Lipid-based food filling suitable for high temperature high pressure retort coextrusion

Abstract

This invention provides a lipid-based food filler suitable for high-temperature, high-pressure cooker-co-extrusion (HTCA). The lipid-based food filler, suitable for HTCA co-extrusion and possessing a soft, creamy texture, comprises: about 30% to about 45% by weight of edible lipids forming a continuous lipid phase; about 0.5% to about 5% by weight of fiber selected from the group consisting of insoluble oat fiber, insoluble sugarcane fiber, and soluble oat β-glucan, the fiber having an oil-binding capacity greater than 120%; about 10% to about 30% by weight of amorphous material; less than 30% by weight of sugar, sugar alcohol, or combinations thereof; and about 0.45 or less of water activity (Aw), wherein the filler has a particle size distribution with a D50 of about 25 micrometers or less. The filler maintains its soft, creamy texture after HTCA co-extrusion, subsequent baking, and throughout storage.

Description

[0001] This application is a divisional application of Chinese patent application No. 202080043605.2, entitled "Lipid-based food filler suitable for high-temperature and high-pressure cooking co-extrusion", which was filed on June 26, 2020, under the PCT international application PCT / US2020 / 039882 and entered the Chinese national phase on December 14, 2021. Technical Field

[0002] This application relates in general to oil-based emulsion fillers, and more specifically to oil-based emulsion fillers suitable for high-temperature and high-pressure cooking co-extrusion. Background Technology

[0003] Foods with contrasting textures, such as baked snacks with fillings, appeal to a wide range of consumers. These dual-texture foods may contain a crisp or doughy component, such as a thin, crunchy biscuit or shell; and a filling component, such as a soft, creamy, shelf-stable sweet or savory filling. Typically, the filling component exhibits the desired creamy texture derived from particles dispersed in a lipid and / or aqueous continuous phase. However, such fillings often have the disadvantage that, in some cases, the dispersion structure may be thermally unstable, leading to diffusion, boiling, and / or oil separation upon heating. Without being bound by theory, it is believed that this thermal instability may result from particle aggregation causing the separation of lipids from other filling components. Therefore, this disadvantage makes the manufacture of dual-texture snacks challenging, as careful control of the heat exposure of the filling is usually required.

[0004] One method for producing dual-texture snacks involves high-temperature, high-pressure cooker-co-extrusion. In this method, a dough shell is cooked / extruded under high temperature, pressure, and shear conditions while filler is injected at a die to co-extrude the filled snack. However, this method is limited by the thermal instability or intolerance of the filler components at cooker-co-extrusion temperatures typically used for cooker-co-extrusion filled snacks, such as approximately 135°C or higher. When the filler components are exposed to high-temperature, high-pressure cooker-co-extrusion conditions, the filler may suffer product defects such as filler diffusion and overflow, boiling, oil separation, loss of smoothness, and discoloration, which can result in the filler having an undesirable hardened texture.

[0005] Existing filler compositions have been formulated to contain significant amounts of humectants that reduce water activity (Aw), such as polyols, glycerol, sugars, syrups, etc., to improve thermal stability. However, from a sensory perspective, these prior art fillers are generally unacceptable, especially in fillers with reduced sweetness and saltiness (such as cheese-based fillers), due to undesirable sweetness and / or unpleasant aftertaste resulting from the use of humectants such as glycerol.

[0006] Given that health-conscious consumers increasingly expect snack products with reduced sweetness and / or saltiness, lipid-based food fillers with a soft and creamy texture, as described herein, are provided for high-temperature, high-pressure co-extrusion. Summary of the Invention

[0007] This application provides a lipid-based food filler with a soft, creamy texture suitable for high-temperature, high-pressure cooking and co-extrusion, the filler comprising: About 30% to about 45% by weight of edible lipids, said edible lipids forming a continuous lipid phase; From about 0.5% by weight to about 5% by weight of a high oil-binding material, said high oil-binding material having an oil-binding capacity of more than 100%; From about 10% to about 30% by weight of amorphous materials; Less than 30% by weight of sugars, sugar alcohols, or combinations thereof; and Water activity (Aw) of approximately 0.45 or lower. The filler has a particle size distribution with a D50 of about 25 micrometers or smaller.

[0008] In some implementations, the filler contains virtually no polyols.

[0009] In some embodiments, the filler comprises about 30% to about 45% by weight of edible lipids, which form a continuous lipid phase within the filler. The edible lipids may have a melting point of about 45°C or lower. Edible lipids may include at least one of, for example, soybean oil, corn oil, sunflower oil, palm oil, palm kernel oil, coconut oil, canola oil, cocoa butter, milk fat, and combinations thereof. In some embodiments, the filler substantially does not contain high-melting-point lipids with a melting point of about 70°C or higher.

[0010] The filler also contains about 0.5% to about 5% by weight of a high oil-binding material. In some methods, the high oil-binding material has an oil-binding capacity of more than 100%, and in some methods more than 120%. The high oil-binding material may include at least one of, for example, starch, protein, fiber, gum, and combinations thereof. In some methods, the high oil-binding material may include one or more edible fibers, which contain at least 80% edible fiber. In some methods, some or all of the high oil-binding material included in the filler may be insoluble oat fiber.

[0011] The filler also contains about 10% to about 30% by weight of amorphous material, and in some methods about 10% to about 25% by weight of amorphous material. Amorphous material may include at least one of, for example, milk powder, milk powder, cheese powder, cocoa powder, fruit powder or vegetable powder, maltodextrin, corn syrup solids, and combinations thereof.

[0012] Fillers typically contain less than 30% by weight of sugar, sugar alcohols, or combinations thereof, making them generally low-sweet or salty. Therefore, fillers preferably contain virtually no high-intensity sweeteners.

