) 2253-2264).

[0008] Therefore, a solution is needed that can simply (i.e., without extrusion, whipping, or foaming) produce non-fried expanded snack products. Such a solution can be used to allow the use of high moisture substrates (e.g., plant substrates) to produce expanded snack products, preferably containing fewer additional ingredients.

[0009] Microwaves are a simple and quick method of cooking food. Microwave ovens are commonly found in home environments, thus providing the opportunity to prepare snack products at home. Using microwaves is economical and saves 80% of energy compared to conventional ovens. It is well known to use microwaves to quickly make moist, puffed foods. For example, Pompe et al. (Food Process Eng. 2020, 43, e13429) discussed the use of microwaves to make puffed products from dough containing cereal flour. EP0901754 relates to a kit for making cakes in a microwave oven, the kit comprising instant cake mix to which edible oil, water and eggs are added; and a mold.

[0010] However, there remains a need for non-fried, non-extruded expanded snack products that have a crisp, non-cakey texture, are simple to prepare and can utilize high moisture food substrates.

[0011] The present disclosure aims to meet this need, and in one embodiment provides a non-fried, non-extruded puffed plant-based snack product, and preferably provides a non-fried, non-extruded puffed snack product containing a high content of plant-based ingredients. The present disclosure also provides a method for preparing such a snack product, and a kit for preparing such a snack product. Summary of the invention

[0012] Thus, in a first aspect, there is provided a non-fried, non-extruded puffed snack product comprising a plant-based substrate, an emulsifier and a starch, wherein the snack product has an puffed hard matrix comprising the plant-based substrate, and wherein the plant-based substrate comprises: (i) one or more fruits and / or vegetables; and (ii) no more than 20 wt % of the powdered or granular substrate.

[0013] In some embodiments, the one or more fruits and / or vegetables are fresh fruits and / or vegetables; or are fresh fruits and / or vegetables that have been frozen. In some embodiments, the plant-based substrate: (a) contains no more than 15 wt% wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa, or buckwheat; (b) contains no more than 15 wt% potatoes; or (c) does not contain cereal crops.

[0014] In some embodiments, the snack product comprises from about 15 wt % to about 70 wt % of the plant-based substrate based on the weight of the snack product; optionally, wherein the snack product comprises from about 19 wt % to about 70 wt % of the plant-based substrate based on the weight of the snack product.

[0015] In some embodiments, the substrate defines a pore structure having a pore size distribution, wherein the pore size distribution: (a) has a number average pore size Φ of 300 μm to 1100 μm 2D , with a normalized standard deviation of 0.8 to 1.8; (b) having a number average pore size Φ of 400 μm to 1400 μm 3D , optionally wherein the pore size distribution has a number average pore size Φ of 1150 μm to 1250 μm 3D ; and / or (c) having a per unit area of ​​8×10 2 Up to 2×10 4 N of holes v , optionally wherein the pore size distribution has a pore size distribution per unit area of ​​about 8.5×10 2 to 9.9×10 2 N of holes v; and / or (d) wherein the pores have a number average anisotropy ratio R of 1.4 to 2.2 max , optionally wherein the pores have a number average anisotropy ratio R of 1.6 to 1.75 or 1.6 or 1.65 max .

[0016] In some embodiments, the moisture content of the snack is from about 0.5 wt % to about 5 wt %. In some embodiments, the starch is a pregelatinized starch.

[0017] In a second aspect, a batter is provided for making a non-fried, non-extruded puffed snack product according to the first aspect, wherein the batter comprises: (a) about 20% to about 95% of a plant-based substrate; (b) about 0.3% to about 2.5% of an emulsifier; (c) about 8% to about 25% of starch; and (d) optionally, added water, wherein the moisture content of the batter is about 65 wt % to about 85 wt % based on the weight of the batter.

[0018] In a third aspect, a method for making a non-fried, non-extruded expanded snack product is provided, comprising: (i) providing a plant-based substrate comprising one or more fruits and / or vegetables; (ii) optionally processing the plant-based substrate to provide a coarse puree; (iii) providing an emulsifier; (iv) providing starch, optionally wherein the starch is pregelatinized starch; (v) mixing the plant-based substrate, the emulsifier and the starch and optionally added water to form a batter having a moisture content of about 65 wt % to about 85 wt % based on the weight of the batter; (vi) dispensing the batter into individual mold compartments; and (vii) dehydrating the batter using microwaves to produce a dehydrated product, the dehydrated product having a moisture content of about 2 wt % to about 20 wt % based on the weight of the dehydrated product.

[0019] In some embodiments of the method, the plant-based substrate comprises no more than 20 wt% of a powdered or granular substrate. In some embodiments of the method, the one or more fruits and / or vegetables are fresh fruits and / or vegetables, or are frozen fresh fruits and / or vegetables. In some embodiments of the method, the plant-based substrate: (i) comprises no more than about 30 wt% of a cereal crop; (ii) comprises no more than about 15 wt% of wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa or buckwheat; and / or (iii) comprises no more than about 15 wt% of potatoes.

[0020] In some embodiments, the method further comprises (viii) a final processing step to provide a finished product having a moisture content of about 3 wt % to 10 wt % based on the weight of the finished product, optionally wherein the final processing step comprises baking the product.

[0021] In a fourth aspect, there is provided a snack product obtained by the method of the third aspect.

[0022] In a fifth aspect, a kit for making a non-fried, non-extruded puffed snack product is provided, wherein the kit comprises a batter according to the second aspect, optionally further comprising one or more separate mold compartments for use with the batter; or an amount of emulsifier and starch sufficient to be mixed with an amount of a plant-based substrate comprising one or more fruits and / or vegetables and optionally added water to produce a batter having a moisture content of about 65 wt % to about 85 wt % based on the weight of the batter, optionally further comprising one or more separate mold compartments for use with the batter. In some embodiments of the kit, the powdered or granular plant-based substrate does not exceed 20 wt %. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which:

[0024] Figure 1 A flow chart of a method of preparing a snack product according to a first embodiment is shown.

[0025] Figure 2 Shows how to measure a given stoma to determine the stomatal pore size.

[0026] Figure 3 shows how to use the maximum width value t max and the value of the width perpendicular to the maximum width t perp Calculate the anisotropy ratio R i .

[0027] Figure 4A SEMs of the pore structures of two prototype products (a) and (b) containing starch, emulsifier, and water are shown; Figure 4B Shows Figure 4A Figure 2 shows the pore size distribution (number and volume) of the pore structure shown in Figure 2.

[0028] Figure 5A Shown are two pieces taken by SEM ((a) and (b)) cross sections; Figure 5B Shows Figure 5A Figure 2 shows the pore size distribution (number and volume) of the pore structure shown in Figure 2.

[0029] Figure 6 An image of a finished snack product made from a vegetable puree including (from left to right) beetroot, parsnip, green peas, sweet potato, mushroom, and red pepper is shown in accordance with an embodiment of the present disclosure.

[0030] Figure 7 shows images of finished snacks made with different amounts of starch: (from left to right): 5wt%, 8wt%, 12wt%, 15wt%, 20wt%, 25wt% starch (for Fig. 7A and Figure 7B are all like this).

[0031] Figure 8 Shown are images of finished products made with native starches: corn starch (A); waxy corn starch (B); potato starch (C); in each case the inset shows a transverse view of the product.

[0032] Fig. 9 Images of finished products made without emulsifier (A), without salt (B) or with 5 wt% starch (C) are shown.

[0033] Fig.10 Images of finished products made with different amounts of water added to the batter are shown: 15 wt% (A); 30 wt% (B); 45 wt% (C); 60 wt% (D); and 75 wt% (E) added water.

[0034] Fig.11 Shown is a cross section of a finished product taken by scanning electron microscopy (SEM) made from the following ingredients: high starch content (A); (B); lecithin (C); low starch content (D).

[0035] Fig. 12A Shows Fig.11 SEM of the pore structure of the matrix of the product (C), and the corresponding mask used for analysis; Fig. 12B Shows Fig. 12A Figure 2 shows the pore size distribution (number and volume) of the pore structure shown in Figure 2.

[0036] Fig.13 An image of a "puffed" snack comprising a plant-based substrate made according to prior art is shown.

[0037] Fig.14 An image of a finished snack product according to an embodiment of the present disclosure is shown, which was made according to Example 9 using the following substrates: apple puree (hemispherical and elongated mold compartments) (A); Spicy salsa (B); Gazpacho soup (C); (D) and sweet corn and SALSA (E). DETAILED DESCRIPTION

[0038] The present disclosure is based on the unexpected discovery of the inventors that by providing a mixture of starch, emulsifier and water, dispensing the mixture into a mold and dehydrating the mixture with microwaves, a non-fried, non-extruded puffed product can be produced, whose texture and mouthfeel are similar to traditional (extruded and then fried) snack products. Another unexpected discovery is that the technology can be applied to produce desired snack products by adding a substrate that imparts desired properties to the substrate (e.g., desired taste, color and / or nutritional content). The inventors unexpectedly discovered that the teachings can be applied to a wide variety of substrates, including substrates with high or very high moisture content.

[0039] In some embodiments, the substrate is a plant-based substrate, thereby providing a snack product with a desired ingredient list, texture, mouthfeel, and taste.

[0040] Accordingly, the present disclosure is directed to non-fried, non-extruded expanded snack products and methods of making such products.

[0041] The method of the present disclosure involves providing a batter comprising a mixture of a desired substrate (e.g., a plant-based substrate), an emulsifier, starch, and optionally added water. The batter is then dehydrated using microwaves and then optionally finalized using conventional dehydration methods (e.g., an oven). The method does not involve extrusion, and the resulting snack product is not an extruded product.

[0042] Figure 1 The flowchart in FIG. 1 shows one embodiment of the product preparation method according to the present disclosure.

[0043] Substrate

[0044] Step 1 of the method involves the selection of a substrate.

[0045] The substrate can be any food or beverage.

[0046] In some embodiments, the substrate is a soft drink, such as a fruit drink or a carbonated beverage.

[0047] In some embodiments, the substrate is a dairy-based substrate, such as a dairy product, a dairy-based product, or a product derived from dairy, such as milk, flavored milk, ice cream, or yogurt, or a combination thereof. In some embodiments, the substrate is ice cream.

[0048] The term "ice cream" covers a range of products, and its definition varies from region to region. For example, the US Food and Drug Administration's definition specifies a frozen product and requires that the product contain no less than 10% milk fat; under UK food labeling regulations, products sold as "ice cream" in the UK must contain at least 5% fat and 2.5% milk protein. Any product described as ice cream can be used as a substrate in the present disclosure.

[0049] In some embodiments, the substrate is a dairy alternative, such as soy milk, oat milk, or nut milk.

[0050] In some embodiments, the substrate can be dehydrated, such as a granular or powdered substrate. In some such embodiments, the substrate can be a base for a product, such as custard powder, cake mix, bread mix, muffin mix, or muffin mix.

[0051] In some embodiments, the substrate is a base for the product, such as custard powder, cake mix, bread mix, muffin mix, or muffin mix that has been mixed with a liquid, such as water, milk, or a milk substitute. In some embodiments, the substrate is a liquid cake mix, muffin mix, or muffin mix. In some embodiments, the substrate is a liquid or powdered muffin mix.

[0052] In some embodiments, the substrate is a plant-based substrate.

[0053] As defined herein, "plant-based substrate" refers to any edible part of a plant or fungus, such as a fruit, vegetable, mushroom, nut, seed or legume.

[0054] In some embodiments, the plant-based substrate is fresh, ie, substantially unprocessed, such as harvested raw vegetables.

[0055] In some embodiments, the plant-based substrate is a fresh substrate that has been minimally processed to preserve the substrate without significantly changing the nutritional content, such as by freezing (optionally previously blanched in boiling water) or canning, such as in natural juice, water, or a preserving solution (e.g., brine).

