Composition and method for reducing the rise time and sodium content of dough containing micron-sized salt particles attached to a carrier.

Abstract

The dough for baked foods produced with a low-sodium salt composition containing salt particles attached to a bulk carrier in a specific proportion according to the present invention, and the method for producing the same, are improved over previous alternative doughs with respect to a reduction in sodium content per serving and a reduction in fermentation, leavening, and / or overall baking time compared to dough prepared with conventional salts.

Description

[Technical Field]

[0001] The various embodiments generally relate to food products and methods for producing them.

[0002] Cross-reference of related applications This application is a non-provisional application claiming priority to U.S. Provisional Patent Application No. 63 / 580,590, filed on September 5, 2023, entitled "COMPOSITIONS AND METHODS FOR REDUCED LEAVENING TIME AND SODIUM CONTENT IN DOUGHS COMPRISING MICRON-SIZED SALT PARTICLES ADHERED TO A CARRIER," which is incorporated herein by reference in its entirety. [Background technology]

[0003] Bread is a staple food in many cultures around the world. However, the baking process can be time-consuming, and the sodium content of bread produced according to conventional recipes and manufacturing processes can account for a significant portion of the maximum recommended daily sodium intake for healthy individuals (2300 milligrams (mg) according to the World Health Organization).

[0004] Top Sodium Food Sources in the American Diet-Using National Health and Nutrition Examination Survey 1According to the authors, Mavra Ahmed, Alena (Praneet) Ng, Anthea Christoforou, Christine Mulligan, and Mary R. L'Abbe, "Reducing sodium intake at the population level, i.e., a key preventive strategy to reduce the risk of cardiovascular disease, the leading cause of death in the United States, can reduce hypertension. Considering that most dietary sodium comes from packaged foods, this study quantitatively estimates the contribution of major food categories from their sources to total sodium intake in Americans and the average sodium intake. Data from the 2017-2018 National Health and Nutrition Examination Survey, which collected 24-hour dietary recall surveys from interviewers of Americans (n=7081), were analyzed." From this analysis, the authors found that bread, rolls, and buns accounted for approximately 4.7% of daily sodium intake, and cookies, brownies, and cakes accounted for a further 2.4% of daily sodium intake. 1 AHMED M., NG AP, CHRISTOFOROU A., MULLIGAN C., L'ABBE MR, Top Sodium Food Sources in the American Diet-Using National Health and Nutrition Examination Survey ,webpage,2023 Feb 6( https: / / www.ncbi.nlm.nih.gov / pmc / articles / PMC9962803 / )

[0005] According to the World Health Organization, cardiovascular disease is a leading cause of death worldwide, accounting for approximately 17.9 million deaths in 2019, or 32% of all deaths globally. Of these deaths, 85% were due to heart attacks and strokes. 2 According to the Centers for Disease Control and Prevention, "Approximately 610,000 people die from heart disease in the United States each year. This accounts for one in four deaths." In the United Kingdom, approximately 160,000 people die from heart disease each year, accounting for 26% of all deaths. 2 WORLD HEALTH ORGANIZATION (WHO),Cardiovascular Diseases(CVDs),2021 June 11( https: / / www.who.int / news-room / fact-sheets / detail / cardiovascular-diseases-(cvds) )

[0006] Yi-Jie Wang et al. 3 According to the study, the risk of cardiovascular disease increases by 6% for every gram (1g) of dietary sodium intake. 3WANG YJ, YEH TL, SHIH MC, TU YK, CHIEN KL, Dietary Sodium Intake and Risk of Cardiovascular Disease:A Systematic Review and Dose-Response Meta-Analysis ,webpage, 2020 Sep 25( https: / / www.ncbi.nlm.nih.gov / pmc / articles / PMC7601012 / #:~:text=The%20risk%20of%20CVD%20with,risk%20of%20CVD%20by%206%25 )

[0007] U.S. Patent No. 8,900,650 describes a salt composition comprising carrier particles having a plurality of salt crystallites arranged on the carrier particles. The method comprises providing an aqueous slurry comprising an aqueous solvent and a selected weight percent of a solid mixture, the solid mixture comprising a salt and a carrier medium, the carrier medium present in an amount of about 25% to about 75% by weight of the aqueous solvent, and the method comprises exposing the slurry to a drying process both to a) form carrier particles comprising the carrier medium and b) form a plurality of salt particles with an average size of less than about 20 microns on the surface of the carrier particles, the salt particles on the surface of the carrier particles having an average size ranging from 100 nanometers to less than 2 microns.

[0008] The salt-carrier products described in U.S. Patent No. 8,900,650 may be fillers, carbohydrates or their derivatives, starch, maltodextrin, hydrophilic colloids, proteins, protein derivatives, starch, pregelatinized starch, modified starch, pyrodextrin, gum, cereal flour or tuber flour, yeast extract, flavor enhancers, or lipids. The drying process may include freeze-drying, spray-drying, spray-heating, or roll-drying processes.

[0009] U.S. Patent No. 11,992,034 describes an improved low-sodium salt composition in which the salt particles attached to the carrier have an average size of less than 2 microns to less than 100 nanometers, and the resulting salt-carrier particles cover and adhere to food better than salt that is not attached to the carrier particles.

[0010] This invention describes a composition and method for incorporating a low-sodium salt composition into food, such as bread dough, for producing low-sodium baked foods that require a shorter leavening time, leading to a faster, more environmentally friendly (e.g., environmentally conscious), and energy-efficient production process. [Overview of the Initiative]

[0011] The composition and related methods relate to foods containing a lower sodium content than conventional table salt when a low-sodium salt composition or product (e.g., a combination of salt and a carrier product) is used in baked foods in the same amount or less than that of conventional table salt. The low-sodium salt composition may consist of one or more micron-sized salt particles attached to carrier particles, such as maltodextrin. In an example to illustrate, by employing a method of using micron-sized salt-carrier particles in a dough-making process, the leavening time and sodium content in bread and other baked foods that conventionally contain salt as an ingredient can be reduced.

