Process for preparing a puffed, egg white-containing snack food and products thereof

Abstract

An optionally seasoned puffed, egg white-containing snack food is made by extruding an extrusion composition comprising a) liquid egg white present in an amount of from about 8 to about 30%, and b) flour selected from the group consisting of whole grain corn, whole grain rice, cassava, soy, whey or mixtures thereof, in an amount of from about 25 to about 92% by weight. The total protein present in the puffed, egg white-containing snack food is from about 6 to about 20 % by weight, and in an aspect may be about 8 to about 40 wt% in the seasoned puffed, egg white-containing snack food. Products made by the process are described.

Description

PROCESS FOR PREPARING A PUFFED, EGG WHITE-CONTAINING SNACK FOOD AND PRODUCTS THEREOFCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 587,544, filed October 3, 2023, which is incorporated by reference herein in its entirety.FIELD

[0002] The present invention relates to puffed snacks. More specifically, the present invention relates to puffed snacks comprising egg whites.BACKGROUND

[0003] Consumer snacking behavior is changing. Snacking now frequently occurs at all times in the day and is often looked upon as a meal replacement. The demand for healthier snacks continues to grow with an emphasis on products bearing claims for protein, absence of gluten, and being made from a simple list of ingredients.

[0004] One category of popular snack products is the crisp snack foods known as “chips” in the United States and as “crisps” in Europe. These products are usually fried and have high fat and carbohydrate content. Low density snack products are also common in the marketplace, such as popcorn and cheese curls or cheese puffs. These products often also have high fat and carbohydrate content.

[0005] US Patent Application Publication Nos. 2014 / 0065285; 2014 / 0154395; 2014 / 0220225; and 2015 / 0064334, all to Alden, describe crunchy egg products that are stated to comprise a high egg percentage by volume and a low water content by weight, audible fracturing characteristics, and brittleness characteristics.

[0006] US Patent Application Publication No. 2013 / 0022731 to Olson relates to high protein, low carbohydrate meal replacements and food. The Summary of the Invention indicates that the invention described therein relates to a new class of food that is crispy, tasty, and low in carbohydrates and has substantial levels of egg white protein and suitable shelflife for packaging in ready to eat form.

[0007] US Patent No. 11,229,222 to Katz describes an expanded extruded high protein product comprising an extrudate of a composition comprising about 10-50% by dry weight of egg white and about 50-90% by dry weight of an edible starch, wherein the product has a moisture content of less than 8%, a protein content of at least 10%, and a density of less than 100 grams per liter.

[0008] US Patent No. 10,681,931 to Ford describes a snack food prepared by extruding an extrusion composition under heat and pressure to form a snack food. The extrusion compositionincludes a) whole liquid egg present in an amount of from about 5 to about 25% by weight based on the total weight of the extrusion composition, b) a protein concentrate or isolate selected from the group consisting of rice protein, soy protein, whey protein or mixtures thereof, in an amount so that the total protein present in the snack food is from about 25 to about 40% by weight, and c) starch.SUMMARY

[0009] An expanded snack food product that is high in protein is prepared by extruding an extrusion composition comprising liquid egg white. The resulting product is a uniquely light, puffed product that has a high protein content. In an aspect, a puffed, egg white-containing snack food is prepared that may be optionally seasoned on the outside surface of the puffed, egg white-containing snack food by a surface seasoning composition to provide a desired flavor profile and organoleptic experience. This product enables consumers to enjoy a satisfying snack food treat while maintaining a high protein diet.

[0010] A process for preparing a puffed, egg white-containing snack food comprises extruding an extrusion composition comprising a) liquid egg white present in an amount of from about 6 to about 30% by weight of the extrusion composition, the liquid egg white having a dry solids content of from about 8 to about 12%, and b) flour selected from the group consisting of whole grain corn, whole grain rice, cassava, soy, or mixtures thereof, in an amount of from about 25 to about 92% by weight. The extrusion is carried out under heat and pressure to form the puffed, egg white-containing snack food having a density of from about 60-110 grams per 100 cubic inches. The total protein present in the puffed, egg white-containing snack food is from about 6 to about 20 % by weight.

[0011] Advantageously, the thus prepared puffed, egg white-containing snack food may additionally be seasoned by a surface seasoning composition having a protein content of from about 5 to about 45 wt% to increase the protein content of the puffed, egg white-containing snack food. In an aspect, a coating may be applied to the puffed, egg white-containing snack food in a coating weight sufficient to increase the relative protein content of the puffed, egg white-containing snack food to from about 8 to about 40 wt%.

[0012] The present process and product prepared by the process may provide a number of significant advantages. Because the present process uses a high content of liquid egg white in the process, most if not all of the moisture content required in the extrusion composition to provide viscosity and lubrication to carry out the extrusion process is satisfied by the liquid egg white itself. The liquid egg white component not only provides necessary moisture, but also is a value-added ingredient from a nutritional perspective.