[0056] In some embodiments, the plant-based substrate has been processed, such as by partial dehydration (eg, raisins, or "ready-to-eat" dried fruit, such as "ready-to-eat" apricots).

[0057] In some embodiments, the plant-based substrate has been highly processed, such as by extensive dehydration or freeze drying, for example to form granules or powders, such as a powdered fruit smoothie, or a fruit powder.

[0058] In a preferred embodiment, the substrate contains no more than about 20 wt% of a powdered or granular plant-based substrate, or no more than about 19 wt%, about 18 wt%, about 17 wt%, about 16 wt%, about 15 wt%, about 14 wt%, about 13 wt%, about 12 wt%, about 11 wt%, about 10 wt%, about 9 wt%, about 8 wt%, about 7 wt%, about 6 wt%, about 5 wt%, about 4 wt%, about 3 wt%, about 2 wt% or about 1 wt% of a powdered or granular plant-based substrate. In some preferred embodiments, the plant-based substrate is not powdered or granular.

[0059] In a preferred embodiment, the plant-based substrate is fresh produce, either fresh or frozen.

[0060] Vegetables can be any vegetables. Examples include carrots, beetroots, peppers (also known as peppers), cabbage, tomatoes, peas, beans, cabbage, eggplant, potatoes, yams, sweet corn, broccoli, spinach; Cucurbitaceae vegetables, such as squash, including winter squash, pumpkin, cucumber, cauliflower, celery root, celery, courgette or zucchini; Allium vegetables, such as onions, garlic, shallots, chives or green onions; or herbs or flavorings, such as thyme, basil, oregano, parsley, peppers or dill; or any mixture of two or more vegetables. The types and combinations of vegetables can be selected to provide different flavors and / or textures. In some embodiments, the vegetable is one or more of red peppers, carrots, broccoli, spinach, pumpkin, beetroot, parsnip, green peas, sweet potatoes and / or mushrooms.

[0061] The fruit may be any fruit, such as one or more of apple, pear, orange, strawberry, raspberry, raspberry, red currant, banana, black currant, blueberry, cranberry, persimmon, plum, peach, apricot, orange, tangerine, lemon, grapefruit, lime, mango, cherry, pineapple, kiwi, fig, papaya, carambola, guava, pomegranate or grape; or any mixture of two or more fruits. The types and combinations of fruits may be selected to provide different flavors and / or textures.

[0062] In some embodiments, the plant-based substrate is not a cereal crop or contains no more than about 50 wt%, no more than about 45 wt%, no more than about 40 wt%, no more than about 35 wt%, no more than about 30 wt%, no more than about 25 wt%, no more than about 20 wt%, no more than about 15 wt%, no more than about 14 wt%, no more than about 13 wt%, no more than about 12 wt%, no more than about 11 wt%, no more than about 10 wt%, no more than about 9 wt%, no more than about 8 wt%, no more than about 7 wt%, no more than about 6 wt%, no more than about 5 wt%, no more than about 4 wt%, no more than about 3 wt%, no more than about 2 wt%, or no more than about 1 wt% of a cereal crop.

[0063] In some embodiments, the plant-based substrate does not contain or is not one or more of the following: wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa and / or buckwheat; or contains no more than about 50 wt%, no more than about 45 wt%, no more than about 40 wt%, no more than about 35 wt%, no more than about 30 wt%, no more than about 25 wt%, no more than about 20 wt%, no more than about 15 wt%, no more than about 14 wt%, no more than about 13 wt%, no more than about 12 wt%, no more than about 11 wt%, no more than about 10 wt%, no more than about 9 wt%, no more than about 8 wt%, no more than about 7 wt%, no more than about 6 wt%, no more than about 5 wt%, no more than about 4 wt%, no more than about 3 wt%, no more than about 2 wt% or no more than about 1 wt% of one or more of wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa and / or buckwheat.

[0064] In some embodiments, the plant-based substrate does not contain potatoes or is not potatoes, or contains no more than about 50 wt%, no more than about 45 wt%, no more than about 40 wt%, no more than about 35 wt%, no more than about 30 wt%, no more than about 25 wt%, no more than about 20 wt%, no more than about 15 wt%, no more than about 14 wt%, no more than about 13 wt%, no more than about 12 wt%, no more than about 11 wt%, no more than about 10 wt%, no more than about 9 wt%, no more than about 8 wt%, no more than about 7 wt%, no more than about 6 wt%, no more than about 5 wt%, no more than about 4 wt%, no more than about 3 wt%, no more than about 2 wt%, or no more than about 1 wt% of potatoes.

[0065] The fungus may be a mushroom or yeast extract.

[0066] The nuts can be any nuts, such as one or more of almonds, pecans, hazelnuts, peanuts, walnuts, cashews, Brazil nuts or pine nuts. The types and combinations of nuts can be selected to provide different flavors and / or textures.

[0067] The seeds may be any seeds, such as one or more of sunflower seeds, sesame seeds, nigella seeds or pumpkin seeds. The types and combinations of seeds may be selected to produce different flavors and / or textures.

[0068] The beans can be any beans, such as one or more of chickpeas, soybeans, broad beans, black eyed beans, lima beans, kidney beans, lentils; or any mixture of two or more beans. The types and combinations of beans can be selected to produce different flavors.

[0069] In some embodiments, the plant-based substrate comprises or consists of one or more fruits, vegetables, nuts, seeds, fungi and / or legumes. In some embodiments, the plant-based substrate comprises or consists of up to 20 kinds of fruits, vegetables, nuts, seeds, fungi and / or legumes; or up to 18 kinds, up to 15 kinds, up to 12 kinds, up to 10 kinds, up to 9 kinds, up to 8 kinds, up to 7 kinds, up to 6 kinds, up to 5 kinds, up to 4 kinds, or up to 3 kinds of fruits, vegetables, nuts, seeds, fungi and / or legumes; or 2 kinds of fruits, vegetables, nuts, seeds, fungi and / or legumes; or a single type of fruit, vegetable, nut, seed, fungi or legume.

[0070] In some embodiments, the plant-based substrate comprises, consists essentially of, or consists of: one or more fruits, vegetables, and / or one or more fungi. In some embodiments, the plant-based substrate comprises, consists essentially of, or consists of: one or more vegetables and / or one or more fungi. In a preferred embodiment, the plant-based substrate may be selected from beetroot, parsnip, sweet potato, mushroom, and pepper, or any combination thereof.

[0071] In some embodiments, the substrate does not contain non-plant-based proteins, i.e., proteins derived from any source other than plants or fungi. In some embodiments, the substrate does not contain animal proteins. In some embodiments, the substrate does not contain eggs or egg components.

[0072] In some embodiments, the plant-based substrate does not include isolated plant proteins, ie, proteins that are extracted or isolated from a plant-based source for their protein properties, such as rice protein, soy protein, or pea protein.

[0073] In some embodiments, the substrate does not contain dairy or ingredients or products derived from dairy. In some embodiments, the substrate does not contain milk, yogurt, butter or cheese.

[0074] In some embodiments, the substrate is pre-processed. For example, the substrate can be a salsa; a soup, such as vegetable soup or Spanish gazpacho; or a juice, such as fruit juice or vegetable juice; or a smoothie, such as a fruit smoothie.

[0075] Gazpacho is a vegetable-based soup in Spanish cuisine. It usually contains tomatoes (usually about 55% to 65%), peppers (usually about 12%), cucumbers (usually about 12%), and onions (usually about 9%). Salsa is a vegetable-based sauce in Mexican cuisine. It usually contains about 50% tomatoes, optional peppers and onions. Any product described as gazpacho or salsa can be used as a base material in the present disclosure.

[0076] Processing

[0077] In optional step 2 of the method, the substrate is processed.

[0078] Whether processing is required may depend on the substrate. For example, soft fruits or vegetables (such as berries, tomatoes) may not require cooking; nuts such as pine nuts or berries such as black currants may not require size reduction. Pre-processed substrates such as salsas, soups or juices may not require processing.

[0079] In some embodiments where the substrate is frozen, such as ice cream, the substrate is thawed.

[0080] In some embodiments where the substrate is a plant-based substrate, the plant-based substrate is cooked or partially cooked, for example, to soften or break down some or all of the cell walls.

[0081] In some embodiments, the plant-based substrate is partially cooked until some softening occurs, but without any significant color loss. In some embodiments, the plant-based substrate can be cooked at a temperature of at least 90°C or at least 100°C, such as up to 250°C, for 2 minutes to 15 minutes, optionally 5 minutes to 10 minutes, optionally 8 minutes to 12 minutes, to blanch or at least partially cook the substrate.

[0082] Additionally or alternatively, in some embodiments, the substrate (such as a plant-based substrate) is reduced in size, for example by dicing, grinding, chopping or pureeing.

[0083] When processing, the substrate need not be processed to obtain a smooth or lump-free mud; particles or fragments of the substrate may remain.

[0084] In some embodiments, processing reduces the size of the substrate, for example, to provide fragments of fruits, vegetables, seeds, nuts, fungi, or legumes. The size of the fragments may depend on the substrate. For example, a denser substrate (e.g., nuts) may be comminuted into smaller sized fragments than a less dense substrate (e.g., fresh peppers). One skilled in the art will appreciate that the size and density of the substrate fragments may affect their position in the finished matrix: fragments suspended in the batter generally result in the fragments being dispersed throughout the matrix of the finished snack, while fragments deposited within the batter may result in the fragments accumulating at the bottom of the finished snack. Thus, the substrate may be reduced to a size to optimize the position of the fragments in the finished matrix. For example, the size of almonds may be reduced to approximately 3 mm. 2 .

[0085] In some embodiments, the substrate may be processed to provide a "rough" mud comprising substrate fragments. In some such embodiments, the substrate fragments may be no larger than about 5 mm in size. 2, not more than about 4.5mm 2 , not more than about 4mm 2 or not more than about 3mm 2 ; or about 2.5mm 2 , 3mm 2 or 3.5mm 2 .

[0086] In some embodiments, the substrate may be processed to provide a smooth puree. In some embodiments where the substrate is a plant-based substrate, the substrate may be processed to provide a juice, for example by pureeing and then filtering.

[0087] In preferred embodiments where the substrate is a plant-based substrate, the plant-based substrate undergoes limited or minimal processing prior to being mixed with the other ingredients of the batter. For example, if the plant-based substrate consists of fresh carrots, the carrots may be partially cooked (so they are just soft or "chewy") and then pureed or partially pureed to provide a "coarse" puree. Limited processing helps retain the color, flavor, and nutritional attributes of the plant-based substrate.

[0088] Additional Ingredients

[0089] Select additional ingredients in step 3 of the method.

[0090] An ingredient may be added to increase the viscosity of the batter. This ingredient may be a fiber material, such as apple or citrus fiber, and / or a gum such as xanthan gum or locust bean gum or gum arabic.

[0091] Providing a batter with increased viscosity helps keep the substrate and substrate fragments (if present) suspended as bubbles are formed during puffing. This helps produce a uniformly puffed product that includes a matrix consisting essentially of the substrate and substrate fragments (if present) distributed within the matrix.

[0092] Another additional ingredient is starch. Adding starch increases the viscosity of the batter. In addition, starch helps achieve the expanded nature of the snack due to its ability to gelatinize and coagulate quickly when dehydrated.

[0093] In some such embodiments, the starch is pregelatinized. In some such embodiments, the starch is pregelatinized waxy corn starch, pregelatinized corn starch, pregelatinized tapioca starch, or pregelatinized potato starch. In some embodiments, the starch is not a native starch.

[0094] Another additional ingredient is an emulsifier. In some embodiments, the emulsifier is amphiphilic. In some embodiments, the emulsifier is one or more lecithin or related edible phospholipids; distilled monoglycerides made from edible fully hydrogenated palm-based oil, such as (distilled monoglycerides made from edible refined hydrogenated palm oil); chickpea water; or an emulsifier derived from protein, such as rapeseed protein or linseed protein. Lecithin can be derived from, for example, sunflower, soy, or egg. In some embodiments, the emulsifier is not derived from protein. In a preferred embodiment, the emulsifier is not derived from egg.