[0012] The object of the present invention is to provide a composition and method for shortening the rise time of dough for making bread, buns, pastries, pizzas, bagels, donuts, and the like.

[0013] The object of the present invention is to provide compositions and methods that have commercial, economic and environmental benefits, for example, by shortening the process and / or production time of dough and baked goods as a result of shortening the dough leavening time, and making the production process more efficient than conventional production processes.

[0014] The object of the present invention is to provide compositions and methods that offer the health benefit of having a low sodium content in food.

[0015] The object of the present invention is to provide compositions and methods for preparing baked foods with improved nutritional content.

[0016] Another object of the present invention is to improve the sodium profile of baked food products including bread, pastries and cakes. In some embodiments, the baked food product may be bagels, pita, puffed confectionery snacks, and / or extruded puffed flavored snacks.

[0017] An object of the present invention is to provide a method for producing dough, which comprises incorporating a low-sodium salt composition comprising micron-sized salt particles attached to carrier particles into the dough, wherein the small-sized low-sodium salt composition particles are more uniformly dispersed in the dough compared to conventional salt.

[0018] An object of the present invention is to provide a method for producing dough incorporating a low-sodium salt composition, in which leavening agents in the dough, such as yeast, are activated more efficiently than when conventional salt is incorporated into the dough.

[0019] Another object of the present invention is to provide a method for producing dough incorporating a low-sodium salt composition, wherein the fermentation time (any fermentation stage) of the dough is shortened in the range of 15 to 50%, for example 25% or 36%, when compared with dough incorporating conventional salt.

[0020] Another object of the present invention is to provide a method for producing dough incorporating a low-sodium salt composition that reduces the effort required by a user to prepare a baked food product.

[0021] An object of the present invention is to provide compositions and methods for obtaining a low-sodium salt composition that comprises one or more salt particles attached to a carrier and has a powder-like shape and / or texture capable of promoting the dissolution rate and distribution of the salt into the dough.

[0022] An object of the present invention is to provide compositions and methods for obtaining low-sodium salt compositions and dough compositions that reduce sodium content, improve the expansion process and lead to shorter production cycles.

[0023] In some embodiments, the low sodium salt composition may be formed by a process comprising: providing an aqueous salt-carrier slurry comprising an aqueous solvent and a selected weight percent of a solid mixture, wherein the solid mixture comprises a salt present in an amount from about 3.9 wt% to less than 25 wt% of the aqueous solvent, and a carrier medium present in an amount from about 2.77 wt% to less than 25 wt% of the aqueous solvent; the combined amount of the salt and the carrier in the aqueous salt-carrier slurry is about 10 wt% to 36 wt% of the aqueous salt-carrier slurry; the aqueous salt-carrier slurry is prepared by heating the salt, the carrier and water to a temperature of about 176°F ± 10°F until the water, salt and carrier are substantially dissolved and the moisture content is about 1.2% to 5%; and exposing the aqueous salt-carrier slurry to a drying process both A) to form carrier particles composed of the carrier medium, and B) to form a plurality of salt particles having an average size of less than 100 nanometers on the surface of the carrier particles.

[0024] In some embodiments, the low sodium salt composition may be formed by a process comprising: providing an aqueous salt-carrier slurry comprising an aqueous solvent and a selected weight percent of a solid mixture, wherein the solid mixture comprises a salt present in an amount from about 2.5 wt% to less than 14.9 wt% of the aqueous solvent, and a carrier medium present in an amount from about 2.77 wt% to less than 25 wt% of the aqueous solvent; the combined amount of the salt and the carrier in the aqueous salt-carrier slurry is about 10 wt% to 36 wt% of the aqueous salt-carrier slurry; the aqueous salt-carrier slurry is prepared by heating the salt, the carrier and water to a temperature of about 176°F ± 10°F until the water, salt and carrier are substantially dissolved and the moisture content is about 1.2% to 5%; and exposing the aqueous salt-carrier slurry to a drying process both A) to form carrier particles composed of the carrier medium, and B) to form a plurality of salt particles having an average size of less than 100 nanometers on the surface of the carrier particles.

[0025] Another object of the present invention is to provide a method for producing dough incorporating a low-sodium salt composition, which, when added to the dough recipe or mixture at the beginning (as opposed to the end) of the dough production process, can shorten the fermentation time (e.g., shorten the fermentation time compared to conventional bread-making processes) and / or reduce the amount of leavening agent (e.g., yeast) required to reach a certain level of fermentation. Such a method of producing bread may be contrary to conventional bread-making processes in which salt is usually added after the leavening agent, such as yeast, has been activated.

[0026] Details of various embodiments are described in the accompanying drawings and the following description. Other features and advantages will become apparent from the description and drawings, as well as the claims. [Brief explanation of the drawing]

[0027] [Figure 1] This is a schematic flowchart illustrating the process for producing the improved salt and support products described herein. [Modes for carrying out the invention]

[0028] The above summary of the invention, the modes for carrying out the invention, the following claims, and the accompanying drawings refer to specific features of various embodiments of the invention. The disclosure of embodiments of the invention herein should be understood to include all possible combinations of such specific features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention or a particular claim, that feature may also be used, as far as possible, in combination with and / or in the context of other particular aspects and embodiments of the invention, and in general use in the invention.