[0013] It further has been surprisingly discovered that puffed, egg white-containing snack foods prepared with liquid egg white as described herein exhibits a unique, crispy, light, and airy crunch followed by a softer texture with minimal toothpack as compared to like products prepared using dry egg white or prepared from whole egg. Traditionally, water is added to the extruder when forming crisp snacks to facilitate the extrusion process. It has been found that extruded egg products using conventional amounts of water to prepare an extruded snack that exhibits a "glassy / shard-like" texture that is not preferred by many consumers. In contrast, the present compositions using liquid egg white as the primary or exclusive moisture source in the extrusion composition provide the favored crunch and softer chewing texture described above.

[0014] It further has been discovered that using too much liquid egg white to provide the desired high protein content of the product adversely affects the texture and consistency of the extruded product. Moreover, at high levels of liquid egg white, it is not even possible to form a puffed product at all.

[0015] It has additionally been found that by preparing the puffed, egg white-containing snack food from selected amounts of liquid egg white in combination with selected flours and optional selected added protein components so that that the total protein present in the puffed, egg whitecontaining snack food is from about 6 to about 20 % by weight, the extruded puffed, egg whitecontaining snack food can be prepared having a unique light texture and does not exhibit an objectionable “eggy” taste. The thus prepared puffed, egg white-containing snack food may provide a shelf stable, kid-friendly puffed snack product with excellent snack appeal.

[0016] It further has been discovered that by applying a surface seasoning composition that itself contains protein to the puffed, egg white-containing snack food to form a seasoned puffed, egg white-containing snack food, a flavorful puffed, egg white-containing snack food may be prepared having an increased relative protein content of from about 8 to about 40 wt% without compromising the light texture of the puffed, egg white-containing snack food.

[0017] In an aspect, the present process provides significant processing advantages. The use of liquid egg white provides easy incorporation of highly desirable egg white protein into the extrusion composition. Further advantages are realized when the liquid egg white is provided as unreconstituted liquid egg white, thereby avoiding additional processing steps of dehydrating and reconstituting the egg white. Additionally, it is common to treat dried egg with added hygroscopic ingredients to facilitate reconstitution or other added ingredients to improve performance of dehydrated egg white. By use of unreconstituted egg white, there is no need to add such ingredients, facilitating maintenance of a simple ingredient statement for the final product.

[0018] The resulting puffed, egg white-containing snack food and seasoned puffed, egg whitecontaining snack food may have a greatly simplified ingredient statement (using a relatively small number of ingredients with names that are pronounceable and perceived to be "healthy" by consumers) that is often times highly valued by consumers.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate several aspects of the invention and together with a description of the embodiments serve to explain the principles of the invention. Where photographs are used, the photograph is provided in gray-scale. Counterpart color copies of such gray-scale photographs are provided as supplemental content in the present provisional application for reference as appropriate in various jurisdictions and for presentation in jurisdictions that permit submission of drawings in color.

[0020] A brief description of the drawings is as follows:

[0021] FIG. l is photograph showing a puffed, egg white-containing snack food prepared from unreconstituted liquid egg white.

[0022] FIG. 2 is a photograph of a puffed, egg white-containing snack food unreconstituted liquid egg white with addition of dried egg white.

[0023] FIG. 3 is a photograph showing an attempted extrusion of a material comprising a high quantity of unreconstituted liquid egg white.DETAILED DESCRIPTION

[0024] The aspects of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather a purpose of the aspects chosen and described is by way of illustration or example, so that the appreciation and understanding by others skilled in the art of the general principles and practices of the present invention can be facilitated.

[0025] For purposes of the present discussion, the term “extrusion composition” refers to the identity and the relative amounts of the ingredients added to the extruder to produce the final product, whether these ingredients are pre-mixed and added in one addition, or are added separately at the same stage or at different stages in the extruder. Thus, the extrusion composition is essentially the starting recipe for the final product.

[0026] For purposes of the present discussion, the term “extruded product” refers to the product immediately after it exits the extruder, but before any additional processing step, such as drying or baking.

[0027] For purposes of the present discussion, the term “puffed, egg white-containing snack food” refers to the product prepared after completion of the extrusion and drying of the puff produced in the extrusion, but before any post-extrusion coating is applied.

[0028] For purposes of the present discussion, the term “seasoned puffed, egg white-containing snack food” refers to the product prepared by application of any surface seasoning composition to the puffed, egg white-containing snack food.

[0029] In an aspect, the surface seasoning composition has a protein content of from about 5wt% to about 45wt%. In an aspect, the surface seasoning composition may be applied to the puffed, egg white-containing snack food in a coating weight sufficient to provide a seasoned puffed, egg white-containing snack food having a total protein content of from about 8 to about 40 wt%. Thus, the relative protein content of an enhanced protein, puffed, egg white-containing snack food may be higher than the protein content of the same puffed, egg white-containing snack food without such surface seasoning.

[0030] The process described herein utilizes liquid egg white as the primary moisture source in the extrusion process.