[0095] Due to its amphiphilic nature, the emulsifier tends to aggregate on the bubble surface to form a double layer when the bubble is formed, thus helping to control the size of the bubbles produced during puffing.

[0096] In some embodiments, other additional ingredients may be selected, such as ingredients that provide organoleptic properties such as condiments, spices, and dry inclusions, such as salt, pepper, cinnamon, mint, lemongrass, chili, onion, or garlic powders or granules, dried herbs, or pre-prepared seasoning mixtures, such as seasoning mixtures designed to impart a specific flavor or feeling (e.g., Thai, Chinese, Japanese, Indian, curry, or umami feelings or flavors); or liquid inclusions, such as vanilla, almond, or peppermint extracts or essences; or sweeteners, such as syrups, such as maple syrup, honey, or agave syrup. These ingredients can enhance the flavor of the product without changing the basic structural or textural characteristics of the product, or the preparation methods discussed herein. Preferably, no artificial additives, such as artificial flavors or colorants, are used. Typically, the size of the additional ingredients does not exceed 5 mm 2 , 4mm 2 or 3mm 2 .

[0097] In some embodiments, the batter may further include cheese. The cheese may be a soft cheese, such as feta cheese or goat cheese; and / or a hard cheese, such as manchego cheese. The cheese may be fresh or dried. In embodiments, the batter may include up to or about 35 wt % cheese, or about 30 wt %, about 25 wt %, about 30 wt %, about 25 wt %, about 20 wt %, about 15 wt %, about 10 wt %, about 5 wt % or about 2 wt % cheese. The cheese is typically grated, powdered or otherwise reduced in size so that the size of individual particles or fragments does not exceed 5 mm 2 , 4mm 2 or 3mm 2 The addition of a given amount of cheese may enhance the flavor of the product without changing the basic structural or textural characteristics of the product, or the method of preparation discussed herein.

[0098] In some embodiments where the substrate is a plant-based substrate, the batter may further include yogurt, cream, milk, or cream cheese. In some embodiments, the batter includes cream cheese. In some embodiments, the batter includes up to or about 4% cream cheese. The addition of this amount of cream cheese does not change the basic structural or textural characteristics of the product, or the preparation methods discussed herein, but may enhance the flavor of the product.

[0099] In some embodiments, the batter may also include oil or fat, such as vegetable oil, sunflower oil (e.g., high oleic sunflower oil (HOSO)), rapeseed oil, or coconut oil. In such embodiments, the batter includes at most 0.5wt%, at most 1wt%, at most 1.2wt%, at most 1.4wt%, at most 1.5wt%, at most 1.6wt%, at most 1.7wt%, at most 1.8wt%, at most 1.9wt%, at most 2wt%, or about 2wt% of the added oil or fat. In some embodiments, the batter does not include the added oil or fat. "Added oil or fat" mentioned herein refers to any oil or fat added to the batter or finished product, i.e., the oil or fat added in addition to the oil or fat naturally present in the batter ingredients.

[0100] In some embodiments, the batter does not include a leavening or raising agent, such as yeast, sodium bicarbonate (baking soda), or baking powder.

[0101] In some embodiments, the batter does not include one or more of ammonium carbonate, ammonium bicarbonate, potato proteinase inhibitors, calcium azide, maltodextrin, or pectin.

[0102] In some embodiments, the batter does not include eggs or any components derived from eggs or egg substitutes (such as chia seeds or flax seeds).

[0103] In some embodiments, the batter does not include isolated plant proteins, i.e., proteins extracted or isolated from plant-based sources, e.g., for their protein properties, such as rice protein, soy protein, or pea protein. In some embodiments, the batter does not include one or more of rice protein, soy protein, or pea protein.

[0104] In some embodiments, the batter does not contain non-plant-based proteins, i.e., proteins derived from any source other than plants or fungi. In some embodiments, the batter does not contain proteins derived from animals.

[0105] In some embodiments, the batter does not contain dairy or ingredients or products derived from dairy. In some embodiments, the base does not include milk, yogurt, butter or cheese.

[0106] Add water and the amount of ingredients in the batter

[0107] In step 4 of the method, water may optionally be added to the substrate and additional ingredients.

[0108] Reference herein to "added water" refers to any water that is added to other batter ingredients, ie, water that is added in addition to the water naturally present in the other ingredients of the batter.

[0109] Whether water needs to be added depends on the moisture content of the other ingredients in the batter. In some embodiments, no water needs to be added, such as when the base material is milk, milk substitute, soup, smoothie or juice.

[0110] Generally, according to embodiments of the present disclosure, a batter comprising a plant-based substrate and added water comprises the following:

[0111] (i) 30 wt % to 46 wt % of a plant-based substrate;

[0112] (ii) 8 wt % to 23 wt % starch;

[0113] (iii) 0.5 wt % to 2.5 wt % of an emulsifier;

[0114] (iv) 0.0 to 1.0 wt % of salt;

[0115] (v) 30 to 50 wt% of added water.

[0116] All ingredients combined are 100% based on the weight of the batter.

[0117] According to embodiments of the present disclosure, a typical batter that does not include added water may include the following:

[0118] (i) 80% to 90% plant-based substrate, such as juice or plant-based soups such as gazpacho; or non-plant-based substrates, such as milk;

[0119] (ii) 8 wt % to 12 wt % starch;

[0120] (iii) 0.3 wt% to 1.5 wt% of an emulsifier.

[0121] All ingredients combined are 100% based on the weight of the batter.

[0122] According to an embodiment of the present disclosure, an example batter without added water may include the following:

[0123] (iv) 88.8 wt% of a plant-based substrate, such as a juice or a plant-based soup such as gazpacho;

[0124] (v) 11.9 wt% starch;

[0125] (vi) 1.29 wt% of emulsifier.

[0126] According to an embodiment of the present disclosure, a second example batter that does not include added water may include the following:

[0127] (i) 86.3 wt % of a base material, such as flavored milk;

[0128] (ii) 11.9 wt% starch;

[0129] (iii) 1.29 wt% of an emulsifier;

[0130] (iv) 0.5% salt.

[0131] In embodiments comprising a plant-based substrate, the batter may comprise from about 20 wt% to about 95 wt% of the plant-based substrate based on the total weight of the batter. In preferred embodiments, the batter comprises from about 20 wt% to about 90 wt% of the plant-based substrate based on the total weight of the batter, or from about 21 wt% to about 87 wt% of the plant-based substrate based on the total weight of the batter, from about 22 wt% to about 87 wt% of the plant-based substrate based on the total weight of the batter, or from about 20 wt% to about 85 wt% of the plant-based substrate based on the total weight of the batter.

[0132] In some embodiments, the batter may contain at most about 94wt%, at most 92wt%, at most 90wt%, at most 88wt%, at most 85wt%, at most 83wt%, at most 80wt%, at most 78wt%, at most 75wt%, at most 73wt%, at most 70wt%, at most 68wt%, at most 65wt%, at most 64wt%, at most 63wt%, at most 62wt%, at most 61wt%, at most 60wt%, at most 59wt%, at most 58wt%, at most 57wt%, at most 56wt%, at most 55wt%, at most 54wt%, at most 53wt%, at most 52wt%, at most 51wt% %, up to 29wt%, up to 28wt%, up to 27wt%, up to 26wt%, up to 25wt%, up to 24wt%, up to 23wt% or up to 22wt% of a plant-based substrate.

[0133] Alternatively, it can be stated that the batter comprises at least about 20 wt% of the plant-based substrate, based on the total weight of the batter, or at least about 21 wt%, at least about 22 wt%, at least about 23 wt%, at least about 24 wt%, at least about 25 wt%, at least about 26 wt%, at least about 27 wt%, at least about 28 wt%, at least about 29 wt%, at least about 30 wt%, at least about 31 wt%, at least about 32 wt%, at least about 33 wt%, at least about 34 wt%, at least about 35 wt%, at least about 36 wt%, at least about 37 wt%, at least about 38 wt%, at least about 39 wt%, at least about 40 wt%, at least about 41 wt%, at least about 42 wt%, at least about 43 wt%, at least about 44 wt%, at least about 45 wt%, at least about 46 wt%, at least about 47 wt%, at least about 48 wt%, at least about 49 wt%, at least about 50 wt%, at least about 51 wt%, at least about 52 wt%, at least about 53 wt%, at least about 54 wt%, at least about 55 wt%, at least about 56 wt%, at least about 57 wt%, at least about 58 wt%, at least about 59 wt%, at least about 60 wt%, at least about %, at least about 47wt%, at least about 48wt%, at least about 49wt%, at least about 50wt%, at least about 51wt%, at least about 52wt%, at least about 53wt%, at least about 54wt%, at least about 55wt%, at least about 56wt%, at least about 57wt%, at least about 58wt%, at least about 59wt%, at least about 60wt%, at least about 65wt%, at least about 68wt%, at least about 70wt%, at least about 72wt%, at least about 75wt%, at least about 78wt%, at least about 80wt%, at least about 82wt%, at least about 85wt%, at least about 88wt%, at least about 90wt%, at least about 91wt%, at least about 92wt%, at least about 93wt%, at least about 94wt% or at least about 95wt% of the plant-based substrate.

[0134] In some embodiments where the batter comprises added water, the batter may comprise 20 wt% to 50 wt% plant-based substrate, or 25 wt% to 48 wt%, 28 wt% to 47 wt%, or 29 wt% to 47 wt% plant-based substrate.

[0135] In some embodiments where the batter does not include added water, the batter can include 50 wt% to 95 wt% plant-based substrate, or 55 wt% to 95 wt%, 60 wt% to 95 wt%, 65 wt% to 95 wt%, 70 wt% to 93 wt%, 75 wt% to 93 wt%, 80 wt% to 92 wt%, 85 wt% to 92 wt%, or 88 wt% to 92 wt% plant-based substrate.

[0136] The batter may contain about 8 wt% to 28 wt% of added starch based on the total weight of the batter. "Added starch" refers to starch that is added to other batter ingredients, i.e., starch that is added in addition to the starch that is naturally present in the other ingredients of the batter. The amount of starch added to the batter may depend on the substrate used. For example, sweet potatoes contain more starch than broccoli. This will be understood by those skilled in the art.

[0137] In some embodiments, the batter can include about 5 wt % to 25 wt % added starch, about 5 wt % to 20 wt % or about 8 wt % to 25 wt % added starch, or about 9 wt % to 23 wt % added starch, about 9 wt % to 20 wt % added starch, about 9 wt % to 18 wt % added starch, about 9.5 wt % to 15 wt % added starch, or about 10 wt % to 12.5 wt % added starch.

[0138] Alternatively, it can be stated that in some embodiments, the batter may include up to about 28wt%, up to 27wt%, up to 26wt%, up to 25wt%, up to 24wt%, up to 23wt%, up to 22wt%, up to 21wt%, up to 20wt%, up to 19wt%, up to 18wt%, up to 17wt%, up to 16wt%, up to 15wt%, up to 14wt%, up to 13wt%, up to 12wt%, up to 11wt%, up to 10wt%, up to 9wt% or up to 8wt% added starch based on the total weight of the batter. Alternatively, it can be said that the batter includes at least about 8wt% added starch, based on the total weight of the batter, or at least about 9wt%, at least about 10wt%, at least about 11wt%, at least about 12wt%, at least about 13wt%, at least about 14wt%, at least about 15wt%, at least about 16wt%, at least about 17wt%, at least about 18wt%, at least about 19wt%, at least about 20wt%, at least about 21wt%, at least about 22wt%, at least about 23wt%, at least about 24wt%, at least about 25wt%, at least about 26wt% or at least about 27wt% added starch, based on the total weight of the batter.

[0139] In some preferred embodiments, the batter comprises about 8 wt % to 25 wt % added starch.