[0029] In general, reducing the sodium content in dough for bread and other baked goods offers several benefits, ranging from improved health to potential changes in flavor and texture. For example, lower sodium intake can reduce the risk of heart disease and stroke by mitigating its adverse effects on the heart and circulatory system. Furthermore, reducing sodium helps lower blood pressure, which is essential for preventing hypertension and related cardiovascular diseases. High sodium intake can lead to elevated blood pressure, which can put a strain on the heart and blood vessels.

[0030] In some cases, excess sodium can strain the kidneys, which are responsible for regulating sodium balance and blood pressure. Reducing sodium intake can alleviate this strain and improve overall kidney function.

[0031] As used herein, the phrases “nanometer to micron size” or “nanometer to micron scale” and similar phrases have their usual meanings, namely, they refer to objects having dimensions of at least one nanometer or micron scale.

[0032] As used herein, the phrases “nanometer to micron size” or “nanometer to micron scale” and similar phrases have their usual meanings, namely, they refer to objects having at least one nanometer or micron-scale dimension. “Salt particles” can refer to a specific size, e.g., a narrow particle size distribution, or a collection of particles of different sizes, e.g., the average size of a collection of salt particles.

[0033] In connection with the disclosure herein, low-sodium salts used in dough compositions may include nanometer to micron-sized salt particles attached to a carrier for delivering ultra-small salt particles into the consumer's mouth. As used herein, the term “attached” has its usual meaning, i.e., connected, integrated, or fitted. Processes involved in attaching salt particles to a carrier may include chemical ions and covalent bonds, surface tension, adhesion, and any other physical processes that join two entities together.

[0034] "Salt" can be any type of salt, for example, sodium chloride, potassium chloride, or a combination thereof. In a particular preferred embodiment, "salt" refers to a salt of sodium ions, chloride ions, potassium ions, or sulfate ions.

[0035] "Leavening agent" may be any type of leavening agent, such as yeast, sourdough starter, baking powder, baking soda (sodium bicarbonate), ammonium bicarbonate (Baker's ammonia), or potassium bicarbonate, or any combination thereof, or any other leavening agent known in the art.

[0036] Examples of carriers include, but are not limited to, fillers derived from any plant or animal source, such as cereals, tubers, dairy products, and whey powder; cereal and tuber starches; maltodextrin; cereal and tuber flours; hydrophilic colloids; proteins; protein powders; flavorings; and seasonings. Proteins can be any plant or animal protein source, including dairy products, meat, corn, etc. Carriers can vary in size and shape and can be processed from their original shape to impart desired functionality, such as bulk flow or bulk density (for example, protein powder can be further refined or ground to a desired size). In some embodiments, using carriers to deliver salt particles can provide certain packaging, storage, and use advantages. For example, a carrier may be selected to impart a desired bulk density to a particular salt-carrier product. In another example, a carrier may be selected for its bulk flow properties in large-scale food processing or for its hydrophobicity or hygroscopicity. Maltodextrin has been determined to be a preferred carrier. In this specification, references to "salt / carrier products," "low sodium salts," or "low sodium salt compositions" refer to salt particles on a nanometer or micron scale attached to a carrier.

[0037] Generally, salt particles can adhere to the surface of a carrier. The degree of salt coating on the particles can be altered to produce various taste effects, including adjustment of the saltiness intensity. Furthermore, the bulk density of salts in the salt-carrier product, such as sodium chloride, can be adjusted by controlling the salt coating on the particles.

[0038] Figure 1 is a schematic flow chart of an exemplary process for producing an improved salt-support product. The salt-support product can be produced by performing the following steps, which do not necessarily have to be performed in the order shown, according to one of many methods.

[0039] In step 100, to create a salt-carrier slurry, a selected carrier, preferably maltodextrin, is added to water in a tank with good stirring, the tank is heated to a temperature of 176°F ± 10°F to dissolve the carrier, the salt is then added to the tank, and the aqueous salt-carrier solution is continued to be heated at a temperature of 176°F ± 10°F, stirring for a sufficient amount of time to ensure that the salt is dissolved, thereby preparing a solid composition of salt and carrier, which in step 300 becomes an aqueous salt-carrier slurry. Alternatively, the salt and carrier may be mixed with water and heated at different temperatures for different times, as long as the salt, carrier, and water are substantially dissolved to form an aqueous salt-carrier slurry.

[0040] The concentration of the salt in the salt solution can be adjusted to give a desired coverage of the salt on the resulting salt-carrier product. The salt can be a single salt (e.g., sodium chloride) or a mixture of salts (e.g., sodium chloride, potassium chloride, ammonium chloride, etc.). The carrier can be any filler, e.g., proteins, carbohydrates or their derivatives (plural) (e.g., maltodextrin, pregelatinized starch, gum, flour, etc.), and may also be a powder filler, e.g., carbohydrates composed of small glucose molecules (e.g., tapioca), hydrophilic colloids, hydrolyzed proteins, yeast extracts, and flavorings. In some embodiments, combinations of different types of carriers can be used, e.g., a combination of carbohydrates, starch, and potassium salts. The ratio of carrier to salt can be selected to obtain a desired working density or other properties of the salt-carrier product. The salt-carrier mixture can then be mixed until homogeneous.

[0041] Examples of solid compositions used to create improved salt-carrier products include 11% to 39.9% by weight of the aqueous solvent (water) in total weight percentage of salt and carrier, 3.9% to less than 25% by weight of salt in total weight percentage of the aqueous solvent (water), 2.77% to 24.9% by weight of carrier in total weight percentage of the aqueous solvent (water), 10% to 39.9% by weight of the aqueous salt-carrier slurry in total weight percentage of salt and carrier, and 2.5% to 14.9% by weight of salt in total weight percentage of the aqueous salt-carrier slurry.