[0031] In an aspect, the liquid egg white is provided as unreconstituted liquid egg white. Naturally occurring unreconstituted liquid egg white generally has a dry solids content of from about 8 to about 12%. Such unreconstituted liquid egg white may be formed by separating egg whites of eggs from their yolks and retaining at least 90% of the moisture in the egg white of the egg. Preferably, the unreconstituted liquid egg white is not subjected to a separate drying step. Although some fraction of moisture might be lost during pasteurization, such pasteurization is not a separate drying step provided no more than about 10wt% of the moisture in the egg white is lost, or in an aspect no more that 5wt% of the moisture in the egg white is lost, of the egg. Preferably, no more that 2wt% of the moisture in the egg white is lost during pasteurization.

[0032] As noted above, the liquid egg white is present in an amount of from about 6 to about 30% by weight of the extrusion composition. In an aspect, the liquid egg white is present in an amount of from about 6 to about 25% by weight of the extrusion composition. In an aspect, the liquid egg white is present in an amount of from about 7 to about 20% by weight of the extrusion composition. In an aspect, the liquid egg white is present in an amount of from about 7 to about 15% by weight of the extrusion composition.

[0033] In an aspect, it has been found that particle size (granulation) of dry ingredients can impact both the runability of the extrusion process and the resulting texture of the extruded product. In an aspect, particle size affects flowability of the extrusion composition in the extruder. It has been found that when the particles are too fine, the extrusion composition will “bridge” in the feeder and not properly flow, leading to surge in the extruder.

[0034] It has been found that incorporation of particles that afford some at least some coarseness in the extrusion composition helps with flowability of the mix into the extruder. In an aspect, these coarse particles are advantageously provided in the flour component of the extrusion composition, since some commercial protein powders are very fine particles.

[0035] At the same time, if the particles are too large, the extrusion composition exhibits undesirably low water absorption and water solubility properties, resulting in less expansion and crispiness of the final extruded product.

[0036] In an aspect, all dry ingredients present in the extrusion composition have a mean particle size of from about 20 to about 1,000 micrometers.

[0037] In an aspect, at least about 75% of all dry ingredients present in the extrusion composition have a particle size range of from about 25 micrometers to about 75 micrometers. In an aspect, at least about 75% of all dry ingredients present in the extrusion composition have a particle size range of from about 40 micrometers to about 60 micrometers.

[0038] In an aspect, the dry ingredients have a particle size distribution, wherein from about 20% to about 50% of all dry ingredients present in the extrusion composition have a particle size range of from about 25 micrometers to about 50 micrometers and from about 20% to about 50% of all dry ingredients present in the extrusion composition have a particle size range of from about 50 micrometers to about 75 micrometers.

[0039] Particle sizes may be determined by particle sizing techniques, such as use of particle sieves, to provide a desired particle size distribution. Alternatively, particle size distribution may be determined by instrumental analysis using, for example, laser diffraction techniques using commercially available instrumentation, such as the Mastersizer 2000 from Malvern Instruments Limited.

[0040] It has additionally been discovered that incorporation of excess protein in the extrusion composition tends to inhibit the expansion of the composition to form a desirable, low density puff product.

[0041] In an aspect, the components of the extrusion composition are selected so the total protein present in the puffed, egg white-containing snack food (regardless of source) is from about 6 to about 20 % by weight on a dry weight basis. In an aspect, the components of the extrusion composition are selected so the total protein present in the puffed, egg whitecontaining snack food is from about 6 to about 17 % by weight on a dry weight basis. In an aspect, the components of the extrusion composition are selected so the total protein present in the puffed, egg white-containing snack food is from about 6 to about 15 % by weight on a dry weight basis. In an aspect, the components of the extrusion composition are selected so the totalprotein present in the puffed, egg white-containing snack food is from about 6 to about 12 % by weight on a dry weight basis.

[0042] As noted above, the extrusion composition comprises flour selected from the group consisting of whole grain corn, whole grain rice, cassava, soy, or mixtures thereof, in an amount of from about 25 to about 92% by weight.

[0043] The flour used in the extrusion composition may in an aspect be selected from any appropriate particle size distribution to facilitate meeting the above discussed particle size distribution targets. In an aspect, the flour has a mean particle size of from about 85 to about 450 micrometers. In an aspect, the flour has a mean particle size of from about 85 to about 175 micrometers. In an aspect, the flour has a mean particle size of from about 175 to about 450 micrometers.

[0044] One type of flour that has been found to be particularly useful is made from whole grain corn that is ground and sized to have a mean particle size of about 175-425 micrometers, which may be larger than conventional com flour. Examples of fine corn meal flour products are known in the industry as “com cones,” and are commercially available, for example, from Cargill as MaizeWise product MW 101 -000 or from Didion Milling as Yellow Corn Cones 3300.

[0045] In an aspect, the protein content of the flour used in the extrusion composition is less than 20%, or preferably less than 15%, or preferably less than 10% protein, and most preferably less than 5%, all on a dry weight basis.