[0013] The filler typically contains less than about 5% water and has a water activity (Aw) of about 0.45 or less. In some methods, the filler contains virtually no polyols.

[0014] Fillers typically have a particle size distribution with a D50 of about 25 micrometers or less, and in some methods about 20 micrometers or less. In some methods, a particle size distribution with the desired D50 can be obtained by grinding the dried ingredient before blending it with edible lipids. In other methods, a particle size distribution with the desired D50 can be obtained by blending the dried ingredient with edible lipids to form a blend and then grinding the blend. In still other methods, a particle size distribution with the desired D50 can be obtained by blending the dried ingredient with edible lipids to form a blend, grinding the blend, and adding additional dried ingredients to the ground blend.

[0015] In some embodiments, the filler may also contain an emulsifier, such as, for example, lecithin, monoglycerides, diglycerides, and combinations thereof. The emulsifier may be included in the filler in an amount from about 0.05% by weight to about 2% by weight.

[0016] This article also describes a method for preparing a lipid-based food filler with a soft, creamy texture suitable for high-temperature, high-pressure cooking co-extrusion. In some methods, the filler can be prepared by combining edible lipids with a melting point of about 45°C or lower, a high oil-binding capacity material, and an amorphous material to form a substantially homogeneous mixture, and subjecting the mixture to a particle size reduction process to obtain a particle size distribution with a D50 of about 25 micrometers or less, and in some methods about 20 micrometers or less.

[0017] Edible lipids may be included in an amount from about 30% to about 45% by weight. Edible lipids may include at least one of, for example, soybean oil, corn oil, sunflower oil, palm oil, palm kernel oil, coconut oil, canola oil, cocoa butter, milk fat, and combinations thereof. In some embodiments, the filler substantially does not contain high-melting-point lipids with a melting point of about 70°C or higher.

[0018] The high oil-binding capacity material has an oil-binding capacity greater than 100%, and in some methods greater than 120%, and may be contained in an amount from about 0.5% by weight to about 5% by weight. The high oil-binding material may include at least one of, for example, starch, protein, fiber, gum, and combinations thereof. In some methods, the high oil-binding material may include one or more edible fibers comprising at least 80% edible fiber. In some methods, some or all of the high oil-binding material contained in the filler may be insoluble oat fiber.

[0019] The amorphous material may be included in an amount of about 10% to about 30% by weight, and in some methods, in an amount of about 10% to about 25% by weight. In some methods, the amorphous material may include at least one of, for example, milk powder, milk powder, cheese powder, cocoa powder, fruit powder or vegetable powder, maltodextrin, corn syrup solids, and combinations thereof.

[0020] The fillers are typically low-sweet or salty and contain less than 30% by weight of sugar, sugar alcohols, or combinations thereof, and are essentially free of high-intensity sweeteners.

[0021] The filler typically contains less than about 5% water and has a water activity (Aw) of about 0.45 or less. In some methods, the filler contains virtually no polyols.

[0022] In some methods, the particle size reduction process includes bead milling. In some methods, one or more dried ingredients undergo particle size reduction before being combined with edible lipids to obtain a particle size distribution with a D50 of about 25 micrometers or less, and in some methods, 20 micrometers or less.

[0023] In some methods, the emulsifier may be mixed with the edible lipid before combining it with the high-oil-binding material and the amorphous material. The emulsifier may include, for example, at least one of lecithin, monoglycerides, diglycerides, and combinations thereof.

[0024] Based on heat resistance testing, a soft and creamy lipid-based food filler according to any embodiment described herein can have a stiffness of less than 4000 Pascals and a firmness of less than 60 Newtons after baking at 149°C for 8 minutes. Preferably, based on heat resistance testing, the soft and creamy lipid-based food filler has both a stiffness of less than 3000 Pascals and a firmness of less than 50 Newtons after baking at 149°C for 8 minutes.

[0025] In some embodiments, the lipid-based food filler of the present invention, suitable for high-temperature and high-pressure cooking co-extrusion, comprises: about 30% to about 45% by weight of edible lipids forming a continuous lipid phase; about 0.5% to about 5% by weight of a high oil-binding capacity material having an oil-binding capacity greater than 100%; about 10% to about 30% by weight of amorphous material; less than 30% by weight of sugars, sugar alcohols, or combinations thereof; and about 0.45 or less of water activity (Aw), wherein the filler has a particle size distribution with a D50 of about 25 micrometers or less.

[0026] In some embodiments, the amorphous material includes at least one of milk powder, milk powder, cheese powder, cocoa powder, fruit powder or vegetable powder, maltodextrin, corn syrup solids, and combinations thereof.

[0027] In some implementations, the edible lipids have a melting point of about 45°C or lower, and the lipid-based food fillers substantially do not contain high-melting-point lipids with a melting point of at least about 70°C.

[0028] In some implementations, the high oil-binding capacity material includes at least one of starch, protein, fiber, gum, and combinations thereof.

[0029] This application provides a brittle co-extruded food product comprising a filler as described above disposed within an edible shell material.

[0030] In some embodiments, the method of preparing a brittle co-extruded food product according to the present invention includes: providing a lipid-based food filler with a soft and creamy texture as described above; providing a shell material; co-extruded the filler and shell material to produce a co-extruded rope; forming a single block from the co-extruded rope; and drying the single block to a moisture content of about 4% or less, wherein the filler retains a soft and creamy texture after co-extrusion and drying.

[0031] In some implementations, the die temperature during co-extrusion is from about 135°C to about 170°C.

[0032] In some implementations, individual blocks are dried at temperatures ranging from about 100°C to about 120°C.