[0140] In some embodiments, the batter comprises at least about 7.5 wt%, at least about 8 wt%, or at least about 8.5 wt% of added starch. In some embodiments, the batter comprises no more than about 27.5 wt%, no more than about 27 wt%, no more than about 26 wt%, no more than about 26.5 wt%, no more than about 25.5 wt%, no more than about 25 wt%, or no more than about 24.5 wt% of added starch.

[0141] The batter may comprise about 0.3 wt% to 2.8 wt% of added emulsifier based on the total weight of the batter. "Added emulsifier" refers to an emulsifier added to the other batter ingredients, ie, in addition to any emulsifier naturally present in the other ingredients of the batter.

[0142] In some embodiments, the batter may include about 0.3 wt % to 2.5 wt % added emulsifier, or about 0.5 wt % to 2.5 wt %, 0.3 wt % to 2.2 wt %, about 0.4 wt % to 2.1 wt %, about 0.5 wt % to 2 wt % added emulsifier.

[0143] In some embodiments, the batter may include up to about 0.4wt%, up to 0.5wt%, up to 0.6wt%, up to 0.7wt%, up to 0.8wt%, up to 0.9wt%, up to 1.0wt%, up to 1.1wt%, up to 1.2wt%, up to 1.3wt%, up to 1.4wt%, up to 1.5wt%, up to 1.6wt%, up to 1.7wt%, up to 1.8wt%, up to 1.9wt%, up to 2.0wt%, up to 2.1wt%, up to 2.2wt%, up to 2.3wt%, up to 2.4wt%, up to 2.5wt%, up to 2.6wt%, up to 2.7wt% or up to 2.8wt% of added emulsifier based on the total weight of the batter.

[0144] Alternatively, it can be said that the batter comprises at least about 2.5 wt% added emulsifier based on the total weight of the batter, or at least about 2.4 wt%, at least about 2.3 wt%, at least about 2.2 wt%, at least about 2.1 wt%, at least about 2.0 wt%, at least about 1.9 wt%, at least about 1.8 wt%, at least about 1.7 wt%, at least about 1.6 wt%, at least about 1.5 wt%, at least about 1.4 wt%, at least about 1.3 wt%, at least about 1.2 wt%, at least about 1.1 wt%, at least about 1.0 wt%, at least about 0.9 wt%, at least about 0.8 wt%, at least about 0.7 wt%, at least about 0.6 wt%, at least about 0.5 wt%, at least about 0.4 wt%, or at least about 0.3 wt% added emulsifier based on the total weight of the batter.

[0145] The batter may comprise about 25 wt % to 55 wt % added water based on the total weight of the batter. In some embodiments, the batter may comprise at most 55wt%, at most 54wt%, at most 53wt%, at most 52wt%, at most 51wt%, at most 50wt%, at most 49wt%, at most 48wt%, at most 47wt%, at most 46wt%, at most 45wt%, at most 44wt%, at most 43wt%, at most 42wt%, at most 41wt%, at most 40wt%, at most 39wt%, at most 38wt%, at most 37wt%, at most 36wt%, at most 35wt%, at most 34wt%, at most 33wt%, at most 32wt%, at most 31wt%, at most 30wt%, at most 29wt%, at most 28wt%, at most 27wt% or at most 26wt% added water based on the total weight of the batter. Alternatively, it can be said that the batter comprises at least about 25 wt % added water, based on the total weight of the batter, or at least about 26 wt %, at least about 27 wt %, at least about 28 wt %, at least about 29 wt %, at least about 30 wt %, at least about 31 wt %, at least about 32 wt %, at least about 33 wt %, at least about 34 wt %, at least about 35 wt %, at least about 36 wt %, at least about 37 wt %, at least about 38 wt %, at least about 39 wt %, at least about 40 wt %, at least about 41 wt %, at least about 42 wt %, at least about 43 wt %, at least about 44 wt %, at least about 45 wt %, at least about 46 wt %, at least about 47 wt %, at least about 48 wt %, at least about 49 wt %, at least about 50 wt %, at least about 51 wt %, at least about 52 wt %, at least about 53 wt %, or at least about 54 wt % added water, based on the total weight of the batter.

[0146] mix

[0147] In step 5 of the method, the ingredients of the batter are mixed. Mixing is performed to combine the ingredients and provide a homogenous or substantially homogenous batter such that the fragments of the substrate, if present, are suspended throughout the batter.

[0148] The batter does not need to be mixed so that any base material fragments in the batter are significantly broken down or pureed.

[0149] Any suitable mixer may be used to mix the ingredients of the batter. For example, the batter may be mixed manually with a spoon or whisk, or by a hand blender, electric mixer, food processor, or industrial mixer.

[0150] There is no need to mix the batter to aerate or foam the batter in large amounts in order to achieve puffing during subsequent microwave dehydration. However, if desired, the batter can be foamed in the siphon by adding compressed gas (e.g., CO2, NO or NO2). The foaming does not result in any significant additional puffing during subsequent microwave dehydration. In a preferred embodiment, the batter is not intentionally foamed or aerated, such as by adding compressed gas.

[0151] The moisture content of the resulting batter is about 55wt% to 90wt% based on the weight of the batter. In some embodiments, the moisture content of the batter is about 60wt% to 90wt%, or about 65wt% to 90wt%, about 70wt% to 90wt%, about 75wt% to 90wt%, about 80wt% to 90wt%, about 81wt% to 90wt%, or about 82wt% to 90wt%. In some embodiments, the moisture content of the batter is at least about 60wt%, at least about 65wt%, at least about 70wt%, at least about 75wt%, at least about 76wt%, at least about 77wt%, at least about 78wt%, at least about 79wt% or at least about 80wt%. In some embodiments, the moisture content of the batter is about 58wt% to about 89wt%, or about 60wt% to about 88wt%, about 65wt% to about 85wt%, about 70wt% to about 85wt%, about 75wt% to about 82wt%, about 78wt% to about 82wt%, or about 79wt% to about 81wt%. In some embodiments, the moisture content of the batter is about 75wt%, about 76wt%, about 77wt%, about 78wt%, about 79wt%, about 80wt%, about 81wt% or about 82wt% based on the weight of the batter.

[0152] The viscosity of the batter can be measured by any suitable method. For example, using a viscometer, such as a Bostwick consistency meter; and / or using a texture analyzer, which can quantify the force required to compress the batter to 25 mm (the greater the force required, the thicker the batter).

[0153] Batter that provides expanded products according to the present disclosure typically travels from about 3 cm to about 11 cm in 1 minute on a Bostwick consistometer, and / or requires a force of from about 70 g to about 250 g to compress to 25 mm in a texture analyzer.

[0154] The viscosity of the batter can vary depending on the starch content of the batter, which can be affected by the base material chosen and / or the amount of starch added to the batter.

[0155] In some embodiments, a batter that travels from about 8 cm to about 2.5 cm in 1 minute on a Bostwick consistometer provides an expanded product according to the present disclosure. In some embodiments where the batter comprises a high liquid: starch ratio, the batter may travel about 7.8 cm in 1 minute on a Bostwick consistometer; while a higher viscosity batter (e.g., comprising a higher level of starch) may travel about 2.7 cm in 1 minute on a Bostwick consistometer.

[0156] The moisture content and viscosity of the batter contribute to the puffed nature of the snack product after microwave dehydration. The use of microwaves is believed to cause the water temperature in the batter to rise rapidly, thereby increasing the internal pressure, resulting in the formation of bubbles in the batter, which gives the product a puffed and textured structure. Lower viscosities tend to produce a lighter, more puffed texture, however, batters with higher moisture content and therefore lower viscosity can result in a loss of bubble structure within the product upon microwave dehydration. This is believed to be because the batter ingredients do not solidify sufficiently and / or quickly enough to prevent so-called "boiling", in which the water in the batter evaporates and is not trapped in bubbles within the product.

[0157] Distribution and mold

[0158] In step 6 of the method, the batter is dispensed into moulds suitable for use in a microwave oven.

[0159] The mold material preferably does not substantially absorb microwave energy. In some embodiments, when the mold material is heated alone, it heats to less than 10°C in 60 seconds at 100% power in a 800W to 1000W domestic microwave oven.

[0160] The mould comprises one or more compartments into which the batter is dispensed.

[0161] The type and configuration of the compartments in the mold help achieve the puffed properties of the snack product after microwave dehydration. During the dehydration step, as the batter is heated, the viscosity of the batter decreases. Therefore, in the absence of a mold, the batter spreads out, resulting in a thin product with random shapes and low expansibility due to its thickness.

[0162] The dimensions of the mold compartments can vary depending on the desired dimensions of the resulting product. In some embodiments, the mold compartments have a depth of about 2.8 cm, about 2.7 cm, about 2.6 cm, about 2.5 cm, about 2.4 cm, about 2.3 cm, about 2.2 cm, about 2.1 cm, about 2.0 cm, about 1.9 cm, about 1.8 cm, about 1.7 cm, about 1.6 cm, or about 1.5 cm.

[0163] The shape of the mold compartments can vary depending on the desired shape of the resulting product. In some embodiments, the compartments define or approximately define a regular 3D shape, such as a cube or a cuboid. Alternatively, the mold compartments can be, for example, hemispherical, or novel shapes such as crescents, hearts, leaves, or animal figures.

[0164] In some cube-shaped embodiments, the dimensions of the mold compartment are about 2.5 cm (height) x about 2.5 cm (length) x about 2.5 cm (depth).

[0165] In some embodiments, each mold compartment contains about 1.8 g to about 8.5 g of batter. In some embodiments, a mold having a cubic or cuboid-shaped compartment or a nearly cubic or cuboid-shaped compartment is used, and each compartment contains about 4 g to about 8 g of batter, or about 4.5 g to about 7.5 g, about 5 g to about 7.5 g, about 5.5 g to about 7 g, or about 6 g to about 7 g of batter, or about 4 g, about 4.5 g, about 5 g, about 5.5 g, about 6 g, about 6.5 g, about 7 g, or about 7.5 g of batter.

[0166] In some embodiments, a mold having irregularly shaped and / or shallowly shaped compartments, such as a hemispherical or heart-shaped compartment, is used, and each compartment contains about 1.8 g to about 4 g of batter, or about 1.9 g to about 3.8 g, about 2 g to about 3.5 g, or about 2 g to about 3.6 g, or about 2 g to about 3 g of batter, or about 2 g, about 2.5 g, about 3 g, or about 3.5 g of batter.

[0167] In some preferred embodiments, the mold compartments are separated so that the risk of arcing between the compartments into which the batter is distributed is negligible and / or the compartments are at least 5 mm apart. The compartments may be arranged in an annular geometry with one or more empty (i.e., batter-free) compartments in the center. The annular ring configuration may be advantageous because it allows optimal loading of the batter while maintaining a distance of at least 5 mm between the compartments and reducing the risk of arcing between the compartments containing batter.

[0168] In some alternative embodiments, when a mold is used that has multiple compartments without distinct divisions between the compartments (i.e., only dividing walls between the compartments), the batter can be loaded into alternating compartments so that the filled mold includes empty (i.e., batter-free) compartments. Configuring in this way can be advantageous because it maintains a distance of at least 5 mm between compartments containing batter, thereby reducing the risk of arcing between the compartments.

[0169] In other alternative embodiments, when a mold is used that has multiple compartments without distinct divisions between the compartments (i.e., only dividing walls between the compartments), the batter can be loaded into each compartment so that the filled mold does not include empty (i.e., batter-free) compartments. This arrangement may be preferred when the product does not undergo a final processing step.

[0170] Microwave dehydration

[0171] In step 7 of the method, the filled mould is subjected to microwave dehydration. The microwave dehydration step can be performed by passing the mould through a multi-zone flat plate microwave cooking device. Alternatively, a catering microwave oven (typically 2600W full power setting, 1300W half power setting; or 1500W full power setting, 750W half power / medium setting) or a household microwave oven (800W to 100W or 800W to 1300W power) can be used.