[0046] In an aspect, the extrusion composition further comprises an added protein component; wherein the added protein component comprises at least 65 wt% protein and is selected from the group consisting of corn protein, rice protein, cassava protein, soy protein, whey protein, or mixtures thereof. In an aspect, the extrusion composition further comprises an added protein component; wherein the added protein component comprises at least 85 wt% protein and is selected from the group consisting of corn protein, rice protein, cassava protein, soy protein, whey protein, or mixtures thereof. In an aspect, the added protein component is prepared from a protein source selected from the group consisting of com, rice, cassava, soy, whey, or mixtures thereof.

[0047] In an aspect, the added protein component may be added to the extrusion composition as a protein concentrate or protein isolate. For purposes of the present discussion a protein concentrate is a protein composition having a protein content of 65% to 85% dry weight. For purposes of the present discussion a protein isolate is a protein composition having a protein content of 85% to 100% dry weight. When is it desirable to increase the amount of protein in the puffed, egg white-containing snack food above the amount provided by the egg white and flour, it has been found beneficial add the protein component in at least a protein concentrateconcentration level, and preferably in a protein isolate concentration level, to reduce incorporation of extraneous components that may otherwise be carried into the extrusion composition along with the added protein component that do not contribute to puff product expansion or increase of protein levels in the final product.

[0048] For example, one may make an extrusion composition that includes whole-grain corn flour as the flour and a corn protein concentrate as the added protein component.

[0049] In an aspect, the added protein component and the flour source are from different species sources. In an aspect, the added protein component is sourced from rice and the flour is sourced from corn.

[0050] In an aspect, the extrusion composition further comprises an added dry egg white component, wherein the added dry egg white component comprises at least 95 wt% egg white protein and is present in an amount of up to 10% by weight of the puffed, egg white-containing snack food. In an aspect, the added dry egg white component may comprise up to about 5% of stabilizers and / or hygroscopic ingredients to facilitate incorporation of the added dry egg white component into the extrusion composition.

[0051] In an aspect, the extrusion composition comprises an added polysaccharide that is in addition to polysaccharide that may be present in the flour. In an aspect, the added polysaccharide is selected from the group consisting of starches, gums, or mixtures thereof. In an aspect, the added polysaccharide is present in the extrusion composition in an amount of up to 12% by weight. In an aspect, the added polysaccharide is a starch selected from the group consisting of tapioca starch, cassava starch, rice starch, corn starch, and mixtures thereof.

[0052] In an aspect, the extrusion composition is free of added starch.

[0053] In an aspect, the gum is selected from locust bean gum, carrageenan (seaweed extract), guar gum, xanthan gum, gellan gum, scleroglucan, agar, pectin, alginate, gum acacia, and mixtures thereof.

[0054] In an aspect, the extrusion composition comprises: a) liquid egg white present in an amount of from about 6% to about 12% by weight of the extrusion composition, b) com flour present in an amount of from about 65% to about 78% by weight of the extrusion composition, c) rice protein present in an amount of from about 6% to about 12% by weight of the extrusion composition, and d) tapioca starch present in an amount of from about 6% to about 12% by weight of the extrusion composition.

[0055] In an aspect, the corn flour is a flour made from whole grain corn that is ground and sized to have a mean particle size of about 175-425 micrometers.

[0056] It has been found that puffed snack products prepared using egg white as opposed to other protein sources have a benefit of providing a snack product having very high Protein Digestibility-Corrected Amino Acid Score (PDCAAS). The PDCAAS, which is a measurement of the nutritional quality of protein in a food product in human nutrition, is determined in accordance with the methodology set forth in “Report of Joint FAO / WHO Expert Consultation: Protein quality evaluation” (FAO 1991). In accordance with that methodology and as used herein, any score calculated as above 1 (wherein the food provides >100% of the reference dietary requirement for each amino acid) is rounded down to 1.0. In an aspect, the puffed, egg white-containing snack food has a PDCAAS of 1.0. In an aspect, the seasoned puffed, egg white-containing snack food has a PDCAAS of greater than 0.5, greater than 0.6, greater than 0.7, greater than 0.8, or greater than 0.9. The PDCAAS value of a seasoned puffed, egg whitecontaining snack food will depend in part on the amino acid profile and digestibility of any protein in the seasoning.

[0057] The extrusion composition is extruded under heat and pressure to form an expanded, cooked, egg white containing snack food to create an airy snack product from the ingredients described herein.

[0058] The extrusion is carried out using any appropriate extruder fitted to provide heat and pressure thereto. In an embodiment, the extruder is a twin screw extruder. An example of such an extruder is the BMIN Buhler BCTG-62 twin screw extruder.

[0059] The extruder is fitted with a die to produce a final product having a desired shape.

[0060] In an embodiment, the die is heated to a temperature of from about 100° C. to about 180° C., more preferably from about 120° C. to about 160° C. In an embodiment, the extruder is operated under a Head Pressure of from about 20 bar to about 80 bar, or from about 30 bar to about 60 bar.

[0061] The use of egg white as the liquid component of the extrusion composition and dry ingredients with the particle sizes as discussed above greatly facilitates the ability to run the extruder as a consistent process without surging, thereby forming a consistent product. Conventionally, it is difficult to obtain a steady state while extruding egg products, and it was therefore surprising that the present product / process exhibited excellent process control to produce a cohesive product with uniform density.