[0042] In an example that helps illustrate this, the solid percentage in the slurry may be 25%, the salt percentage in the solid composition may be 70%, and the salt percentage in the solution may be 17.5%. In such an example, the carrier percentage in the solid composition may be 30%, and the carrier percentage in the solution may be 7.5%.

[0043] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 25%, the salt percentage in the solid composition may be 80%, and the salt percentage in the solution may be 20%. In such an example, the carrier percentage in the solid composition may be 20%, and the carrier percentage in the solution may be 5%.

[0044] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 25%, the salt percentage in the solid composition may be 60%, and the salt percentage in the solution may be 15%. In such an example, the carrier percentage in the solid composition may be 40%, and the carrier percentage in the solution may be 10%.

[0045] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 25%, the salt percentage in the solid composition may be 48%, and the salt percentage in the solution may be 12%. In such an example, the carrier percentage in the solid composition may be 52%, and the carrier percentage in the solution may be 13%.

[0046] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 20%, the salt percentage in the solid composition may be 70%, and the salt percentage in the solution may be 14%. In such an example, the carrier percentage in the solid composition may be 30%, and the carrier percentage in the solution may be 6%.

[0047] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 20%, the salt percentage in the solid composition may be 60%, and the salt percentage in the solution may be 12%. In such an example, the carrier percentage in the solid composition may be 40%, and the carrier percentage in the solution may be 8%.

[0048] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 20%, the salt percentage in the solid composition may be 50%, and the salt percentage in the solution may be 10%. In such an example, the carrier percentage in the solid composition may be 50%, and the carrier percentage in the solution may be 10%.

[0049] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 15%, the salt percentage in the solid composition may be 70%, and the salt percentage in the solution may be 10.5%. In such an example, the carrier percentage in the solid composition may be 30%, and the carrier percentage in the solution may be 4.5%.

[0050] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 15%, the salt percentage in the solid composition may be 60%, and the salt percentage in the solution may be 9%. In such an example, the carrier percentage in the solid composition may be 40%, and the carrier percentage in the solution may be 5%.

[0051] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 15%, the salt percentage in the solid composition may be 50%, and the salt percentage in the solution may be 7.5%. In such an example, the carrier percentage in the solid composition may be 50%, and the carrier percentage in the solution may be 7.5%.

[0052] In another example that may be helpful for further explanation, the solid percentage in the slurry may be 36%, the salt percentage in the solid composition may be 60%, and the salt percentage in the solution may be 21.6%. In such an example, the carrier percentage in the solid composition may be 40%, and the carrier percentage in the solution may be 14.4%.

[0053] In some embodiments, the aqueous slurry may contain the salt and the carrier together in an amount of about 10% to 36% by weight of the aqueous salt-carrier slurry, and the salt in an amount of about 2.5% to less than 25% by weight of the aqueous salt-carrier slurry, and the aqueous salt-carrier slurry is prepared by heating the salt, the carrier, and water to a temperature of about 176°F ± 10°F until the water, salt, and carrier are substantially dissolved and the water content is about 1.2% to 5%. For example, the solid percentage in the slurry may be 36%, 25%, 20%, or 15%. In an example useful for illustration, if the solid percentage in the slurry is 15%, the water content in the slurry is 85%.

[0054] In step 400, the aqueous salt-carrier slurry is supplied to a nozzle in the drying chamber, which has several orifices for ejecting the slurry into the drying chamber at different angles and diameters that can affect the particle size in step 500, with the particle size being inversely proportional to the opening angle and directly proportional to the diameter of the orifice. The inlet temperature of the drying chamber is preferably 360°F ± 25°F. By changing the amount of slurry pumped through the nozzle in step 400, the moisture content can be controlled from 1.2% to 5%. The moisture content is the water content of the resulting product. The amount of slurry pumped from the nozzle into the drying chamber is controlled by a pump and compressor, while being reduced by nozzle resistance (pressure loss).

[0055] The slurry is left in the drying chamber until it reaches the desired moisture content and settles in the collection hopper, or is drawn out by a cyclone according to a periodic spray drying operation, after which it exits the outlet of the drying chamber at a temperature of 200°F ± 25°F, and in step 700, the cyclone collects the small-diameter particles that are too light to be drawn by gravity into the hopper of the drying chamber. This process is particularly important in terms of particle size because it produces smaller-diameter particles than a normal spray drying process. Step 750 is a suction blower / scrubber process, and step 800 is a bagging process in which the resulting salt-carrier particles are bagged.

[0056] The salt-carrier mixture can then be subjected to a process to remove (evaporate) the water. Generally, it may be advantageous to remove the water quickly in order to shorten the growth time of salt nuclei that form on the surface of the carrier during the drying process. Exemplary processes for removing water from the carrier-slurry mixture include, among others, spray drying, spray heating, freeze-drying, and drum drying.

[0057] One approach is to control the average size of the salt particles by adjusting the drying process parameters, such as those of a spray drying process, including one or more (but not limited to) the salt-to-carrier ratio in the slurry described in the example above, as well as the spray drying parameters, including one or more of the inlet temperature, pump speed, airflow, and compressor pressure. It will be understood that various other means may be used to achieve similar results. Drying temperature and time may vary, especially when methods other than spray drying are used in the drying process.

[0058] This improved process can produce salt particles with an average size of 100 nanometers to less than 50 microns on or attached to the surface of the carrier. In some examples, this improved process can produce salt particles with an average size of less than 30 microns on or attached to the surface of the carrier.

[0059] The present invention aims to provide a method for reducing the leavening time and sodium content in dough or batter for baked foods, such as bread, cakes, pastries, and cookies. This may provide economic and health benefits for preparing baked foods with improved nutritional aspects. The method may generally include the steps of (1) preparing a low-sodium salt composition comprising micron-sized salt particles attached to a carrier (e.g., maltodextrin), (2) adding the low-sodium salt composition and flour to a mixture of a leavening agent (e.g., yeast), water, and / or sugar at a ratio of one teaspoon of low-sodium salt composition per cup of flour, and (3) baking the dough or batter in an oven.