[0033] In some embodiments, the method of preparing a lipid-based food filler with a soft and creamy texture suitable for high-temperature and high-pressure cooking co-extrusion according to the present invention comprises: combining about 30% to about 45% by weight of edible lipids, about 0.5% to about 5% by weight of a high oil-binding capacity material and about 10% to about 30% by weight of amorphous material to form a substantially homogeneous mixture; and subjecting the mixture to a particle size reduction process to obtain a particle size distribution with a D50 of about 25 micrometers or smaller, wherein the edible lipids have a melting point of about 45°C or lower, and the high oil-binding capacity material has an oil-binding capacity of greater than 100%.

[0034] In some implementations, lipid-based food fillers have a water activity (Aw) of about 0.45 or less.

[0035] In some implementations, lipid-based food fillers substantially do not contain high-melting-point lipids with a melting point of at least about 70°C.

[0036] In some embodiments, the lipid-based food filler of the present invention, suitable for high-temperature and high-pressure cooking co-extrusion, comprises: about 30% to about 45% by weight of edible lipids forming a continuous lipid phase; about 0.5% to about 5% by weight of fiber selected from the group consisting of insoluble oat fiber, insoluble sugarcane fiber, and soluble oat β-glucan, the fiber having an oil-binding capacity of greater than 120%; about 10% to about 30% by weight of amorphous material; less than 30% by weight of sugar, sugar alcohol, or combinations thereof; and about 0.45 or less of water activity (Aw), wherein the filler has a particle size distribution with a D50 of about 25 micrometers or less.

[0037] In some implementations, lipid-based food fillers do not contain polyols.

[0038] In some implementations, the edible lipids have a melting point of about 45°C or lower, and the filler does not contain high-melting-point lipids with a melting point of at least about 70°C.

[0039] In some implementations, lipid-based food fillers do not contain high-intensity sweeteners.

[0040] In some implementations, the fiber consists of one or more added fibrous materials containing at least 80% by weight of fiber content.

[0041] In some embodiments, the method of preparing a lipid-based food filler suitable for high-temperature and high-pressure cooking co-extrusion according to the present invention comprises: combining about 30% to about 45% by weight of edible lipids, about 0.5% to about 5% by weight of fibers selected from the group consisting of insoluble oat fiber, insoluble sugarcane fiber, and soluble oat β-glucan, and about 10% to about 30% by weight of amorphous material to form a homogeneous mixture; and subjecting the mixture to a particle size reduction process to obtain a particle size distribution with a D50 of about 25 micrometers or less, wherein the edible lipids have a melting point of about 45°C or lower, and wherein the fibers have an oil binding capacity of greater than 120%.

[0042] In some implementations, lipid-based food fillers do not contain high-melting-point lipids with a melting point of at least about 70°C.

[0043] In some implementations, the method further includes mixing the emulsifier with the edible lipids before combining them with the high oil-binding capacity material and the amorphous material.

[0044] A soft, creamy, lipid-based food filler according to any embodiment described herein may be disposed within an edible shell material to form a brittle co-extruded food product. The edible shell material may include, for example, any suitable dough material or matrix.

[0045] This document also describes brittle co-extruded food products comprising a soft, creamy textured lipid-based food filler. Brittle co-extruded food products can be prepared by providing a soft, creamy textured lipid-based food filler according to any embodiment described herein, providing a shell material, and co-extruded the filler and shell material to produce a co-extruded tow. In some methods, the die temperature during co-extrusion can be from about 135°C to about 170°C. The co-extruded tow is then formed into individual blocks, and the individual blocks are dried to a moisture content of about 4% or less. In some methods, the individual blocks can be dried at a temperature from about 100°C to about 120°C. The filler in the brittle co-extruded food product retains its soft, creamy texture after co-extrusion and drying, and throughout storage. Attached Figure Description

[0046] Figure 1 This is a flowchart of an exemplary method for preparing a lipid-based food filler with a soft, creamy texture suitable for high-temperature, high-pressure cooking and co-extrusion. Detailed Implementation

[0047] The foregoing summary and the following description are not intended to be restrictive, but rather to illustrate the general principles of exemplary embodiments and methods. Throughout this specification, references to “a method,” “method,” “some methods,” “implementation,” “some implementations,” “some applications,” or similar language refer to specific features, components, attributes, or characteristics described in connection with the method, including those in at least one method of the invention. Therefore, the phrases “in a method,” “in one method,” “in some methods,” “in some implementations,” and similar language appearing throughout this specification may, but not necessarily all, refer to the same embodiments. Indeed, it should be understood that, unless otherwise expressly stated, specific features, components, attributes, or characteristics described herein with respect to one or more methods, implementations, or applications can be combined in any combination with any other features, components, attributes, or characteristics described herein.

[0048] Unless otherwise specified, all percentages used herein are by weight and based on filler composition.

[0049] This disclosure describes lipid-based food fillers with a soft, creamy texture and low water activity that can withstand typical high-temperature, high-shear cooking co-extrusion conditions without significant oil separation and hardening, and provide a creamy texture and mouthfeel in the finished product. The fillers described herein typically have a water activity (Aw) of 0.45 or less and a water content of 5% or less.

[0050] The inventors have discovered that while prior art creamy fillers with high sugar content (e.g., greater than 60% by weight) typically remain stable and retain a soft, creamy texture after high-temperature, high-pressure cooking / extrusion and subsequent baking, salty or reduced-sweetness creamy fillers become powdery, hard, and lose their soft, creamy texture. In a typical high-temperature, high-pressure cooking co-extrusion process, at an extruder internal pressure of 70 to 100 bar, the die temperature can be, for example, 135°C or higher, while at 150 to 220 psig, the filler temperature can be, for example, 80°C or higher.

[0051] The inventors have discovered a unique combination of ingredients and processing techniques that surprisingly produces a soft and creamy textured lipid-based food filler that maintains its soft and creamy texture after high-temperature, high-pressure cooking co-extrusion and throughout its shelf life.