[0062] In an embodiment, the process further comprises the step of drying the extrusion product to a water content of from about 1% to about 3% water by weight based on the total weight of the final product. Drying may be carried out by any appropriate technique, such as by passingthe extruded and cut product through a drying oven. In an embodiment, the composition immediately after drying comprises no more than about 3% water by weight based on the total weight of the product.

[0063] In an aspect, the puffed, egg white-containing snack food prepared by extruding the extrusion composition as described herein has a maximum crush force as determined by the Texture Analysis Method described herein of from about 1900g to about 2600g, e.g., from about 2000g to about 2500g.

[0064] In an aspect, the puffed, egg white-containing snack food prepared by extruding the extrusion composition as described herein has an average Compression Force as determined by the Texture Analysis Method described herein of from about 1800 g to about 2800 g, preferably about 2000 g to about 2500 g.

[0065] In an aspect, the puffed, egg white-containing snack food prepared by extruding the extrusion composition as described herein has a density of from about 50 to about 175 grams per cubic inch (about 3.1 to about 10.7 g / cc), e.g., from about 60 to about 150 g / in3(about 3.7 to about 9.2 g / cc), or from about 60 to about 125 g / in3(about 3.7 to about 7.6 g / cc). It has been found that a particularly desirable puffed, egg white-containing snack food from an overall organoleptic perspective has a density of from about 60 to about 110 g / in3(about 3.7 to about 6.7 g / cc).

[0066] The extrusion composition can be extruded in a wide variety of equipment to form extrudates of varying sizes and shapes. One extrudate commercially useful for snack foods takes the form of generally spherical pellets having a diameter of from about 0.5cm to about 1.5cm. The size of extruded materials may alternatively be expressed in units referred to as "pellet count," which is the number of pieces of extrudate (pellets in this instance) that after drying are required to reach a given sample weight target. In an aspect, the pellet count evaluation may be carried out for evaluation of the unseasoned puffed, egg white-containing snack food, which is generally prepared as an intermediate product that is to be seasoned. In general, it has been found to be useful to carry out the pellet count evaluation on the seasoned puffed, egg whitecontaining snack food for use in evaluating product uniformity and serving size consistency. Useful pellet count amounts may be, for example 10g or 30g pellet counts. In an aspect, the puffed, egg white-containing snack food has a 30g pellet count of from about 80 to about 100.

[0067] It has been found that the pellet count will greatly be determined by the piece size and shape. In an aspect, the puffed snack food is generally spherical in shape. In an aspect, the puffed snack food is generally spherical in shape, having a diameter of from about 0.5cm to about 1.5cm. In an aspect, the puffed snack food is generally spherical in shape and has a 30g pellet count of from about 80 to about 100.

[0068] In an aspect, the puffed snack food is elongated along an axis, and is generally cylindrical in shape. For a cylindrical shaped snack, the pellet count will be less and the sizing will be greater than that of a generally spherical puffed snack food. In an aspect, the puffed snack food is generally cylindrical in shape, having a diameter of from about 0.5cm to about 1 ,5cm and a long axis length of from about 2 to about 5 times the diameter of the cylinder. The length of the long axis of the cylindrical shaped snack can be varied easily by changing the cutter speed of the extruder. In an aspect, the puffed snack food is generally cylindrical in shape and has a 30g pellet count of from about 40 to about 80.

[0069] In an aspect, the puffed, egg white-containing snack food is prepared that may be optionally seasoned on the outside surface of the puffed, egg white-containing snack food by a surface seasoning composition.

[0070] Advantageously, the surface seasoning composition has a protein content of from about 5 to about 45% to provide an increased protein content of the final seasoned puffed, egg whitecontaining snack food. In an aspect, the surface seasoning composition has a protein content of from about 5 to about 15 %. In an aspect, the surface seasoning composition has a protein content of from about 5 to about 40wt%. In an aspect, the surface seasoning composition has a protein content of from about 8wt% to about 30 wt%.

[0071] In an aspect, the surface seasoning composition has a protein content sufficiently high and is applied at a coating weight sufficient high to make a weight percentage protein content contribution to the seasoned puffed, egg white-containing snack food that is provides an outsized contribution to the overall protein content of the puffed, egg white-containing snack food to which the seasoning composition is applied. In an aspect, the surface seasoning composition contributes from about 5 to about 45wt% of the total protein content of the seasoned puffed, egg white-containing snack food. In an aspect, the surface seasoning composition contributes from about 5 to about 30wt% of the total protein content of the seasoned puffed, egg white-containing snack food. In an aspect, the surface seasoning composition contributes from about 5 to about 15wt% of the total protein content of the seasoned puffed, egg white-containing snack food. In an aspect, the surface seasoning composition contributes from about 15 to about 45wt% of the total protein content of the seasoned puffed, egg white-containing snack food. In an aspect, the surface seasoning composition contributes from about 20 to about 45wt% of the total protein content of the seasoned puffed, egg white-containing snack food.