[0172] The microwave dehydration step produces a product having a moisture content of about 2wt% to 20wt% based on the weight of the product. In some embodiments, the microwave dehydration step produces a product having a moisture content of about 2wt%, about 3wt%, about 4wt%, about 5wt%, about 6wt%, about 7wt%, about 8wt%, about 9wt%, about 10wt%, about 11wt%, about 12wt%, about 13wt%, about 14wt%, about 15wt%, about 16wt%, about 17wt%, about 18wt% or about 19wt% based on the weight of the product. In some preferred embodiments, the moisture content of the dehydrated product is about 8wt% to 15wt%, or 10wt% to 13wt%, or about 12% based on the weight of the product.

[0173] To achieve a product with a desired moisture content, the microwave exposure time and microwave power density required may vary, depending on the moisture content of the batter and the type of microwave oven used.

[0174] If an industrial microwave oven is used, typically, the microwave dehydration step uses a power density setting of 15 kW to 50 kW for about 72 seconds. This can be achieved in multiple steps, such as using a power density setting of 47 kW for 25 seconds, then a power density setting of 35 kW for 25 seconds, and then a power density setting of 17 kW for 22 seconds.

[0175] If a catering microwave oven is used, typically the microwave dehydration step is performed at a power setting of 2600 W for about 2 minutes and then at a power setting of 1300 W for about 2 minutes.

[0176] In some embodiments where a finishing step is not required, the microwave dehydration step can be performed using a household microwave oven set to a power of 750W to 800W (optionally set to "medium" (600W)). In some such embodiments, multiple short (30 seconds to 1 minute) microwave dehydration steps can be performed so that the total microwave dehydration time is about 4 minutes to 6 minutes or 5 minutes to 6 minutes. For example, microwave dehydration can be performed for 1 minute and repeated 3 times so that the total dehydration time is 4 minutes. The product can then optionally be visually inspected and, if necessary, microwave dehydrated for another 30 seconds, and then optionally visually inspected and, if necessary, microwave dehydrated for another 30 seconds. Shorter (30 second) microwave dehydration time intervals can help ensure that the product is not overcooked or burned.

[0177] In some embodiments, no additional steps are required prior to the microwave dehydration step, for example, the batter does not need to be cooled or partially dehydrated prior to dehydration in the microwave.

[0178] After the microwave dehydration step, the dehydrated snack product comprises a puffed matrix consisting primarily of a plant-based matrix. If the matrix comprises fragments, the fragments may be visible within the matrix. It is the dehydration step that creates the puffed product, not any subsequent finishing step.

[0179] In some preferred embodiments, the snack product does not undergo a finishing step. In such embodiments, the microwave dehydration step is sufficient to reduce the moisture content of the product to a desired level for the final product.

[0180] Final processing

[0181] In step 8, the dehydrated snack product is removed from the mold and may optionally be subjected to final processing steps. Final processing steps reduce the moisture content of the product without fundamentally changing the microstructure of the product.

[0182] In a preferred embodiment, the final processing step does not involve frying.

[0183] In some embodiments, the final processing step is a baking step, such as in a hot air convection oven, to produce a baked snack product having a moisture content of about 2 wt % to 10 wt % based on the weight of the product. In some embodiments, the final processing step produces a product having a moisture content of about 2 wt %, about 3 wt %, about 4 wt %, about 5 wt %, about 5.5 wt %, about 6 wt %, about 6.5 wt %, about 7 wt %, about 7.5 wt %, about 8 wt %, about 8.5 wt %, about 9 wt %, about 9.5 wt %, or about 10 wt % based on the weight of the product.

[0184] The oven temperature and length of baking time required to achieve a product with the desired moisture content may vary, depending on the moisture content of the dehydrated product.

[0185] Typically, the baking step is performed at an oven temperature of 50° C. to 200° C. for 10 to 30 minutes. In some embodiments, hot air convection cooking is performed at an oven temperature of about 100° C. to 120° C. for 12 to 22 minutes.

[0186] Finished Product

[0187] After the final processing step, the snack product comprises a puffed, substantially hard matrix consisting primarily of the substrate ingredient (e.g., the plant-based ingredient). If the substrate comprises fragments, the fragments may be visible within the substrate. For example, when the substrate is a muffin or muffin comprising fruit fragments or chocolate fragments; or when the substrate is a plant-based substrate comprising fragments (e.g., fragments of fruit, vegetables, or nuts), these fragments may be visible within the substrate.

[0188] "Substrate content" refers to the content derived from the substrate after the dehydration step and any final processing steps. Thus, "plant-based ingredients" refers to the content derived from the plant-based substrate after dehydration and any final processing steps.

[0189] In some embodiments, the snack product has a substrate content of about 8 wt % to about 87 wt % based on the weight of the snack product. In some embodiments, the snack product has a substrate content of about 15 wt % to about 87 wt %. In some embodiments, the snack product has a substrate content of about 35 wt % to about 87 wt %, about 36.5 wt % to about 87 wt %, about 40 wt % to about 87 wt %, about 45 wt % to about 87 wt %, about 45 wt % to about 87 wt %, about 50 wt % to about 87 wt %, about 55 wt % to about 87 wt %, about 60 wt % to about 87 wt %, about 65 wt % to about 87 wt %, or about 68 wt % to about 87 wt %.

[0190] The base content of the snack may vary depending on the type of base used in the batter.

[0191] For example, when the substrate is a powdered muffin mix, the resulting snack product may have a substrate content of about 37 wt% based on the weight of the snack product, and a moisture content of about 4 wt% based on the weight of the snack product. As another example, when the substrate is vanilla ice cream, the snack product may have a substrate content of about 60 wt% based on the weight of the product, and a moisture content of about 4 wt% based on the weight of the snack product.

[0192] In some embodiments where the substrate is a plant-based substrate, the snack product has about 15 wt % to about 70 wt % plant-based ingredients, based on the weight of the snack product, or about 30 wt % to about 87 wt %, or about 35 wt % to about 87 wt %, or about 36 wt % to 87 wt %, or about 37 wt % to about 87 wt %, or about 35 wt % to about 70 wt %, or about 36 wt % to about 70 wt %, or about 36 wt % to about 56 wt %, or about 37 wt % to about 55.5 wt % plant-based ingredients, based on the weight of the snack product.

[0193] For embodiments comprising a plant-based substrate, the plant-based ingredients in the snack may vary depending on the type of plant-based substrate used in the batter. For example, a batter comprising chili puree as a plant-based substrate (according to Examples 2, 7, and 8) provides a dehydrated finished product having a moisture content of about 4 wt% and comprising about 19.5 wt% of the plant-based ingredients based on the weight of the product. Such a product may contain about 69.7 wt% starch based on the weight of the product.

[0194] As another example, a batter comprising green pea puree as a plant-based base and about 8% starch provides a dehydrated finished product having a moisture content of about 4 wt % and comprising about 66 wt % of plant-based ingredients based on the weight of the product. Such a product comprises about 24 wt % starch based on the weight of the product.

[0195] As another example, a batter comprising gazpacho as a plant-based base provides a dehydrated finished product having a moisture content of about 4 wt% and comprising about 53 wt% of plant-based ingredients based on the weight of the product. Such a product comprises about 34 wt% starch based on the weight of the product.

[0196] The finished product has a crispy structure commonly associated with snack products, wherein the matrix has a light and crisp uniform puffed structure containing air pore voids. The puffed structure can be achieved without frying. Thus, the present disclosure provides a puffed, non-fried snack product.

[0197] The microstructure of the finished product can be analyzed and characterized using microscopy and calculations as described below.

[0198] In the analysis, the finished product is broken at a statistically significant number of locations on the surface of the product to reveal the internal microstructure of the cross section. The cross section is analyzed using microscopy, preferably scanning electron microscopy (SEM), although optical microscopy may alternatively be used.

[0199] like Figure 2 As shown, the pore size is determined by measuring a given pore by taking a statistically significant number of measurements of the distance between the opposite edges of the pore extending through the center point (i.e., the width of the pore). Figure 2As shown, there can be 8 pore widths t i See Figure 2 , for any given pore, the pore size Φ is preferably calculated as the pore width t i The average value of is therefore calculated in this embodiment as:

[0200] Φi=Σ1 8 t i / 8.

[0201] The pore size of the pore structure of the matrix is ​​calculated as the average pore size Φ of a statistically significant number of pores (i.e., n pores) 2D , which is a two-dimensional value obtained from the two-dimensional measurement of the pores on the cross section. Therefore, in this embodiment, the pore diameter expressed as a two-dimensional area is calculated as follows:

[0202] Φ 2D =Σ i＝1 n Φ i / n.

[0203] In this embodiment, the three-dimensional value of the pore size of the pore structure, i.e., the volume, is calculated by applying a normalized correction factor of 1204.3 to the two-dimensional pore size, thus:

[0204] Φ 3D =1204.3Φ 2D .

[0205] The anisotropy ratio R of the pores was also calculated. As mentioned above, for a given pore, the width t i multiple values ​​of , and from these values ​​the maximum value of the width t can be obtained max .

[0206] For any given pore, the anisotropy ratio R i By the maximum width value t max and the value of the width perpendicular to the maximum width t perp (like Figure 3 Calculated as shown).

[0207] The anisotropy ratio of any given pore is calculated as follows:

[0208] Ri=t max / t perp .

[0209] The anisotropy ratio R of the pore structure of the matrix max Calculated as the average anisotropy ratio R of a statistically significant number of pores (i.e., n pores) i, which is a two-dimensional value obtained from a two-dimensional measurement of the pores in the cross section. Therefore, in this embodiment, the anisotropy ratio R of the pore diameter of each of the first pore structure or the second pore structure is max The calculation is as follows:

[0210] R max =Σ i＝1 n R i / n.

[0211] To analyze the size distribution of pores, the standard deviation SD was calculated as follows:

[0212] SD=√((Σ i＝1 n (Φ i –Φ) 2 ) / n-1)

[0213] where Φi is the size of each individual pore and Φ is the average (by number) pore size of the distribution.

[0214] The normalized standard deviation NSD is calculated as:

[0215] NSD=SD / Φ

[0216] where Φ is the average (by number) pore size of the distribution.

[0217] Fig. 12A A SEM of a cross section of a product according to an embodiment of the present disclosure is shown and shows the internal matrix pore structure. A corresponding mask generated for analysis purposes is also provided. Fig. 12B Shows Fig. 12A The pore size distribution diagram of the pore structure shown in . The following Table 3 provides the pore size distribution diagram from Fig. 12A Parameters for the analysis of the pore structure.

[0218] Finished products according to the present disclosure may have a defined pore size distribution.

[0219] In some embodiments, the pore size distribution has a number average pore size Φ of about 300 μm to 1100 μm. 2D , and its normalized standard deviation NSD is about 0.6, 0.7 or 0.8 to 1.8. In some embodiments, the number average pore size Φ of the pore size distribution is 2Dis about 350 μm to 1050 μm, about 400 μm to 1000 μm, about 500 μm to 950 μm, about 650 μm to 950 μm, about 700 μm to 950 μm, about 750 μm to 950 μm, about 800 μm to 950 μm, or about 850 to 950 μm; or about 900 μm, about 920 μm, about 940 μm, about 950 μm, about 960 μm, about 970 μm, about 980 μm, about 990 μm, or about 1000 μm. In some embodiments, the normalized standard deviation NSD is about 0.6 to 1.5, 0.65 to 1.5, 0.7 to 1.5, or 0.8 to 1.5, about 0.8 to 1.3, or about 0.8 to 1.2. Number average pore size Φ 2D and the normalized standard deviation NSD were calculated as described above.