[0052] This filler comprises a limited amount of amorphous material (which has a high tendency to agglomerate and expel oil), lecithin or other emulsifiers for modifying the surface properties of the particles, and a certain amount of high-oil-binding material such as fibers to control oil migration during co-extrusion processing and shelf life. Without being limited by theory, the total surface area of ​​the filler particles is increased by milling. The surface of the milled particles is coated with an emulsifier, thus becoming hydrophobic. It is believed that the increased hydrophobic surface area of ​​the milled particles interacts with the lipid continuity phase and reduces the tendency for oil separation and particle agglomeration during cooking / extrusion, baking, and storage. Due to this improved stability, the filler described herein is able to maintain a soft and creamy texture in high-temperature, high-pressure co-extruded food products.

[0053] The fillers described herein comprise one or more edible lipids forming a continuous phase within the filler. Preferably, the edible lipids are low-melting-point lipids with a melting point of about 45°C or lower. Suitable low-melting-point lipids typically include hydrogenated, non-hydrogenated, or partially hydrogenated fractionated or unfractionated oils and mixtures thereof with melting points of about 45°C or lower. Exemplary low-melting-point lipids include, for example, soybean oil, corn oil, sunflower oil, palm oil, palm kernel oil, coconut oil, canola oil, cocoa butter, milk fat, and combinations thereof.

[0054] Preferably, the fillers described herein contain no or substantially no high-melting-point lipids with a melting point of at least about 70°C. High-melting-point lipids include, for example, long-chain fatty acids, their monoglycerides, diglycerides, and triglycerides, their alkali metal salts, and other derivatives thereof. Prior art savory filler formulations contain a certain amount of high-melting-point lipids to stabilize the filler and improve baking stability. See, for example, U.S. Patent 9,465,620. However, the inclusion of high-melting-point lipids can provide a waxy texture in the final filler, which may be undesirable in some applications. The fillers described herein unexpectedly exhibit thermal stability in high-temperature, high-pressure co-extrusion applications without the use of high-melting-point lipids.

[0055] The filler described herein contains a certain amount of high oil-binding material having an oil-binding capacity of greater than 100%, greater than 115% in some methods, and greater than 120% in some methods.

[0056] As used herein, the term "oil-binding capacity" refers to the amount of oil (as a percentage of sample weight) that a component sample can bind after full saturation and subsequent centrifugation to remove oil. Generally, oil-binding capacity can be measured using a concept similar to the solvent retention capacity test for wheat flour, originally developed by Nabisco and now standardized as AACCI Method 56-11. More specifically, the oil-binding capacity of the various fibers used in the experimental examples described herein was determined using the following method: For each 5.0 g sample, 25.0 g of edible liquid oil (e.g., canola oil) was added to the pre-weighed centrifuge tube. The sample and oil were then thoroughly mixed using an automated sample mixer (Shakematic 1095, Perten Instruments), shaking for 4 seconds each time, for a total of 3 shakes. To ensure proper saturation of the sample, the tubes were vortexed at speed 5 for 6 seconds at 5-minute intervals, for a total of 20 minutes, on a Fisher Scientific digital vortex mixer (model 945415). To remove excess oil, the tubes were immediately centrifuged at 1000 g for 15 minutes at 23°C (Thermo Fisher Scientific Heraeus Multifuge X1R) 20 minutes after saturation. After centrifugation, the supernatant oil was carefully decanted, and the tubes were inverted on clean paper towels to allow all free oil to drain properly for 10 minutes. The tube containing the precipitate was weighed again to determine the weight gain, and the oil binding capacity of a particular sample (expressed as a percentage of sample weight) was calculated as (precipitate weight - sample weight) / (sample weight) × 100%. The oil binding capacity measurement was performed in duplicate.

[0057] Suitable high-oil-binding materials may include, for example, starch, protein, fiber, gum, etc., having an oil-binding capacity of greater than 100%, greater than 115% in some methods, and greater than 120% in others. As used herein, the term "fiber" generally refers to those components containing at least about 80% edible fiber content, and at least about 85% edible fiber content in some methods. In some embodiments, the high-oil-binding material includes edible fibers such as, for example, insoluble oat fiber, some or all of which are insoluble oat fiber.

[0058] High-oil-binding materials typically function in fillers to absorb liquid oils that may precipitate into the matrix during cooking / co-extrusion, thus controlling oil migration within the filler. If the material's oil-binding capacity is too low, oil precipitation may occur, potentially resulting in a hardened texture in the filler. Excessive high-oil-binding materials can lead to a pasty, undesirable firmness and a reduced creamy texture. Therefore, it is important to include sufficient high-oil-binding components to control oil migration, resulting in a soft, creamy filler with the desired flavor and texture.

[0059] In some methods, the high-oil-bound material may be included in the filler in an amount from about 0.5% to about 5% by weight of the filler. In some methods, the high-oil-bound material may be included in an amount from about 0.5% to about 4.5% by weight of the filler; from about 0.5% to about 4% by weight of the filler; from about 0.5% to about 3.5% by weight of the filler; from about 0.5% to about 3% by weight of the filler; from about 0.5% to about 2.5% by weight of the filler; from about 0.5% to about 2% by weight of the filler; from about 0.5% to about 1.5% by weight of the filler; or from about 0.5% to about 1% by weight of the filler.

[0060] Preferably, the high-oil binding material is insoluble oat fiber and is included in the filler in an amount of about 0.5% to about 2.5% by weight.