[0072] In an aspect, the surface seasoning composition comprises a protein source component that is a dairy component. Dairy protein sources have been found to provide excellent mouthfeel and flavor profile in a seasoning due to pairing well with common cheese / dairyflavored snack seasonings. Proteins from other protein sources, such as plant proteins, could be used to add protein content to the surface seasoning composition. Examples of particularly useful plant protein sources include pea and soy protein. In an aspect, the dairy component is selected from the cheese and sour cream. In an aspect, the surface seasoning composition comprises a cheese selected from the group consisting of parmesan cheese, cheddar cheese, or mixtures thereof. In an aspect, the surface seasoning comprises one or more non-cheese components, such as onion and paprika.

[0073] In an aspect, the surface seasoning composition comprises one or more of cheddar cheese (milk, salt, cheese cultures, enzymes), whey protein concentrate, salt, sugar, sour cream powder (cream, nonfat dry milk, cultures), acacia gum, citric acid, lactic acid, and natural flavors. In an aspect, an anti-caking agent may be incorporated in the surface seasoning composition to facilitate handing of the seasoning composition during the coating process. It has been found that an anti -caking agent such as silicon dioxide works well even in small amounts. In an aspect, the surface seasoning composition comprises not more than 2% of an added anticaking agent.

[0074] In an aspect, the surface seasoning composition is applied to the puffed, egg whitecontaining snack food by first applying oil to the outer surface of the puffed, egg whitecontaining snack food, and then applying the surface seasoning composition to the oil coated puffed, egg white-containing snack food, so that the surface seasoning composition adheres to the outer surface of the puffed, egg white-containing snack food.

[0075] In an aspect, the surface seasoning composition and oil are applied simultaneously to the outer surface of the puffed, egg white-containing snack food, so that the surface seasoning composition adheres to the outer surface of the puffed, egg white-containing snack food.

[0076] For example, the surface seasoning composition may be applied in a batch process wherein the unseasoned puffs are tumbled with application of oil, followed by application of seasoning while continuously tumbling to obtain an even coating.

[0077] In an aspect, the oil is selected from canola oil, sunflower oil, and rapeseed oil. In an aspect, the oil is a high oleic oil, which has been found to provide better shelf life. In an aspect, the oil is selected to provide clean flavor and high stability.

[0078] In an aspect, the seasoned puffed, egg white-containing snack food has a listed total dietary fiber content of from 1g to 3g in a 30g serving size, or about 3.3 to 10% by weight.

[0079] In an aspect, the seasoned puffed, egg white-containing snack food has a listed cholesterol content of less than 5mg in a 30g serving size , or less than about 170 ppm by weight. In an aspect, the seasoned puffed, egg white-containing snack food has 0 grams of listed cholesterol in a 30g serving size.

[0080] In an aspect, the seasoned puffed, egg white-containing snack food has a listed total fat content of from 3g to 6g in a 30g serving size, or about 10 to 20% by weight. In an aspect, the seasoned puffed, egg white-containing snack food has a listed total fat content of from 4g to 5g (in a 30g serving size, or about 13 to 17% by weight.

[0081] As used herein, a “listed” content is determined for the stated serving size in accordance with USDA Nutrition Facts Label requirements as of 1 January 2023.

[0082] In an aspect, the seasoned puffed, egg white-containing snack food is free of one or more of nuts, gluten, added leavening agent, and added sugar.EXPERIMENTAL METHODSTexture Analysis Method

[0083] A TA-XT Plus Texture Analyzer from Texture Technologies Corporation was used to characterize the texture profile of the snack product. A TA-93 “Forward Extrusion Rig” was used to crush a sample and gather texture data. The probe was lowered at a rate of Imm / sec. The texture analyzer collected force measurements when the probe first contacted the sample and while the sample was being crushed. The sample was a single “puff,” i.e. one piece of the puffed, egg white-containing snack food. Ten puffs were selected as being generally visually representative of a given batch of the puffed, egg white-containing snack food. The results below are based on the data from all ten samples.

[0084] Maximum crush force: As used herein, the maximum crush force is the 10-sample mean of the maximum force measured by the texture analyzer. The maximum crush force is analogous to the maximum resistance to chewing. The bite pressure will vary somewhat from one person to the next due to tooth morphology and other factors, but this standardized measurement generally relates to perception of how hard the puff is when chewing it.

[0085] Compression Force: For each puff, the total force exerted over time was calculated by adding up the force measurements for a 5-second interval between about 2.5 seconds and about 7.5 seconds after the probe contacted the sample. This total force measurement was then divided by time to determine a mean force per second for that sample over that 5-second interval. As used herein, the Compression Force is the mean of the 10 samples’ individual mean-force-per-second measurements.