[0060] According to embodiments of the present invention, a method for reducing the leavening time and sodium content in baked foods may include the steps of (1) adding a salt-carrier composition comprising a plurality of micron-sized salt particles attached to one or more carrier particles to a batter mixture comprising flour, at least one leavening agent (e.g., yeast) and water, and (2) baking the batter mixture to form a baked food. In some embodiments, the plurality of salt particles attached to the carrier particles may have an average size of less than 100 nanometers. In some examples, the plurality of salt particles may have an average size of 30 to less than 50 microns. In yet another example, the plurality of salt particles may have an average size of less than 30 microns. In some embodiments, the salt-carrier composition may comprise 15 to 60% by weight of carrier particles and 40 to 85% by weight of salt particles.

[0061] According to embodiments of the present invention, the low-sodium dough composition may comprise flour, at least one leavening agent (e.g., yeast), water, and a low-sodium salt composition (for example, in a ratio of one teaspoon of low-sodium salt composition per cup of flour), wherein the low-sodium salt composition comprises a plurality of salt particles with an average size of less than 50 microns to less than 30 microns attached to the surface of one or more carrier particles. In some embodiments, the plurality of salt particles may have an average size of less than 30 microns. In some embodiments, the salt-carrier composition may comprise 15 to 60% by weight of carrier particles and 40 to 85% by weight of salt particles.

[0062] According to embodiments of the present invention, micron-sized salt particles may have a particle size approximately 1000 times smaller than conventional salt (e.g., conventional table salt) (or 100 times smaller than ground salt). Using micron-sized salt in dough compositions may help reduce the sodium content of baked goods, such as bread, by increasing the rate of salt dissolution at sodium receptors on the tongue, and thus reducing the amount of salt needed while producing a comparable sensory profile. Furthermore, as will be discussed in more detail below, micron-sized salt particles may help break down gluten in dough more efficiently and / or effectively, which may result in a shorter rise time.

[0063] While not wishing to be bound by theory, the applicant believes that, according to the disclosure herein, the low-sodium salt compositions disclosed herein, which may include micron-sized salt particles attached to a carrier, may help align gluten chains in kneaded dough, facilitate adhesion between gluten chains, and bind the dough and / or bread structure together. Gluten is a protein that gives baked goods, such as bread, their structure and elasticity. When gluten in dough is broken down, the dough becomes more pliable and easier to work with. In some cases, this may shorten the rise time or leavening time because carbon dioxide bubbles inside the dough can easily expand and remain in the bread (since gluten chains hold carbon dioxide inside the dough and / or bread).

[0064] Since salt also functions as an enzyme and can act as a yeast inhibitor, reducing salt content should be balanced between gluten formation and yeast inhibition. If the same flavor can be achieved with lower salt levels and gluten is formed, lower salt content may inhibit yeast activation less than with conventional table salt. This improved process may also accelerate the dough's fermentation (rising) time, as it may work to speed up the yeast fermentation process.

[0065] According to embodiments of the present invention, the low-sodium salt composition may contain one to more micron-sized salt particles attached to a carrier. In preferred embodiments, the carrier is maltodextrin. Maltodextrin is a type of carbohydrate composed of small glucose molecules. Maltodextrin can be a good energy source for yeast and can help accelerate the yeast fermentation process. When yeast ferments, carbon dioxide gas is produced, causing the dough or batter to swell, become lighter, and more porous. Adding maltodextrin to the dough may provide the yeast with more energy to produce carbon dioxide gas, thereby potentially speeding up the rise time. Maltodextrin also helps to initiate the browning process of bread and other baked foods (e.g., toast) more quickly, as the Maillard reaction (a chemical reaction between amino acids and reducing sugars that gives browned foods their distinctive aroma) starts at a lower temperature.

[0066] According to embodiments of the present invention, in addition to shortening the leavening time, producing dough using micron-sized salt particles attached to maltodextrin can also improve the texture and flavor of any baked food, including bread, that may result. The salt particles help prevent the formation of large air bubbles in the dough, which may result in a more uniform crumb structure. Maltodextrin also helps retain moisture in the dough, resulting in moist and flavorful bread. Furthermore, maltodextrin may improve the overall time required to produce the appearance of toasted bread. Maltodextrin incorporated into the low-sodium salts of this disclosure has a lower "toast point" (e.g., the time and / or temperature required to give the appearance, taste, and / or feel after toasting) compared to conventional salts, which may allow for a reduction in in-store production time of finished sandwiches. In some cases, for example, in commercial production and other applications, even a small improvement (less than 1 second) is significant, given the importance of sandwich production at the store (e.g., retail and / or commercial) level.

[0067] The mechanism by which salt-carrier particles containing micron-sized salt particles attached to a carrier (e.g., maltodextrin) shorten the rise time in bread can be summarized as follows: (1) Micron-sized salt particles may be able to align gluten chains in the kneaded dough, help to bond gluten chains together, and hold the dough and / or bread structure together. (2) As gluten is broken down, the dough becomes more pliable and carbon dioxide bubbles inside the dough expand more easily. (3) The specific carrier molecule to which the micron-sized salt particles attach may have specific advantages of its own; for example, one advantage of a maltodextrin carrier is that it is a good energy source for yeast and may be involved in accelerating the fermentation process. (4) Faster rise time of dough, more uniform crumb structure, and a moister, more flavorful bread or other baked goods. and / or (5) Approximately 50% reduction in sodium content in food preparations due to the faster dissolution rate when the food comes into contact with the saltiness sensors of the tongue.