[0061] The fillers described herein also include a certain amount of amorphous material. As used herein, the term "amorphous material" refers to a material that is not in a crystalline state. Exemplary amorphous materials include, for example, milk powder, dairy powder, cheese powder, fruit or vegetable powder, maltodextrin, corn syrup solids, etc. Some ingredients, such as native starch, contain both amorphous and crystalline regions. If these materials agglomerate after being heated in a sealed container at approximately 125°C for 30 minutes, they are considered amorphous materials. Since native starch typically does not agglomerate after heating at approximately 125°C, it is not considered an amorphous material.

[0062] The inventors have discovered that high-sugar, creamy fillers, which typically do not contain a large amount of amorphous material, can maintain their soft and creamy texture after high-temperature, high-pressure cooking co-extrusion and subsequent baking. However, savory and reduced-sweet creamy fillers, which typically use amorphous materials as flavoring agents or leavening agents, become powdery, harden, and lose their soft and creamy texture. This presents unique technical challenges for savory and reduced-sweet fillers used in cooking co-extrusion applications.

[0063] Therefore, the fillers described herein typically contain at least about 10% by weight of amorphous material, and in some methods, no more than about 40% by weight of amorphous material. Excessive amorphous material in the filler can lead to agglomeration and oil separation, resulting in a filler with an undesirable texture. Therefore, the fillers described herein typically contain no more than about 40% by weight of amorphous material, and in some methods, no more than about 35% by weight, in some methods, no more than about 30% by weight, and in some methods, no more than about 25% by weight of amorphous material. In some embodiments, the filler contains about 10% to about 30% by weight of amorphous material, and in some embodiments, about 10% to about 25% by weight of amorphous material.

[0064] The filler described herein may also contain an emulsifier. Any suitable emulsifier may be used. In some embodiments, a suitable emulsifier may include at least one of, for example, lecithin, monoglycerides, diglycerides, and combinations thereof. In some embodiments, the filler contains about 0.05% by weight to about 2% by weight of the emulsifier. In some embodiments, the filler contains about 0.05% by weight to about 1.5% by weight; about 0.05% by weight to about 1% by weight; about 0.05% by weight to about 0.75% by weight; or about 0.05% by weight to about 0.5% by weight of the emulsifier. Preferably, the filler contains about 0.05% by weight to about 1% by weight of the emulsifier.

[0065] The fillers described herein are typically salty or reduced-sweet creamy fillers. Therefore, the fillers generally contain no more than about 30% by weight, in some methods no more than about 25% by weight, and in some methods no more than 20% by weight of sugars (e.g., sucrose, fructose, glucose, maltose, lactose, etc.), sugar alcohols (e.g., maltitol, sorbitol, xylitol, mannitol, etc.), or combinations thereof. Preferably, the sugars contained in the fillers are in the form of lactose, which has a lower sweetness level than, for example, sucrose, fructose, etc.

[0066] In some methods, the filler is essentially free of high-intensity sweeteners (e.g., saccharin, aspartame, acetaminophen, sucralose, neotame, adventitia, stevia, etc.).

[0067] The fillers described herein may contain any suitable flavoring or coloring agents, provided that the resulting filler is a low-sweet or low-salty filler. Suitable flavoring or coloring agents may include, for example, dehydrated powders, flavoring or coloring agents such as dehydrated fruit powder, cocoa powder, milk powder, cheese powder, vegetable powder, soy powder, spices, and herbs, which may be added to the filler before and / or after grinding the filler / reducing the filler particle size.

[0068] The fillers described herein may have a small or no aqueous phase and substantially contain no polyols or polyol-based humectants such as glycerin, which often alters the taste and mouthfeel of prior art creamy fillers. As used herein, substantially containing no polyols or polyol-based humectants generally means that the filler contains less than about 5% by weight, less than about 2% by weight in some methods, and less than about 1% by weight in others. Such amounts are generally ineffective in providing any functional benefits to the fillers described herein.

[0069] The fillers described herein typically comprise particles with a particle size distribution having a D50 of less than about 25 micrometers. In some embodiments, the fillers have a particle size distribution with a D50 of less than about 22 micrometers. In some embodiments, the fillers have a particle size distribution with a D50 of less than about 20 micrometers. Smaller particles are generally preferred because they have been found to provide a softer texture and a more creamy mouthfeel to the filler.

[0070] Suitable grinding methods include, but are not limited to, the use of hammer mills, roller mills, ball mills, bead mills, and combinations thereof. In some embodiments, the desired particle size distribution can be achieved by pre-grinding the dried ingredients before mixing them with edible lipids, or by pre-mixing the dried ingredients with edible lipids to form a mixture, then grinding the mixture to achieve the desired particle size, or a combination of these methods. In some embodiments, the desired particle size distribution can be achieved by pre-mixing certain dried ingredients with edible lipids to form a mixture, grinding the mixture to the desired particle size to form a ground mixture, and then incorporating additional pre-ground dried ingredients into the ground mixture.

[0071] As described above, the unique combination of ingredients and processing techniques presented herein produces a soft, creamy, lipid-based food filler suitable for high-temperature, high-pressure co-extrusion applications. The suitability of the filler for high-temperature, high-pressure co-extrusion applications can be verified using heat resistance testing. Heat resistance testing is designed to predict the filler's texture after the process by modeling the heat exposure patterns during high-temperature, high-pressure co-extrusion and the associated drying process using an oven baking method. Heat resistance testing can be performed as described below.