[0086] The Compression Force correlates to the structural strength of the sample and resistance to chewing. During the 5-second interval in the middle of the probe’s travel, a larger probe surface area is in contact with the sample. That is believed to give a broader sense of how muchforce is needed to compress the sample, and thus better correlate with the experience of chewing the puffed, egg white-containing snack food.Extrusion

[0087] The compositions described below are extruded in a Baker-Perkins MP24 extruder 25:1 twin screw extruder, by pre-mixing of the addition of dry ingredients and introduction of the mixed dry ingredients to the extruder. The liquid ingredients (including liquid egg white) are introduced downstream in the extruder. The extruder has multiple heating zones that ramp up in temperature in the feed direction. The final heating zone adjacent the extrusion die was heated at a temperature of 300° F (149° C). The profiles of the screws in the extruder were selected to produce a first mixing zone with low-shear mixing; a second mixing zone with higher shear mixing; a third mixing zone that generates some backpressure in the first two mixing sones, and a fourth mixing zone with low-shear mixing that is adapted to allow the extrusion composition to reach the desired temperature prior to extrusion.

[0088] The composition was extruded under pressure greater than atmospheric pressure through the extrusion die, which had a 3 mm circular die opening. The product exiting the die was cut at intervals to create discrete, generally spheroidal “puffs” upon expansion having a mean diameter of about 0.6 to about 0.75 in. (15.2-19.1 mm). The same extruder conditions were used in producing all samples so product characteristics may be evaluated based on the extrusion compositions alone without variation of process conditions.EXAMPLES

[0089] Example 1 Preparation of Puffed. Egg White-Containing Snack Food incorporating Rice Protein Isolate to increase protein levels

[0090] A dry ingredient blend was prepared by combining 32 lb (14.5 kg or 80 wt%) whole grain corn flower and 4 pounds (1.81 kg or 10 wt%) each of rice protein and tapioca starch. 9.8 parts of egg white were added for each 90.2 parts of the dry ingredient blend. The liquid egg white had a dry solids content of about 11%. The ingredients and their weight percentages in the resultant extrusion composition are shown in Table 1 below:TABLE 11Whole Grain Corn Flour is Maizewise Yellow Whole Grain Corn Flour: MW101-000 (Cargill)2Rice protein is 90 Silk (Axiom), which has a nominal rice protein concentration of 90-95 wt%3SimPure 99607 (Cargill)

[0091] Example 2 Preparation of Puffed, Egg White-Containing Snack Food incorporating dried egg white to increase protein levels

[0092] A dry ingredient blend was prepared by combining 32 lb (14.5 kg or 80 wt%) whole grain corn flower and 4 pounds (1.81 kg or 10 wt%) each of dried egg white and tapioca starch.9.8 parts of egg white were added for each 90.2 parts of the dry ingredients. The liquid egg white had a dry solids content of about 11%. The ingredients and their weight percentages in the resultant extrusion composition are shown in Table 2 below:TABLE 21Whole Grain Corn Flour is Maizewise Yellow Whole Grain Corn Flour: MW101-000 (Cargill)2SimPure 99607 (Cargill)

[0093] Discussion of results

[0094] The puff product prepared in Example 1 contains only unreconstituted liquid egg white. It is shown in FIG. 1 and has a slightly brown color. The puff product prepared in Example 2 contains unreconstituted liquid egg white and added dried egg white to augment the protein content of the puff. The puff product prepared in Example 2 is shown in FIG. 2, and is lighter and more yellow in color than the puff of Example 1. Both compositions provided a desirable product with no complications in the extrusion process.

[0095] The puffs in Example 1 had a PDCAAS of about 0.55. The PDCAAS for a food is based on the amino acid with the lowest ratio of the content of the amino acid in the sample to that in the reference dietary requirement for that amino acid. Rice and tapioca proteins have a lower PDCAAS, which brings down the PDCAAS for these puffs. One can increase the PDCAAS by selection of ingredients (other than liquid egg white, which already has a PDCAAS that is rounded down to 1.0) with complementary amino acid profiles. For example, pea protein and rice protein each of a PDCAAS less than one, but a blend of pea and rice protein can have a PDCAAS of 1.0 because one makes up for the limiting amino acid in the other.

[0096] Moisture content, water activity (aW), 10g pellet count and density of the resulting puff products is reported in Table 3.TABLE 3

[0097] Texture Analysis data was collected for ten separate samples of puffs made in Example 1. TABLE 4 shows the results. The sample of Example 1 had a maximum crush force of 2134g, which is the average of the force measured for ten samples. The samples’ measurements individually ranged from 1876 g to 2551g.TABLE 4 Texture Analysis data for Example 1

[0098] Texture Analysis data was collected for ten separate puffs made in Example 2. TABLE5 shows the results. The sample of Example 2 had an average max force of 2419g (1987-2874g). TABLE 5 Texture Analysis data for Example 2

[0099] The texture analysis results for the puffed, egg white-containing snack food from Examples 1 and 2 show that both of those formulations had a desirable crispy, light, and airy initial crunch that is not overly hard followed by a softer texture, yielding a satisfying, crunchy mouthfeel profile rather than a consistently hard, brittle texture that is seen in some high-protein snacks.