[0220] In some embodiments, the pore size distribution has a number average pore size Φ of about 400 μm to 1400 μm. 3D In some embodiments, the number average pore size Φ of the pore size distribution is 3D The average pore size is about 450 μm to 1350 μm, about 500 μm to 1300 μm, about 550 μm to 1300 μm, about 600 μm to 1300 μm, about 700 μm to 1250 μm, about 800 μm to 1250 μm, about 900 μm to 1250 μm, about 1000 μm to 1250 μm, about 1100 μm to 1250 μm, or about 1150 μm to 1250 μm; or about 1190 μm, about 1200 μm, about 1205 μm or about 1210 μm. The average pore size Φ 3D Calculated as above.

[0221] In some embodiments, the pore size distribution N v About 8×10 per unit area 2 Up to 2×10 4 Optionally, the pore size distribution N v About 8.5×10 per unit area 2 Up to 1×10 4 , about 8.5×10 2 Up to 5×10 3 , about 9×10 2 Up to 1×10 3 , about 9.5×10 2 Up to 8×10 3 , about 9.5×10 2 Up to 5×10 3 , about 9.5×10 2 Up to 5×10 3 , about 9.5×10 2 Up to 2×10 3 , about 9.6×102 Up to 1×10 3 , about 9.7×10 2 Up to 1×10 3 , or about 9.7×10 2 to 9.9×10 2 The number of holes per unit area is N v Calculated as above.

[0222] In some embodiments, the number average anisotropy ratio R of the pores is max is about 1.4 to 2.2. Optionally, the number average anisotropy ratio R of the pores is max is about 1.4 to 2.1, about 1.5 to 2.0, about 1.55 to 1.9, about 1.55 to 1.8, about 1.6 to 1.75; or about 1.6 or 1.65. The number average anisotropy ratio R max Calculated as above.

[0223] Analysis of the products according to the present disclosure showed similar puffing levels and internal structures to conventionally made puffed snack products. Therefore, the present disclosure can be used to prepare non-fried puffed snack products containing plant-based substrates, which fills a gap in the current snack market.

[0224] The present disclosure also provides a kit for making non-fried, non-extruded puffed snack products using a microwave oven. In a preferred embodiment, the kit is suitable for use in a home environment.

[0225] In some embodiments, the kit comprises a batter according to the present disclosure. Alternatively, the kit may comprise an amount of base material; and an amount of emulsifier and starch sufficient to mix with an amount of base material and optionally added water to produce a batter suitable for use according to the present disclosure.

[0226] Alternatively, the kit may contain an amount of emulsifier and starch sufficient to be mixed with an amount of base selected by the user and optionally added water to produce a batter suitable for use according to the present disclosure.

[0227] In each case, the kit may also include one or more separate mould compartments for use with the batter.

[0228] In embodiments of the kit comprising a substrate, the substrate can be any substrate discussed in the present disclosure. In embodiments of the kit comprising a starch and an emulsifier, the starch and the emulsifier can be in accordance with the present disclosure.

[0229] In some embodiments where the kit comprises a substrate, the substrate may be in liquid or powder form; in some such preferred embodiments, the substrate is in powder form.

[0230] The kit may also include user instructions detailing, for example, how to make the batter, the amounts to dispense into the mould compartments and details relating to microwave settings and dehydration / finishing times.

[0231] advantage

[0232] The inventors of the present disclosure unexpectedly discovered that a batter comprising a substrate (e.g., a plant-based substrate), starch, and an emulsifier can be dehydrated using microwaves to produce an expanded snack. Thus, the present disclosure advantageously allows for the production of non-fried, non-extruded expanded snack products from a wet substrate, particularly non-fried, non-extruded expanded snack products comprising a high level of minimally processed plant substrates (including fresh plant substrates, such as fresh fruits and vegetables). The product has a desired "fluffy and light" low-density, high-porosity microstructure, similar to snack products conventionally made by extrusion followed by frying; and retains the bright color and flavor of the minimally processed plant-based substrate from which the snack product is made. The method for making the snack product has the advantages of being simple and inexpensive, and can be easily implemented in industrial or home kitchens.

[0233] Without being bound by any theory, it is believed that these products are achieved using an explosive dehydration method (i.e., microwaves) that causes the temperature of the water in the batter to rise rapidly, increasing the internal pressure, resulting in the formation of bubbles of varying sizes but primarily spherical. The size of the bubbles is controlled by the addition of an amphiphilic emulsifier and careful selection of the mold (to avoid the center of the snack being just empty), while the viscosity of the batter helps to keep the substrate fragments, specifically, suspended as the batter gels. It is believed that while the batter solidifies, the water in the batter begins to evaporate from the snack, resulting in a puffed shape that does not collapse. It is said that the heating and dehydration need to be done quickly, otherwise the steam escapes faster than solidification, resulting in a flat, dense product.

[0234] The present invention will now be described in more detail with reference to the following non-limiting examples.

[0235] Example

[0236] Example 1

[0237] Experiments were conducted to demonstrate the unexpected discovery that by providing a mixture of starch, emulsifier and water, dispensing the mixture into a mould and dehydrating the mixture using microwaves, an expanded matrix having a texture similar to that of a conventional (extruded then fried) snack product can be produced.

[0238] Make the batter as follows:

[0239]

[0240] The batter is mixed until all ingredients are well combined, but without stirring or intentional aeration. The mixture, which resembles a thick batter, is then poured into cubic silicone molds (about 7 g per mold unit). The filled molds are dehydrated in a microwave oven at half power (1300 kW) for 2 minutes to 3 minutes, and then at full power (2600 kW) for 2 minutes to 3 minutes, until the cubes have expanded and become mostly solid. The cubes are then removed from their molds and finished by baking on a metal tray in an oven at 100 degrees for 15 minutes to 20 minutes. The moisture content after baking is 3%.

[0241] Figure 4A (a) and (b) show SEM images of cross sections of two resulting products (referred to herein as "prototypes").

[0242] Figure 4B Shows Figure 4A Table 1 below provides average data for analyzing the pore structures of multiple prototypes as shown in (a) and (b) of FIG. 4 .

[0243] Table 1

[0244] <![CDATA[Φ 2D (μm)]]> <![CDATA[Φ 3D (μm)]]> SD NSD Ry / x Rmax 544.6 693.2 367.5 0.67 1.38 1.88

[0245] As a comparison, Figure 5A (a) and (b) show two SEM image of the cross section. It is made of fortified corn flour, vegetable oil, cheese seasoning salt, whey protein concentrate, monosodium glutamate, lactic acid, citric acid, sunset yellow and salt, and is made by extrusion followed by frying.

[0246] right Figure 5A The two shown The pore structures of the samples were compared and analyzed. Figure 5B Shows Figure 5A The pore size distribution diagram of the pore structure ((a) and (b)) shown in FIG. The following Table 2 provides multiple The average data.

[0247] Table 2

[0248] <![CDATA[Φ 2D (μm)]]> <![CDATA[Φ 3D (μm)]]> SD NSD Ry / x Rmax 425.9 542.2 331.0 0.78 1.16 1.72

[0249] It can be seen that the length of the prototype product is The longer the prototype, the more uniform the pores are. However, the prototype has Similar internal structure, and the overall pore size distribution is also similar to resemblance.

[0250] Example 2

[0251] Products were prepared according to the present disclosure using 6 different plant-based substrates and in each case water was added.

[0252] Element Amount (wt%) Pregelatinized waxy corn starch 11.90 water 43.65 Plant-based substrate: vegetable puree 42.66 Salt 0.50 Lecithin 1.29

[0253] The vegetable puree in each case was made from one vegetable selected from the following: beetroot, parsnip, green peas, sweet potato, mushroom, red pepper.

[0254] 1. Cook IQF (Individually Quick Frozen) vegetables at 100°C until cooked through and soft. For example, for red peppers this takes about 9 minutes.

[0255] 2. Then use a hand blender to blend the cooked vegetables into a smooth paste.

[0256] 3. Combine the vegetable puree with the water, then mix in the dry ingredients (pre-gelatinized waxy corn starch, salt, and lecithin). Mix the batter until all ingredients are well combined, but without stirring or intentionally aerating.

[0257] 4. Then pour the mixture similar to a thick batter into cubic silicone molds (about 7g per mold unit).

[0258] 5. The filled moulds were dehydrated in a microwave oven at half power (1300 kW) for 2 to 3 minutes and then at full power (2600 kW) for 2 to 3 minutes until the cubes had expanded and were mostly solid.

[0259] 6. The cubes are then removed from their molds and given a final finishing touch by baking them on a metal tray in the oven at 100 degrees for 15 to 20 minutes.

[0260] Finished product density: 0.05g / ml to 0.1g / ml

[0261] Moisture Content:

[0262] Batter: 80wt%

[0263] After microwave dehydration: 12wt%

[0264] After oven baking: 4-5wt%

[0265] Figure 6 An image of the finished product is shown where the vegetable puree is (from left to right) beetroot, parsnip, green peas, sweet potato, mushroom, red pepper.

[0266] Example 3

[0267] Experiments were conducted to determine the effect of varying the amount of starch in the batter.

[0268] The batter was prepared using red pepper according to Example 2, but containing 5wt%, 8wt%, 12wt%, 15wt%, 20wt% and 25wt% of pregelatinized waxy corn starch respectively. The amount of water added was changed accordingly to reach 100wt%. The batter was distributed into molds, dehydrated and finished as in Example 2.

[0269] The results are shown in Figure 7, indicating that increasing the amount of starch results in increased puffing of the product, with a small "collar" or "edge" appearing at the top, where the batter extends above the mold during puffing ( Fig. 7A In addition, an increase in the amount of starch results in a decrease in color intensity ( Figure 7B ).

[0270] These findings indicate that about 8 wt% to 25 wt% added starch provides a suitably expanded product.

[0271] Example 4

[0272] Experiments were conducted to determine the effect of using native starch in batter.

[0273] The batter is made of 43.65wt% water, 42.66wt% chili paste, 0.5wt% salt and 1.29wt% lecithin, and 11.9wt% corn starch, waxy corn starch or potato starch. Each batter is distributed into a mold according to Example 2, dehydrated and finished.

[0274] The results are as follows Figure 8 As shown, it is shown that the use of corn starch (A), waxy corn starch (B) and potato starch (C) results in a denser and firmer texture than the use of pregelatinized starch.

[0275] Example 5

[0276] Experiments were carried out to determine the effect of removing emulsifier (A) or salt (C) from batters. These batters were compared to batters containing low levels (5 wt%) of added starch (B).

[0277] Batter (A) (without emulsifier) ​​contains:

[0278] 11.9 wt% starch;

[0279] 0.5 wt% salt;

[0280] 43.95 wt% chili puree; and

[0281] 43.65 wt% of added water.

[0282] Batter (B) (low starch) contains:

[0283] 5.29 wt% starch;

[0284] 2.12wt% (distilled monoglycerides made from edible refined hydrogenated palm oil);

[0285] 0.53 wt% salt;

[0286] 45.50 wt% chili puree; and

[0287] 46.56 wt% water.

[0288] Batter (C) (without salt) contains:

[0289] 11.9 wt% starch;

[0290] 1.29 wt% lecithin;

[0291] 43.16 wt% chili puree; and

[0292] 43.65 wt% of added water.

[0293] The batter was distributed into moulds, dehydrated and finished as in Example 2.

[0294] The results are as follows Fig. 9 The results show that, as expected, using 5 wt% added starch (B) produced a darker, less over-expanded product than using higher levels of starch (see results in Figure 7). Removing salt from the batter did not affect over-expanding, producing a light and porous product (C). Removing emulsifiers from the batter significantly affected over-expanding (A).

[0295] Example 6

[0296] Experiments were conducted to determine the effect of varying the amount of water added to the batter. The batter contained 11.9 wt% starch, 1.29 wt% lecithin and 0.5 wt% salt, and contained 15 wt%, 30 wt%, 45 wt%, 60 wt% and 75 wt% of added water, respectively. Chilli puree was then added as needed to reach 100 wt%.

[0297] The batter was distributed into moulds, dehydrated and finished as in Example 2.