[0072] The filling sample is shaped into a 3.5mm (inner diameter) × 4mm (height) disc using a mold. This disc is then placed in a 4-layer Whatman container (10cm outer diameter × 3.2cm height, Papermart.com 8 oz shallow round steel can, catalog number 6512800P) with an airtight lid. ® #3 filter paper (i.e., two layers on each side; 9.0cm diameter, Whatman) ®The sample was baked at 149°C (set temperature, laboratory oven model 20E, Quincy Lab, Inc., Chicago, IL) for 8 minutes. Filter paper was moistened with 0.3 g of water to provide a relative humidity similar to that in the extruder within the container. The baked sample was cooled overnight at 22°C and then evaluated. Fillers suitable for high-temperature, high-pressure retort co-extrusion applications will typically have a Young's modulus of less than 4000 Pa and a firmness of less than 60 Newtons. (GE Healthcare Life Sciences UK Limited, Buckinghamshire, UK)

[0073] This document also describes a method for preparing a soft, creamy, lipid-based food filler suitable for high-temperature, high-pressure cooker co-extrusion. Non-limiting examples of exemplary methods for preparing a soft, creamy, lipid-based food filler suitable for high-temperature, high-pressure cooker co-extrusion are shown in… Figure 1 middle.

[0074] like Figure 1 As shown, an exemplary filler can be prepared by mixing edible lipids 101, a high oil-binding material 102, and an amorphous material 103 in a mixing tank 104 to form a substantially homogeneous mixture 105. (Reference) Figure 1 The edible lipids 101, high-oil binding material 102, and amorphous material 103 may contain the above-mentioned amounts of the edible lipids, high-oil binding material, and amorphous material.

[0075] In some embodiments, edible lipids 101 and emulsifier 108 may optionally be premixed by mixing edible lipids 101 and emulsifier 108 at a temperature of about 43°C ± 5°C for about 10 minutes or until the fat is completely melted. The remaining ingredients (including any flavoring or coloring agents) may then be added to the mixer and blended to form a substantially homogeneous mixture 105. In some methods, powdered ingredients may be added in groups to the mixing tank 104, and each group may be mixed for about 5 minutes to about 20 minutes until the mixture is substantially homogeneous.

[0076] The substantially homogeneous mixture 105 is subjected to particle size reduction 106 to form a soft and creamy filler 107 with a desired particle size. The filler with the desired particle size typically comprises particles having a particle size distribution with a D50 of less than about 25 micrometers, less than about 22 micrometers in some methods, and less than about 20 micrometers in others. Particle size reduction can be achieved using any suitable grinding technique, such as, for example, hammer mills, roller mills, ball mills, bead mills, and combinations thereof. Preferably, the homogeneous mixture is continuously fed into a high-speed stirred bead mill, where the D50 of the particle size distribution is reduced to less than about 25 micrometers, less than about 22 micrometers in some methods, and less than about 20 micrometers in others.

[0077] In some embodiments, the material may optionally be pre-ground before being mixed with edible lipids 101 in mixing tank 104 to form a substantially homogeneous mixture 105 (see [link to relevant documentation]). Figure 1 Some or all of the dried components (109 and 110) may be included, which may include some or all of the high-oil-bound material 102 and / or amorphous material 103. In some methods, additional pre-ground dried components 111 may optionally be added to the mixture after particle size reduction 106.

[0078] In a non-limiting example, an exemplary soft and creamy lipid-based food filler suitable for high-temperature, high-pressure cooking co-extrusion can be prepared by adding solid fat, liquid oil, and lecithin to a mixing tank and mixing at a temperature of about 43°C ± 5°C for about 10 minutes or until the fat is completely melted. Powdered ingredients are added in the groups outlined below, and each group is mixed for 5 to 20 minutes until the mixture is homogeneous.

[0079] i. Group 1: Salt, lactic acid, oat fiber, cheese powder ii. Group 2: Maltodextrin iii. Group 3: Corn starch iv. Group 4: Lactose After adding Group 2, the mixing speed is increased to maintain sufficient turbulence for complete incorporation of all ingredients. Following the addition of Group 4 lactose, the slurry is recirculated in the mixing tank to aid mixing and ensure a homogeneous mixture. The slurry is then pumped to a storage tank under slow stirring, where it is maintained at a temperature between approximately 35°C and approximately 48°C. The slurry is continuously fed into a high-speed stirred bead mill, where the particle size distribution is reduced to the desired particle size. The packing material exiting the mill is typically at a temperature of approximately 65°C ± 5°C.

[0080] The soft, creamy, lipid-based food fillers described herein can be incorporated into co-extruded baked goods products using any conventional co-extrusion method. For example, the filler can be incorporated into crisp co-extruded snack products, as described in U.S. Patent Publication 2017 / 0332677, the entire contents of which are incorporated herein by reference.

[0081] Fillers are particularly useful in the production of high-temperature, high-pressure co-extruded snacks. For example, the fillers described herein can be incorporated into co-extruded snacks (such as, for example, grain-based snacks) during high-temperature, high-pressure cooker extrusion and retain a soft, creamy texture after co-extrusion and drying and throughout the shelf life.

[0082] In a non-limiting method, the filler described herein may be incorporated into a co-extruded baked goods product as follows: Add the filler to the mixing vessel, along with any suitable amount of powdered seasoning (which may include powdered flavoring agents, cheese powder, or spices). Mix the filler for 5 to 15 minutes until the seasoning is evenly distributed. At this point, transfer the filler to a use tank, where it is pumped directly into the extrusion die and encapsulated in the feed rope of the extruded shell. The shell can be formed from any suitable shell material, depending on the nature of the final product. Typical die temperatures are generally from about 135°C to about 170°C.

[0083] The extruded product is then rolled into individual blocks and fed into a convection dryer for final moisture removal to achieve a moisture content of approximately 5% or less. Typical dryer temperatures are typically from approximately 100°C to approximately 120°C. The dried product is then passed through a seasoning drum, where oils and seasonings are applied. The product is then conveyed to packaging.

[0084] A better understanding of this disclosure and its many advantages will be illustrated by the following examples. These examples are illustrative and do not limit the scope or substance of this disclosure. Those skilled in the art will readily understand that variations of the components, methods, steps, and apparatus described in these examples can be used. Unless otherwise stated, all percentages, ratios, and parts mentioned in this disclosure are by weight.