[0068] Dough produced according to the compositions and methods of this disclosure may have some or all of the following advantages: reduced rise time, reduced sodium content, and improved texture and flavor. Specifically, salt-carrier particles, for example, containing micron-sized salt particles attached to a carrier, may be configured to dissolve faster than conventional salt, and in practice, reduce rise time. This can be a significant advantage for bakers looking to shorten bread production time. Furthermore, because salt-carrier particles, for example, containing micron-sized salt particles attached to a carrier, may dissolve faster than conventional salt, less salt-carrier particles may be needed to match the conventional saltiness or profile. This may help reduce the sodium content of the bread, which can be a valuable advantage for consumers looking to reduce their sodium intake. In addition, salt-carrier particles, for example, containing micron-sized salt particles attached to a carrier (e.g., maltodextrin), may improve the texture and flavor of the resulting baked food (e.g., bread). This can make the resulting bread more appealing to consumers.

[0069] In some cases, sodium can affect the texture of dough by influencing gluten formation. Reducing the sodium content in the dough can lead to changes in texture, potentially allowing for various adjustments to achieve the desired consistency.

[0070] The following are examples that are helpful in explaining the present invention.

[0071] Example 1:

[0072] According to embodiments of the present invention, micron-sized salt particles can be mixed with carrier particles, such as maltodextrin, to form a low-sodium salt composition. This low-sodium salt composition can be mixed with the remaining ingredients for cooking the dough, such as flour, yeast, water, and oil, using a ratio of one teaspoon of low-sodium salt per cup of flour. This dough (e.g., bread dough) may be baked according to the bread production specifications provided in a recipe or product packaging (e.g., flour packaging), for example, in an oven at a temperature of 350°F to 475°F for any of 20 to 40 minutes. According to embodiments of the present invention, by substituting conventional salt (e.g., standard table salt) with the salt-carrier particles produced according to the process described herein, this bread may be baked in 10 to 25 percent less time than specified in a given recipe or packaging (e.g., flour or dough packaging). Bread produced according to this process or a similar process may have the same, substantially the same, or similar texture and flavor as bread produced with a good dough recipe, for example, one containing conventional salt (e.g., standard table salt). In some cases, bread produced according to the aforementioned process may have an improved bread texture and flavor.

[0073] Example 2:

[0074] According to embodiments of the present invention, micron-sized salt particles can be mixed with carrier particles, such as maltodextrin, to form a low-sodium salt composition. This low-sodium salt composition can be mixed with the remaining ingredients for cooking the dough, such as flour, at least one leavening agent (e.g., yeast), water, and oil, using a ratio of one teaspoon of the low-sodium salt composition per cup of flour. This dough (e.g., bread dough) can be baked according to a bread-making specification. According to embodiments of the present invention, by substituting conventional salt (e.g., standard table salt) with salt / carrier particles produced according to the process described herein, the bread can be baked in 10-25% less time than specified in a comparative baking recipe containing conventional salt as an ingredient. Bread produced according to this process or a similar process may have the same, substantially the same, similar, or better texture and flavor as bread produced with a good dough recipe, for example, containing conventional salt (e.g., standard table salt). In some cases, bread produced according to the aforementioned process may have improved bread texture and flavor.

[0075] The table below compares the fermentation (e.g., rising) and cooking times between a conventional bread dough formulation containing table salt and a bread dough formulation containing the low-sodium salt of the present invention. [Table 1]

[0076] The first significant difference is the primary fermentation time; conventional table salt dough has a total primary fermentation time of 1 hour, while the low-sodium salt dough of this disclosure has a total primary fermentation time of 45 minutes. The second significant difference is the secondary fermentation time; conventional table salt dough has a total secondary fermentation time of 30 minutes, while the low-sodium salt dough of this disclosure has a total secondary fermentation time of 19 minutes. Significant differences in fermentation time are observed at both fermentation stages.

[0077] In some embodiments, this improved low-sodium salt can reduce the proofing time during the primary fermentation process by at least 15 minutes compared to dough prepared with conventional salt. This reduction represents a decrease in fermentation time of at least 25%, from an initial 60 minutes to 45 minutes.

[0078] In some embodiments, during the secondary fermentation process, the use of this improved low-sodium salt can reduce the proofing time of the dough by at least 11 minutes, and a reduction in fermentation time of at least 36% from an initial 37 minutes to 26 minutes can be achieved.

[0079] According to embodiments of the present invention, shortening fermentation time may lead to accelerated production cycles, which can improve overall manufacturing efficiency.

[0080] According to embodiments of the present invention, shorter proofing time can contribute to reduced energy consumption because the time that the dough needs to stay in the fermentation equipment can be shortened.

[0081] With exceptions, most baking times for conventionally baked bread (e.g., bread baked using conventional table salt) typically fall within the following range 4 :

Table 2

[0082] The following table shows several other common baking time ranges for baked bread and other baked food products 5 :

Table 3

[0083] In general, by incorporating the low-sodium salt compositions of the present invention into bread dough instead of conventional table salt (or other conventional salt crystals), the baking time for any bread, including the types of bread specified in the table above, can be reduced by about 20% when using one teaspoon of the low-sodium salt per cup of flour in the dough preparation. In some embodiments, this low-sodium salt can reduce baking time by 15% to 50%.

[0084] The following is an illustrative table showing the energy cost savings resulting from, for example, the reduction in fermentation time and / or baking time when baking bread and other baked goods with the low-sodium salt composition of the present invention, as opposed to conventional table salt: [Table 4] TIFF2026532605000006.tif51159

[0085] As shown in the table above, the cost of baking certain breads and other baked goods can be reduced by approximately 20% by using the low-salt composition of the present invention.