[0298] The results are as follows Fig.10As shown (10A: 15 wt% added water; 10B: 30 wt% added water; 10C: 45 wt% added water; 10D: 60 wt% added water; 10E: 75 wt% added water), it is shown that lower levels of added water produce a darker and harder product, while batters containing higher levels of added water produce a lighter color and a more open cell structure.

[0299] Example 7

[0300] The microstructures of the different products were visually compared. The batter was prepared according to the following recipe:

[0301]

[0302]

[0303] Other details are as per Example 2.

[0304] Fig.11 A shows a SEM image of a cross section of products A to D.

[0305] Will Fig.11 Product C in A is similar to Figure 5 (Figure 5 shows two Visual comparison of the products according to the present disclosure with SEM images of cross sections of the products shown in Figure 1 (A) shows that the products according to the present disclosure have similar puffing levels and internal structures as known conventionally made puffed snack products.

[0306] Example 8

[0307] Quantitative analysis was used to compare the microstructure of Product C according to the present disclosure in Example 7 with known conventionally prepared expanded snack products.

[0308] Fig. 12A An SEM of the pore structure of a cross section of Product C is shown, along with the corresponding mask used for the analysis.

[0309] Fig. 12B Shows Fig. 12A The pore size distribution diagram of the pore structure shown in Table 3 below is provided. Fig. 12A Parameters for mesopore structure analysis:

[0310] Table 3

[0311] <![CDATA[Φ 2D (μm)]]> <![CDATA[Φ 3D (μm)]]> SD NSD <![CDATA[N v (pores / cm 3 )]]> Ry / x Rmax 946.0 1204.3 781.5 0.83 <![CDATA[9.8E +02 ]]> 1.02 1.64

[0312] Fig. 12A The product shown has a highly expanded structure with a uniform size distribution of most of the pores <1250 μm. Some larger voids are present, which may be due to the coalescence of bubbles during the dehydration of the batter.

[0313] As mentioned above, Figure 5A The two types shown in A comparative analysis was conducted. Figure 5B Shows Figure 5A The pore size distribution diagram of the pore structure ((a) and (b)) shown in FIG. Table 2 above provides Figure 5A Parameters for mesopore structure analysis.

[0314] Products (such as Figure 5A ) and the product made according to the present disclosure (as shown Fig.11 A), having a highly expanded structure in which most of the pore voids have a uniform size distribution, which is comparable to the present disclosure (taking into account the standard deviation), and there are some larger voids.

[0315] This analysis showed that the products according to the present disclosure had similar expansion levels and internal structure as known conventionally made expanded snack products.

[0316] Example 9

[0317] According to the present disclosure, 20 different products were prepared, as shown in the following table (Note: Precisa Crisp It is waxy corn starch; The Rainbow Maker smoothie contains apple juice from concentrate (from 2.25 apples), kiwi puree (half a kiwi), blueberry puree (46 blueberries), banana puree (half a banana), mango puree (a quarter of a mango), blackberry puree (6 blackberries), beet juice (from 1 / 5 of a red beet), calcium nitrate, vitamin E acetate, niacinamide, vitamin C, vitamin B5, vitamin B6, vitamin B12 and vitamin D3. Gazpacho contains tomatoes (59%), red peppers (12%), cucumbers (12%), onions (9%), extra virgin olive oil (2.6%), white wine vinegar, salt, garlic, lemon juice (93% vegetable content); Hot or Mild Salad containing tomatoes (68%; pureed, diced, mashed), peppers (14%), onions (13%), vinegar, salt, sugar, garlic, vegetable gum (xanthan gum), firming agent (calcium chloride), food acid (citric acid), coriander, vegetable oil and spice extract (capsicum); Pepsi Contains soda water, color (caramel E150d), sweeteners (aspartame, acesulfame potassium), acids (phosphoric acid, citric acid), flavors (including caffeine), preservatives (potassium sorbate); vanilla ice cream contains whole milk, heavy cream (27%), demerara sugar, skimmed milk powder, pasteurized eggs, maltodextrin, vanilla extract, sugar and crushed vanilla pods. An alternative ice cream was also used as a base material and an expanded snack product was produced according to the present disclosure (results not shown here); it contains reconstituted skimmed milk concentrate, sugar, partially reconstituted buttermilk powder, coconut oil, palm stearin, palm oil, dextrose, palm kernel oil, emulsifiers (mono- and diglycerides of fatty acids), flavors, stabilizers (locust bean gum, guar gum), vanilla pods, color (algae carotene, beet red, curcumin); muffin mix contains wheat flour, sugar, whey powder, dried egg yolks, dextrose and salt.

[0318]

[0319]

[0320]

[0321]

[0322] method

[0323] Prepare the batter according to the recipe shown: Dry ingredients (e.g. Precisa lecithin and salt) in one bowl; wet ingredients in another bowl; then gradually mix dry ingredients into wet ingredients using a hand mixer.

[0324] The table below shows the moisture content and viscosity of some test batters.

[0325]

[0326] The mould used has 20 compartments, each measuring 2.5cm x 2.5cm x 2.5cm, with each compartment separated only by a dividing wall. 6g to 7g of batter is added to alternating compartments as follows:

[0327]

[0328] The filled mould is placed in a microwave oven (as used in Example 2) and dehydrated by a number of short microwave steps as follows: 30 seconds at half power (750 W), then 3×10 seconds; then 9×6 seconds; then 2×20 seconds; then 20 seconds at full power (1500 W), then 2×30 seconds; then 1×20 seconds; then 10 seconds. At the end of each time interval, the mould is rotated 90° (because the microwave oven used does not have an internal rotating plate; if there is an internal rotating plate, it is not necessary to rotate). At the end of microwave dehydration, the mould is removed from the microwave oven, the product is removed from the mould compartment and baked in an oven at 100°C for 15 minutes. The resulting cube is puffy and mostly solid.

[0329] Example 10 - Microwave dehydration only (no finishing step)

[0330] The batter was prepared according to the present disclosure. The mould used had 20 compartments, each compartment was 2.5 cm x 2.5 cm x 2.5 cm, each compartment was separated only by a dividing wall. 4 g to 5 g of batter was added to each compartment.

[0331] The mold was placed in a Kenwood household microwave oven (model K23MSS15; relevant voltage: 230-240V ~ 50Hz; microwave input power: 1200-1250W; frequency: 2450MHz; microwave output power: 750-800W) and the microwave oven was set to the "medium" power setting. The microwave exposure time was slightly different depending on the moisture content of the batter.

[0332] Microwave dehydration for 1 minute, repeat 3 times for a total dehydration time of 4 minutes. Then visually inspect the product and, if necessary, microwave dehydrate for another 30 seconds, then visually inspect again and, if necessary, microwave dehydrate for another 30 seconds. This gives a total microwave dehydration time of 5 to 6 minutes. Use shorter (30 second) intervals to help ensure that the product is not overcooked or burned.

[0333] The dehydrated product is then removed from the mould. No final processing steps are taken.

[0334] Consumer testing

[0335] The products obtained in Example 9 were rated by different consumer groups. Generation Z consumers (18-25 years old, at least part-time job) believed that the most satisfactory products were Thai winter squash curry, Spanish cold soup, maple syrup muffins and Japanese peas; family group consumers (parents with children aged 3-9 years old) believed that the most satisfactory products were cauliflower cheese, sweet corn and salsa sauce and vanilla ice cream; while the middle-aged consumer group (45-65 years old) believed that the most satisfactory products were Spanish cold soup and red pepper and Manchego cheese.

[0336] Comparative Example: "Babypuff" recipe from Jean Choi's website "What great grandmaate"

[0337] Make the batter as follows: 120 grams oat flour; 225 grams fruit puree; 1 tablespoon melted coconut oil; 2 egg yolks; 1 teaspoon baking powder.

[0338] Place the ingredients in a bowl and mix until a batter similar to a thick muffin batter is formed, adding 1 tablespoon of water at a time if necessary. Heat a conventional oven to 180°C and line a baking sheet with parchment paper. Pour the batter into a piping bag or a resealable plastic bag (with one corner cut off) and pipe the batter onto the baking sheet in small portions, making sure they do not touch each other. Then place the tray in the oven and bake for 8 minutes, turning it over once halfway through. Then reduce the oven temperature to 120°C and bake for a further 20-30 minutes (depending on the shape and size of the puffs), until the puffs are dry to the touch and are lightly golden on the sides and bottom. Remove the puffs from the oven, transfer to a work surface and leave to cool completely on the baking sheet. The resulting product is as follows Fig.13 As shown, a dense and minimally expanded product is shown.

[0339] Various modifications to the embodiments of the invention described herein will be apparent to those skilled in the art and are intended to be included within the scope of the appended claims.

[0340] In addition, the following technical aspects are provided:

[0341] 1. A non-fried puffed snack product comprising a plant-based ingredient, an emulsifier and starch, wherein the snack product comprises a hard matrix containing the plant-based ingredient, wherein the matrix defines a pore structure having a pore size distribution, wherein the pore size distribution has a number average pore size Φ of 300 μm to 1100 μm 2D , with a normalized standard deviation ranging from 0.8 to 1.8.

[0342] 2. A non-fried puffed snack product according to aspect 1, wherein the plant-based ingredient (a) contains no more than 15 wt% of wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa or buckwheat; and / or (b) contains no more than 15 wt% of potatoes.

[0343] 3. The non-fried expanded snack product according to aspect 1 or aspect 2, wherein the pore size distribution has a number average pore size Φ of 400 μm to 1000 μm 2D , with a normalized standard deviation of 0.8 to 1.5; optionally, wherein the pore size distribution has a number average pore size Φ of 850 μm to 950 μm 2D , with a normalized standard deviation ranging from 0.8 to 1.2.

[0344] 4. The non-fried expanded snack product according to any one of aspects 1 to 3, wherein the pore size distribution has a number average pore size Φ of 400 μm to 1400 μm. 3D , optionally wherein the pore size distribution has a number average pore size Φ of 1150 μm to 1250 μm 3D .

[0345] 5. The non-fried expanded snack product according to any one of aspects 1 to 4, wherein the pore size distribution has a pore size distribution of 8×10 2 Up to 2×10 4 N of holes v , optionally wherein the pore size distribution has a pore size distribution per unit area of ​​about 8.5×10 2 to 9.9×10 2 N of holes v .

[0346] 6. The non-fried expanded snack product according to any one of aspects 1 to 5, wherein the air cells have a number average anisotropy ratio R of 1.4 to 2.2. max , optionally wherein the pores have a number average anisotropy ratio R of 1.6 to 1.7 or 1.6 or 1.65 max .

[0347] 7. The non-fried expanded snack product according to any one of aspects 1 to 6, comprising 15 wt% to 70 wt% of the plant-based ingredients based on the weight of the snack product.

[0348] 8. The non-fried expanded snack product according to any one of aspects 1 to 6, comprising 19 wt% to 70 wt% of the plant-based ingredients based on the weight of the snack product.

[0349] 9. A non-fried puffed snack according to any one of aspects 1 to 8, wherein the moisture content of the snack is from 0.5 wt% to 5 wt%.

[0350] 10. A batter for making a non-fried puffed snack product according to any one of aspects 1 to 9, comprising a plant-based base, an emulsifier and starch, wherein the batter contains: (a) about 20% to 95% of the plant-based base; (b) about 0.3% to 2.5% of the emulsifier; (c) about 8% to 25% of the starch; and (d) optionally added water.

[0351] 11. The batter according to aspect 10, wherein the plant-based substrate: i comprises one or more fresh vegetables and / or fruits; ii comprises no more than about 15 wt % wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa or buckwheat; and / or iii comprises no more than about 15 wt % potatoes.

[0352] 12. The batter according to aspect 10 or 11, wherein the moisture content of the batter is about 55 wt% to 90 wt% based on the weight of the batter.

[0353] 13. The batter according to any one of aspects 10 to 12, wherein the starch is pregelatinized starch.