[0085] Example The following examples demonstrate the importance of the various characteristics of the fillers described herein. The fillers of Examples 1 to 5 were prepared according to the formulations shown in Table 1.

[0086] Table 1 Example 1 - Comparative Fillers The comparative filler in this embodiment confirms the importance of reducing the particle size of the filler. The comparative filler in this embodiment has the same formulation as the exemplary filler in Example 3, but the comparative filler in this embodiment did not undergo particle size reduction. The fiber used in this comparative example is insoluble oat fiber (Canadian Harvest). ® HF300-58 (J. Rettenmaier USA, Schoolcraft, MI), this insoluble oat fiber has an oil-binding capacity of approximately 181%. All ingredients were mixed in a heated mixer at approximately 49°C until homogeneous and free of lumps. After mixing, the filler was cooled to room temperature overnight and then evaluated. The filler had a particle size distribution with a D50 of 33.7 micrometers.

[0087] Example 2 - Comparison of Fillers The comparative filler in this embodiment confirms the importance of the oil-binding capacity of the fibers contained in the filler. The comparative filler in this embodiment has a similar formulation to the exemplary fillers in Examples 3 to 5, but contains a higher amount of different types of fibers with an oil-binding capacity of less than 120%. Similar to the exemplary fillers in Examples 3 to 5, the comparative filler in this embodiment has undergone particle size reduction.

[0088] The fiber used in this embodiment is soluble glucose fiber (Promitor) ® SGF70R (Tate & Lyle, Decatur, IL), this soluble glucose fiber has an oil-binding capacity of approximately 70%. All components were first mixed in a heated mixer at approximately 49°C, then passed through a high-speed stirred bead mill (Buhler K8) filled with 82% 1.5 mm ceramic beads at a flow rate of approximately 110 g / min and a grinding speed of 1200 rpm. The milled filler had a particle size distribution with a D50 of 15.6 μm. The sample was cooled to room temperature overnight before evaluation.

[0089] Example 3 - Exemplary Filler The filler in this embodiment is a non-limiting embodiment of the filler of the present invention according to this disclosure. The filler in this embodiment contains the same components and formulation as the comparative filler in Example 1, but the particle size of the filler in this embodiment is reduced using a high-speed stirred bead mill. All components were first mixed in a heated mixer at approximately 49°C, and then passed through a high-speed stirred bead mill (WAB KD-15) filled with 80% 1.6 mm–2.0 mm ceramic beads at a flow rate of approximately 1200 g / min and a grinding speed of 1300 rpm. The milled filler had a particle size distribution with a D50 of approximately 14 micrometers. The sample was cooled to room temperature overnight and then evaluated.

[0090] Example 4 - Exemplary Filler The filler in this embodiment is a non-limiting embodiment of the filler of the present invention according to this disclosure. The filler in this embodiment comprises insoluble sugarcane fiber (Vitacel). ® SF601 (J. Rettenmaier USA, Schoolcraft, MI), this insoluble sugarcane fiber has an oil-binding capacity of approximately 189%. The mixing and grinding process is the same as described above in Example 3. The ground filler has a particle size distribution with a D50 of 15.6 micrometers.

[0091] Example 5 - Exemplary Filler The filler in this embodiment is a non-limiting embodiment of the filler of the present invention according to this disclosure. The filler in this embodiment comprises soluble oat β-glucan fiber (PromOat ® The soluble oat β-glucan fiber (Tate & Lyle, Decatur, IL) has an oil-binding capacity of approximately 121%. The mixing and grinding process was the same as described above in Example 3. The ground filler had a particle size distribution with a D50 of 14.4 micrometers. The sample was cooled to room temperature overnight before evaluation.

[0092] Example 6 - Filler Evaluation The comparative fillers from Comparative Examples 1 and 2 and the exemplary fillers from Examples 3 to 5 were evaluated using the above-described benchtop heat resistance test (HTT). The following parameters of the HTT baking fillers were evaluated: (1) stiffness and firmness; (2) oil migration to filter paper, based on filler weight as a percentage; and (3) round-table sensory evaluation. The results of the HTT tests are shown in Table 2.

[0093] The stiffness and firmness of baked fillers were measured using a compression test performed on a TA.XT plus texture analyzer (Texture Technologies Corp., South Hamilton, MA). After cooling, the baked fillers were removed from the container, and the bottom layer of filter paper was carefully peeled off to avoid damaging the baked surface. The bare sample was then compressed to 40% of its strain using a 1” diameter cylindrical probe at a speed of 1 mm / s. The forces (N) encountered during the test were plotted against time (i.e., compression distance) for calculation. The stiffness of the sample was determined by calculating the Young's modulus (Pa) at the initial peak (at approximately 15% strain), and the firmness was determined by the peak force (N), which was the maximum force encountered during the compression test. All measurements were performed in triplicate. A satisfactory heat-resistant filler should have a Young's modulus of less than 4000 Pa and a firmness of less than 60 N.

[0094] The particle size distribution of the filler in the oil dispersion was measured using a Malvern Mastersizer 3000 with a Hydro SM wet dispersion unit. The median of the volume distribution, D50, was used as the measure of particle size.

[0095] The texture of each baked filling was described using a round-table sensory evaluation. Attributes included the filling's creamy texture, softness, and smoothness.

[0096] The fillers from Comparative Examples 1 and 2 were dried and hardened after HTT. Based on this test, the two comparative fillers showed higher oil migration to the filter paper, as well as higher stiffness and firmness measurements, as shown in Table 2. On the other hand, the exemplary fillers from Examples 3 to 5 maintained a soft and creamy texture after baking.