[0086] According to the U.S. Food and Drug Administration (FDA) and the World Health Organization, the recommended maximum daily sodium intake for healthy individuals is 2300 milligrams (mg). Considering this, the sodium content of bread made using conventional recipes (e.g., incorporating conventional salt (e.g., table salt)) and manufacturing processes can account for a significant portion of the recommended maximum daily sodium intake for healthy individuals. For example, the table below shows examples of sodium content in various types of bread: [Table 5]

[0087] Therefore, by using the low-sodium salt of the present invention, a reduction of approximately 20% in the sodium content of bread, including the types of bread described above, can reduce an individual's daily sodium intake percentage.

[0088] According to embodiments of the present invention, the low-sodium salt composition may have a size and shape modified to influence the dissolution rate and distribution of the salt in the dough. For example, the low-sodium salt composition may be in powder (e.g., powder-like) form and may be configured to dissolve and distribute rapidly in the dough. In some examples, the powder form of the low-sodium salt may contribute to a faster dissolution and distribution rate of the salt, resulting in shorter fermentation or leavening times and faster baking times.

[0089] Although several embodiments are disclosed, further embodiments of the invention will become apparent to those skilled in the art from the modes for carrying out the invention. The invention is capable of countless modifications in various obvious aspects without departing from the spirit and scope of the invention. Accordingly, these drawings and description are considered to be illustrative and not limiting in nature.

[0090] In this disclosure, various features may be described as optional, for example, by the use of the verb “may,” or by the use of any of the phrases “in some embodiments,” “in some embodiments,” “in some designs,” “in various embodiments,” “in various designs,” “in illustrative examples,” or “for example,” or by the use of parentheses. For the sake of brevity and clarity, this disclosure does not explicitly describe all permutations that may be obtained by selecting from a set of optional features. However, this disclosure is construed to explicitly disclose all such permutations. For example, a system described as having three optional features may be realized in seven different ways: by only one of the three possible features, by any two of the three possible features, or by all three of the three possible features.

[0091] In this disclosure, the term “any” can be understood to mean any number of elements, i.e., one, at least one, at least two, each, or all of each element. Similarly, the term “any” can be understood to mean any set of each element, i.e., one or more sets of each element, a set containing one, at least one, at least two, each, or all of each element. Each set does not have to contain the same number of elements.

[0092] While various embodiments of the present invention have been disclosed and described in detail herein, it will be apparent to those skilled in the art that various modifications can be made to their configuration, operation, and form without departing from the spirit and scope of the invention. In particular, it should be noted that each feature of the embodiments of the present invention may be combined in any configuration, except for those that are readily apparent to those skilled in the art as being meaningless if disclosed only in combination with other features of the embodiments of the present invention. Similarly, the use of singular and plural forms is for illustrative purposes only and should not be construed as limiting.

[0093] In this disclosure, all embodiments in which “including” is used may have “essentially consisting of” or “consisting of” as an alternative. In this disclosure, any embodiment of a method or apparatus may lack one or more process steps or components. Embodiments in this disclosure that employ negative limitations are expressly disclosed and are considered part of this disclosure.

[0094] The term “comprises” and its grammatical equivalents are used herein to mean, among other things, the optional presence of other components, ingredients, or steps. For example, an article “comprising” (or “which comprises”) components A, B, and C may consist of components A, B, and C (i.e., include only them), or it may include components A, B, and C as well as one or more other components.

[0095] Where a method comprising two or more defined steps is referred to herein, such defined steps may be performed in any order or simultaneously (unless the context excludes such possibility), and such method may include one or more other steps, which may be performed before any of the defined steps, between two of the defined steps, or after all of the defined steps (unless the context excludes such possibility).

[0096] The term “at least” followed by a number is used herein to indicate the beginning of a range that starts at that number (which may have an upper limit or no upper limit, depending on the variable being defined). For example, “at least 1” means 1 or greater than 1. The term “at most” followed by a number (which may have a lower limit of 1 or 0, or no lower limit, depending on the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%. Wherever a range is given herein as “(first number) to (second number)” or “(first number) ~ (second number)”, it means a range whose end is the second number. For example, 25~100mm means a range with a lower limit of 25mm and an upper limit of 100mm.

[0097] No element of the claims herein that is not expressly described as “means for” or “steps for” performing a particular function shall be construed as a “means” or “step” clause as defined in § 112(f) of the United States Patent Act. Specifically, no use of “steps of” in the claims herein is intended to evoke the provisions of § 112(f) of the United States Patent Act.

[0098] Several embodiments have been described. Nevertheless, it will be understood that various modifications are possible. For example, favorable results may be achieved if the steps of the technology of the Disclosure are performed in a different order, or if the components of the System of the Disclosure are combined in a different way, or if other components are added to those components. Accordingly, other embodiments are contemplated within the following claims.

Claims

1. A method for producing low-sodium dough, A step of mixing a predetermined amount of powder, at least one leavening agent, and water with a low-sodium salt composition, wherein the low-sodium salt composition is present in a ratio of one teaspoon of the low-sodium salt composition per cup of powder, and the low-sodium salt composition contains a plurality of salt particles with an average size of less than 30 microns attached to the surface of the carrier particles, and The method comprising the step of subjecting the dough to one or more fermentation stages for a time shorter than the standard fermentation time for dough formed with conventional table salt.