[0354] 14. A method for making a non-fried expanded snack product, comprising: (i) providing a plant-based substrate; (ii) optionally processing the plant-based substrate to provide a coarse puree; (iii) providing an emulsifier; (iv) providing starch, optionally wherein the starch is pregelatinized starch; (v) mixing the plant-based substrate, the emulsifier and the starch and optionally added water to form a batter having a moisture content of about 55 wt % to about 90 wt % based on the weight of the batter; (vi) dispensing the batter into individual mold compartments; and (vii) using microwaves to dehydrate the batter to produce a dehydrated product, the dehydrated product having a moisture content of about 2 wt % to 20 wt % based on the weight of the dehydrated product.

[0355] 15. A method according to any one of aspects 9 to 12, wherein step (ii) comprises cooking or partially cooking the substrate to soften its cell walls and / or reduce the size of the substrate to no more than 5 mm 2 , not more than 4mm 2 or less than 3mm 2 .

[0356] 16. A method according to aspect 14 or 15, wherein the individual mould compartments are spaced at least 5 mm apart, optionally wherein the compartments are arranged in a ring geometry with one or more empty (ie containing no batter) compartments in the centre.

[0357] 17. The method according to any one of aspects 14 to 16, further comprising (viii) a final processing step to provide a finished product having a moisture content of about 3 wt % to 10 wt % based on the weight of the finished product, optionally wherein the final processing step comprises baking the product.

[0358] 18. A snack product obtainable by the method of any one of aspects 14 to 17.

[0359] 19. A non-fried, non-extruded puffed snack product comprising an edible base, an emulsifier and a starch, wherein the snack product comprises an puffed hard matrix comprising the base.

[0360] 20. The non-fried, non-extruded puffed snack product according to aspect 1, wherein the substrate does not comprise:

[0361] i. Leavening agent or leavening agent;

[0362] ii. eggs or egg components;

[0363] iii. isolated plant protein; and / or

[0364] iv. More than 15 wt% potatoes.

[0365] 21. The non-fried, non-extruded expanded snack product according to aspect 19 or aspect 20, wherein the substrate does not contain yeast, sodium bicarbonate, baking powder, ammonium carbonate, ammonium bicarbonate or calcium azide.

[0366] 22. The non-fried, non-extruded expanded snack product according to any one of aspects 19 to 21, wherein the substrate comprises:

[0367] (a) a dairy product, optionally wherein the substrate is ice cream;

[0368] (b) A base for the product, optionally wherein the base material is a liquid or powdered muffin mix.

[0369] 23. A non-fried, non-extruded puffed snack product according to any one of aspects 9 to 22, wherein the snack product comprises from about 15 wt % to about 85 wt % of the substrate based on the weight of the snack product; optionally wherein the snack comprises from about 19 wt % to about 70 wt % of the substrate based on the weight of the snack product.

[0370] 24. The non-fried, non-extruded expanded snack product according to any one of aspects 19 to 23, wherein the substrate defines a pore structure having a pore size distribution, wherein the pore size distribution:

[0371] (a) having a number average pore size Φ of 300 μm to 1100 μm 2D , whose normalized standard deviation is 0.8 to 1.8;

[0372] (b) having a number average pore size Φ of 400 μm to 1400 μm 3D , optionally wherein the pore size distribution has a number average pore size Φ of 1150 μm to 1250 μm 3D ; and / or

[0373] (c) has a per unit area of ​​8×10 2 Up to 2×10 4 N of holes v , optionally wherein the pore size distribution has a pore size distribution per unit area of ​​about 8.5×10 2 to 9.9×10 2 N of holes v ; and / or

[0374] (d) wherein the pores have a number average anisotropy ratio R of 1.4 to 2.2 max , optionally wherein the pores have a number average anisotropy ratio R of 1.6 to 1.75 or 1.6 or 1.65max .

[0375] 25. The non-fried, non-extruded puffed snack product according to any one of aspects 19 to 24, wherein the moisture content of the snack product is from about 0.5 wt% to about 5 wt%.

[0376] 26. The non-fried, non-extruded puffed snack product according to any one of aspects 19 to 25, wherein the starch is a pregelatinized starch.

[0377] 27. A batter for making a non-fried, non-extruded puffed snack product according to any one of aspects 19 to 26, wherein the batter comprises:

[0378] a. about 20% to about 95% of the substrate;

[0379] b. about 0.3% to about 2.5% of an emulsifier;

[0380] c. about 8% to about 25% starch;

[0381] d. Optionally, added water,

[0382] The moisture content of the batter is about 65 wt % to about 85 wt % based on the weight of the batter.

[0383] 28. A method for preparing a non-fried, non-extruded puffed snack product comprising:

[0384] (i) providing an edible substrate;

[0385] (ii) optionally processing the substrate;

[0386] (iii) providing an emulsifier;

[0387] (iv) providing starch, optionally wherein the starch is pregelatinized starch;

[0388] (v) mixing the base, the emulsifier and the starch and optionally added water to form a batter having a moisture content of about 65 wt % to about 85 wt % based on the weight of the batter;

[0389] (vi) dispensing the batter into individual mould compartments; and

[0390] (vii) dehydrating the batter using microwaves to produce a dehydrated product having a moisture content of about 2 wt % to about 20 wt % based on the weight of the dehydrated product.

[0391] 29. The method according to aspect 28, wherein the substrate comprises no more than 20 wt% of the powdered or granular substrate.

[0392] 30. The method according to aspect 28 or aspect 29, wherein the substrate is one or more of the following:

[0393] (a) a dairy product, optionally wherein the substrate is ice cream;

[0394] (b) A base for the product, optionally wherein the base material is a liquid or powdered muffin mix.

[0395] 31. A method according to any one of aspects 28 to 30, wherein the individual mould compartments are spaced at least 5 mm apart, optionally wherein the compartments are arranged in a ring geometry with one or more empty (ie, containing no batter) compartments in the centre.

[0396] 32. The method according to any one of aspects 28 to 31, further comprising (viii) a final processing step to provide a finished product having a moisture content of about 3 wt % to 10 wt % based on the weight of the finished product, optionally wherein the final processing step comprises baking the product.

[0397] 33. A snack product obtainable by the method of any one of aspects 28 to 32.

[0398] 34. A kit for making a non-fried, non-extruded puffed snack product, wherein the kit comprises:

[0399] (a) A batter according to aspect 27, optionally further comprising one or more separate mould compartments for use with the batter; or

[0400] (b) an amount of substrate; and an amount of emulsifier and starch sufficient to mix with the amount of substrate and optionally added water to produce a batter having a moisture content of about 65 wt % to about 90 wt % based on the weight of the batter; optionally further comprising one or more separate mold compartments for use with the batter;

[0401] (c) an amount of emulsifier and starch sufficient to mix with an amount of base material and optionally added water to produce a batter having a moisture content of about 65 wt % to about 90 wt % based on the weight of the batter; optionally further comprising one or more separate mold compartments for use with the batter.

[0402] 35. A kit according to aspect 34(b), wherein the substrate comprises one or more of a dairy product or a product base; optionally wherein the substrate comprises ice cream or a pancake mix.

[0403] 36. A kit according to aspect 34(b) or (c) or aspect 35, wherein the substrate is in liquid or powder form.

Claims

1. A non-fried, non-extruded puffed snack product comprising a plant-based substrate, an emulsifier and starch, wherein the snack product comprises an puffed hard matrix comprising the plant-based substrate, and wherein the plant-based substrate comprises: a) one or more fruits and / or vegetables; and b) The base material in powder or granular form does not exceed 20 wt%.

2. The non-fried, non-extruded puffed snack product according to claim 1, wherein the one or more fruits and / or vegetables are fresh fruits and / or vegetables; or are fresh fruits and / or vegetables that have been frozen.

3. The non-fried, non-extruded expanded snack product of claim 1 or claim 2, wherein the plant-based substrate: a) contains no more than 15 wt% wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa or buckwheat; b) contains not more than 15 wt% potatoes; or c) Does not contain cereal crops.

4. The non-fried, non-extruded puffed snack product according to any one of claims 1 to 3, wherein the snack product comprises from about 15 wt % to about 70 wt % of the plant-based substrate, based on the weight of the snack product; optionally, wherein the snack product comprises from about 19 wt % to about 70 wt % of the plant-based substrate, based on the weight of the snack product.

5. The non-fried, non-extruded puffed snack product of any one of claims 1 to 4, wherein the matrix defines a pore structure having a pore size distribution, wherein the pore size distribution: (a) having a number average pore size Φ of 300 μm to 1100 μm 2D , whose normalized standard deviation is 0.8 to 1.8; (b) having a number average pore size Φ of 400 μm to 1400 μm 3D , optionally wherein the pore size distribution has a number average pore size Φ of 1150 μm to 1250 μm 3D ; and / or (c) has a per unit area of ​​8×10 2 Up to 2×10 4 N of holes v , optionally wherein the pore size distribution has a pore size distribution per unit area of ​​about 8.5×10 2 to 9.9×10 2 N of holes v ; and / or (d) wherein the pores have a number average anisotropy ratio R of 1.4 to 2.2 max , optionally wherein the pores have a number average anisotropy ratio R of 1.6 to 1.75 or 1.6 or 1.65 max .

6. The non-fried, non-extruded puffed snack product of any one of claims 1 to 5, wherein the snack has a moisture content of about 0.5 wt% to about 5 wt%.

7. The non-fried, non-extruded puffed snack product according to any one of claims 1 to 6, wherein the starch is a pregelatinized starch.

8. A batter for making a non-fried, non-extruded puffed snack product according to any one of claims 1 to 7, wherein the batter comprises: a. about 20% to about 95% plant-based substrate; b. about 0.3% to about 2.5% of an emulsifier; c. about 8% to about 25% starch; d. Optionally, added water, The moisture content of the batter is about 65 wt % to about 85 wt % based on the weight of the batter.

9. A method for making a non-fried, non-extruded puffed snack product, comprising: (i) providing a plant-based substrate comprising one or more fruits and / or vegetables; (ii) optionally, processing the plant-based substrate to provide a coarse puree; (iii) providing an emulsifier; (iv) providing starch, optionally wherein the starch is pregelatinized starch; (v) mixing the plant-based substrate, the emulsifier and the starch, and optionally water, to form a batter having a moisture content of about 65 wt % to about 85 wt % based on the weight of the batter; (vi) dispensing the batter into individual mould compartments; as well as (vii) dehydrating the batter using microwaves to produce a dehydrated product, the dehydrated product having a moisture content of about 2 wt % to about 20 wt % based on the weight of the dehydrated product.

10. The method of claim 9, wherein the plant-based substrate comprises no more than 20 wt% of the powdered or granular substrate.

11. A method according to claim 9 or claim 10, wherein the one or more fruits and / or vegetables are fresh fruits and / or vegetables, or are fresh fruits and / or vegetables which have been frozen.

12. The method according to any one of claims 9 to 11, wherein the plant-based substrate: (a) comprising no more than about 30 wt% of a cereal crop; (b) contains no more than about 15 wt % wheat, corn, rice, barley, oats, millet, rye, sorghum, spelt, quinoa or buckwheat; and / or (c) comprises no more than about 15 wt % potatoes.

13. The method according to any one of claims 9 to 12, further comprising (viii) a final processing step to provide a finished product having a moisture content of about 3 wt% to 10 wt% based on the weight of the finished product, optionally wherein the final processing step comprises baking the product.

14. A snack product obtainable by the method of any one of claims 9 to 13.

15. A kit for making a non-fried, non-extruded expanded snack product, wherein the kit comprises: (a) The batter of claim 8, optionally further comprising one or more separate mould compartments for use with the batter; or (b) an amount of emulsifier and starch sufficient to be mixed with an amount of a plant-based substrate comprising one or more fruits and / or vegetables and optionally added water to produce a batter having a moisture content of about 65 wt % to about 90 wt % based on the weight of the batter; optionally further comprising one or more separate mold compartments for use with the batter.

16. The kit of claim 15(b), wherein the plant-based substrate in powdered or granular form does not exceed 20 wt%.

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