[0097] Table 2 Example 7 - High-Temperature and High-Pressure Co-Extruded Snacks Prepared with Comparative and Exemplary Fillers Two fillers with the same formulation as described in Example 3 were prepared with different degrees of milling. As shown in Table 3, the low-milled filler (comparative filler) had a particle size distribution with a D50 of 28.8 micrometers, and the high-milled filler (exemplary filler) had a particle size distribution with a D50 of approximately 17.0 micrometers. These fillers were mixed with 3.5% of a flavoring (Kerry Ingredients and Flavors USA, Beloit, WI) until homogeneous. The fillers were then extruded using a Buhler twin-screw extruder (high-temperature, high-shear retorting extruder) at a fill level of approximately 45% (by weight). The extruded product was dried at 104°C for approximately 9 minutes to achieve a shelf-stable moisture content of approximately 3.5%. The extruded snacks were stored in sealed metallized pouches and evaluated 4 weeks after production. Based on the results from the qualitative descriptive analysis sensory group shown in Table 3 below, extruded products made with the exemplary filler have a higher filler perception and a more creamy, smooth (wet) filler texture perception compared to the comparative filler.

[0098] Table 3 - Particle size and key sensory differences among sensory groups based on qualitative descriptive analysis The matters described in the foregoing specification and figures are provided by way of example only and are not intended to be limiting. While specific embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications can be made without departing from the broad aspects of the applicant's contributions. The actual scope of protection sought is defined in the claims, which are properly defined based on the prior art.

Claims

1. A lipid-based food filler with a soft, creamy texture suitable for high-temperature, high-pressure cooking and co-extrusion, the filler comprising: About 30% to about 45% by weight of edible lipids, said edible lipids forming a continuous lipid phase; From about 0.5% by weight to about 5% by weight of fiber, said fiber being selected from the group consisting of insoluble oat fiber, insoluble sugarcane fiber, and soluble oat β-glucan, said fiber having an oil-binding capacity of greater than 120%; From about 10% to about 30% by weight of amorphous materials; Less than 30% by weight of sugars, sugar alcohols, or combinations thereof; and Water activity (Aw) of approximately 0.45 or lower. The filler has a particle size distribution with a D50 of about 25 micrometers or smaller.

2. The filler according to claim 1, wherein the filler does not contain polyols.

3. The filler according to claim 1, wherein, based on a heat resistance test, the filler has a stiffness of less than 4000 Pascals and a solidity of less than 60 Newtons after baking at 149°C for 8 minutes.

4. The filler of claim 1, wherein the filler comprises about 10% to about 25% by weight of the amorphous material.

5. The filler according to claim 1, wherein the amorphous material comprises at least one of milk powder, milk powder, cheese powder, cocoa powder, fruit powder or vegetable powder, maltodextrin, corn syrup solids, and combinations thereof.

6. The filler of claim 1, wherein the edible lipid has a melting point of about 45°C or lower, and the filler does not contain high-melting-point lipids with a melting point of at least about 70°C.

7. The filler of claim 1, wherein the filler does not contain a high-intensity sweetener.

8. The filler according to claim 1, wherein the fiber is composed of one or more added fiber materials containing at least 80% by weight fiber content.

9. A brittle co-extruded food product comprising a filler according to claim 1 disposed within an edible shell material.

10. A method for preparing a brittle co-extruded food product, the method comprising: Provides a lipid-based food filler with a soft and creamy texture as described in claim 1; Provide shell material; The filler and the shell material are co-extruded to produce a co-extruded rope; The co-extruded rope is used to form a single block; as well as The individual blocks are dried to a moisture content of approximately 4% or less. The filler retains a soft and creamy texture after co-extrusion and drying.

11. The method of claim 10, wherein the die temperature during co-extrusion is from about 135°C to about 170°C.

12. The method of claim 10, wherein the individual block is dried at a temperature from about 100°C to about 120°C.

13. A method for preparing a lipid-based food filler with a soft, creamy texture suitable for high-temperature, high-pressure cooking and co-extrusion, the method comprising: The mixture comprises approximately 30% to approximately 45% by weight of edible lipids, approximately 0.5% to approximately 5% by weight of fibers selected from the group consisting of insoluble oat fiber, insoluble sugarcane fiber, and soluble oat β-glucan, and approximately 10% to approximately 30% by weight of amorphous materials to form a homogeneous mixture; and The mixture is subjected to a particle size reduction process to obtain a particle size distribution with a D50 of approximately 25 micrometers or smaller. The edible lipids described therein have a melting point of about 45°C or lower, and The fiber has an oil-binding capacity of more than 120%.

14. The method of claim 13, wherein the filler does not contain polyols.

15. The method of claim 13, wherein, based on a heat resistance test, the filler has a stiffness of less than 4000 Pascals and a firmness of less than 60 Newtons after baking at 149°C for 8 minutes.

16. The method of claim 13, wherein the filler has a water activity (Aw) of about 0.45 or less.

17. The method of claim 13, wherein one or more dried ingredients undergo particle size reduction before being combined with the edible lipids to obtain a particle size distribution with a D50 of about 25 micrometers or less.

18. The method of claim 13, wherein the amorphous material is contained in an amount of about 10% by weight to about 25% by weight of the filler.

19. The method of claim 13, wherein the amorphous material comprises at least one of milk powder, milk powder, cheese powder, cocoa powder, fruit powder or vegetable powder, maltodextrin, corn syrup solids, and combinations thereof.

20. The method of claim 13, wherein the filler does not contain high-melting-point lipids with a melting point of at least about 70°C.

21. The method of claim 13, further comprising mixing the emulsifier with the edible lipid before combining the edible lipid with the fiber and the amorphous material.

22. The method of claim 13, wherein the filler does not contain a high-intensity sweetener.

23. The filler of claim 13, wherein the fiber comprises one or more added fibrous materials having a fiber content of at least 80% by weight.

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