2. The low-sodium salt composition is To provide an aqueous salt-carrier slurry comprising an aqueous solvent and a selected weight percent of a solid mixture, wherein the solid mixture comprises a salt present in an amount of about 3.9% to less than 25% by weight of the aqueous solvent, and a carrier medium present in an amount of about 2.77% to less than 25% by weight of the aqueous solvent, wherein the aqueous salt-carrier slurry contains the salt and the carrier together in an amount of about 10% to 36% by weight of the aqueous salt-carrier slurry, and the aqueous salt-carrier slurry is prepared by heating the salt, the carrier, and water to a temperature of about 176°F ± 10°F until the water, the salt, and the carrier are substantially dissolved and the water content is about 1.2% to 5%, and to provide the above, and The method according to claim 1, comprising a process of exposing the aqueous salt-carrier slurry to a drying process for both A) to form carrier particles composed of the carrier medium, and B) to form a plurality of salt particles having an average size of less than 100 nanometers on the surface of the carrier particles.

3. The method according to claim 1, wherein the baked food is selected from the group consisting of bread, pastry, cake, cookie, bagel, pita, puffed confectionery snack, and extruded puffed flavored snack.

4. The method according to claim 1, wherein the primary fermentation of the one or more fermentation steps is shortened by at least 25% compared to the standard fermentation time for dough formed with conventional table salt, and the secondary fermentation of the one or more fermentation steps is shortened by at least 36% compared to the standard fermentation time for dough formed with conventional table salt.

5. The method according to claim 1, wherein the carrier particles are maltodextrin and the at least one leavening agent is yeast.

6. A method for reducing the expansion time and sodium content in baked foods, A step of preparing a dough containing flour, at least one leavening agent, and water. A step of incorporating a salt / carrier composition containing multiple micron-sized salt particles attached to one or more carrier particles into the dough. The steps of subjecting the dough to two fermentation stages, The method comprising the step of baking the dough to form a baked food product.

7. The low-sodium salt composition is To provide an aqueous salt-carrier slurry comprising an aqueous solvent and a selected weight percent of a solid mixture, wherein the solid mixture comprises a salt present in an amount of about 2.5% to less than 14.9% by weight of the aqueous solvent, and a carrier medium present in an amount of about 2.77% to less than 25% by weight of the aqueous solvent, the aqueous salt-carrier slurry contains the salt and the carrier together in an amount of about 10% to 36% by weight of the aqueous salt-carrier slurry, and the aqueous salt-carrier slurry is prepared by heating the salt, the carrier, and water to a temperature of about 176°F ± 10°F until the water, the salt, and the carrier are substantially dissolved and the water content is about 1.2% to 5%, and to provide the above, and The method according to claim 6, wherein the aqueous salt-carrier slurry is formed by a process comprising: A) exposing the aqueous salt-carrier slurry to a drying process for both to form carrier particles composed of the carrier medium, and B) to form a plurality of salt particles having an average size of less than 100 nanometers on the surface of the carrier particles.

8. The method according to claim 6, wherein the primary fermentation of the two fermentation stages is shortened by at least 25% compared to the standard fermentation time for conventional dough containing table salt.

9. The method according to claim 6, wherein the secondary fermentation in the two fermentation stages is shortened by at least 36% compared to the standard fermentation time for conventional dough containing table salt.

10. The method according to claim 6, wherein each particle of the salt / carrier composition has a particle size of 30 to less than 50 microns.

11. The method according to claim 6, wherein each particle of the salt / carrier composition has a particle size of less than 100 nanometers.

12. The method according to claim 6, wherein the carrier particles are maltodextrin particles, and the salt / carrier composition comprises 15 to 60% by weight of the carrier particles and 40 to 85% by weight of the salt particles.

13. The method according to claim 6, wherein the carrier is tapioca and the at least one leavening agent is yeast.

14. The method according to claim 6, wherein the baked food is selected from the group consisting of bread, pastries, cakes, bagels, pitas, puffed confectionery snacks, and extruded puffed flavored snacks.

15. A dough base comprising flour, at least one leavening agent, and water, and A low-sodium dough composition comprising a low-sodium salt composition containing multiple salt particles with an average size of less than 50 microns to less than 30 microns attached to the surface of one or more carrier particles.

16. The low-sodium salt composition is To provide an aqueous salt-carrier slurry comprising an aqueous solvent and a selected weight percent of a solid mixture, wherein the solid mixture comprises a salt present in an amount of about 3.9% to less than 25% by weight of the aqueous solvent, and a carrier medium present in an amount of about 2.77% to less than 25% by weight of the aqueous solvent, wherein the aqueous salt-carrier slurry contains the salt and the carrier together in an amount of about 10% to 36% by weight of the aqueous salt-carrier slurry, and the aqueous salt-carrier slurry is prepared by heating the salt, the carrier, and water to a temperature of about 176°F ± 10°F until the water, the salt, and the carrier are substantially dissolved and the water content is about 1.2% to 5%, and to provide the above, and The low-sodium dough composition according to claim 15, formed by a process comprising: A) exposing the aqueous salt-carrier slurry to a drying process for both A) forming carrier particles composed of the carrier medium, and B) forming a plurality of salt particles having an average size of less than 100 nanometers on the surface of the carrier particles.

17. The low-sodium dough composition according to claim 15, wherein the low-sodium dough is used to produce baked goods selected from the group consisting of bread, pastries, cakes, cookies, bagels, pitas, puffed confectionery snacks, and extruded puffed flavored snacks.

18. The low-sodium dough composition according to claim 15, wherein the carrier particles are maltodextrin and the at least one leavening agent is yeast.

19. The low-sodium dough composition according to claim 15, wherein the plurality of salt particles have an average size of less than 30 microns, and the low-sodium salt composition has a powder-like texture.

20. The low-sodium dough composition according to claim 15, wherein the plurality of salt particles have an average size of less than 100 nanometers.

21. The low-sodium dough composition according to claim 15, wherein the salt-carrier composition comprises 15 to 60% by weight of the carrier particles and 40 to 85% by weight of the salt particles.

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