[0100] Example 3 - Comparative Example - Attempt to Prepare Puffed, Egg White-Containing Snack Food Containing at least 10% Egg White by Dry Weight from Liquid Egg White

[0101] US Patent No. 11,229,222 to Katz describes an expanded extruded high protein product comprising an extrudate of a composition comprising about 10-50% by dry weight of egg white powder or its equivalent in liquid form at column 9, lines 10-13. Since liquid egg white has a dry solids content of from about 8 to about 12%, this means that if one were to prepare an extrusion composition as described herein with enough liquid egg white to provide the composition with Katz’s minimum of 10% egg white by dry weight as taught in the Katz patent,the resulting extrusion composition would have a liquid egg white content of 83 wt% to an impossible 125 wt%.

[0102] A composition having about 91 wt% liquid egg white was prepared by combining 90.98 wt% egg whites with 9.02 wt% of the same dry ingredient blend described in Example 2. The liquid egg white had a dry solids content of about 11%, so 90.98 wt% of the liquid egg white is an equivalent of 10.0% dry weight of egg white powder in liquid form. The ingredients and their amounts in that composition are shown in Table 6:TABLE 6

[0103] An attempt to prepare an extruded puff product from that composition failed to produce anything even resembling a puff product. Instead, liquid shot out of the extruder, immediately followed by the extruder shutting down. It is believed that in order to convey product out of the end of the machine, a minimum level of solids must be present in the extrusion composition, because an extrusion composition having a liquid content that is too high will backfill the extruder, causing an immediate hard shut down.

[0104] Example 4 - Comparative Example -Attempt to Prepare Puffed, Egg White-Containing Snack Food Containing 24,8 wt% Liquid Egg White (i.e. as high a liquid egg content as possible to convey product from the extruder)

[0105] Through iterative experimentation, it was determined that the highest amount of liquid egg white that would extrude an expanded dough of any kind was 24.8 wt% liquid egg white. The extruded product of this formulation is shown in FIG. 3. As can be seen, the material that is extruded has the appearance of a rope of cooked dough. Even at this comparatively low level of liquid egg white (24.8 wt% vs 83-125 wt% as suggested in Katz’s 10-50% dry egg white or its equivalent in liquid form), there is no possibility of preparing a puffed, egg white-containing snack food.

[0106] Example 5. Preparation of Seasoned Puffed, Egg White-Containing Snack Food

[0107] Seasoned puffed, egg white-containing snack food was prepared using the puffed, egg white-containing snack food of Example 1 with the following ingredients:TABLE 7

[0108] The puffs were those produced in Example 1. The seasoning was a high-protein cheese- flavored seasoning composition having a protein content of about 24% prepared by mixing cheddar cheese (milk, salt, cheese cultures, enzymes), whey protein concentrate, salt, sugar, and sour cream. The dry puffs, seasoning mix, and oil were weighed out individually, at the ratios listed. To get an even seasoning coating, the puffs were tumbled in a portable Anderson Dahlen enrober. The oil was sprayed on with an air hose controlled oil sprayer to slowly mist the puffs and get an even coating. The seasoning was sifted to avoid clumps and even distribution, then shaken on slowly while the oil-coated puffs were tumbling. The seasoned puffs continued to tumble for approx. 1 minutes to adequately distribute the seasoning onto the puffs.

[0109] As used herein, the terms "about" or "approximately" mean within an acceptable range for the particular parameter specified as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, e.g., the limitations of the sample preparation and measurement system. Examples of such limitations include preparing the sample in a wet versus a dry environment, different instruments, variations in sample height, and differing requirements in signal-to-noise ratios.

[0110] All patents, patent applications (including provisional applications), and publications cited herein are incorporated by reference as if individually incorporated for all purposes. Unless otherwise indicated, all parts and percentages are by weight and all molecular weights are weight average molecular weights. The foregoing detailed description has been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. The invention is not limited to the exact details shown and described, for variations obvious to one skilled in the art will be included within the invention defined by the claims.

Claims

CLAIMSWhat is claimed is:

1. A process for preparing a puffed, egg white-containing snack food comprising extruding an extrusion composition comprising a) liquid egg white present in an amount of from about 6% to about 30% by weight of the extrusion composition, the liquid egg white having a dry solids content of from about 8% to about 12%, and b) flour selected from the group consisting of whole grain com, whole grain rice, cassava, soy, or mixtures thereof, in an amount of from about 25 to about 92% by weight; under heat and pressure to form the puffed, egg white-containing snack food having a density of from about 60 to about 110 grams per 100 cubic inch; wherein the total protein present in the puffed, egg white-containing snack food is from about 6 to about 20 % by weight.

2. The process of claim 1, wherein the liquid egg white is provided as unreconstituted liquid egg white.

3. The process of any one of the above claims, wherein the liquid egg white is present in an amount of from about 6 to about 30% by weight of the extrusion composition, or from about 6 to about 25% by weight of the extrusion composition, or from about 7 to about 20% by weight of the extrusion composition, or from about 7 to about 15% by weight of the extrusion composition.

4. The process of any one of the above claims, wherein at least about 75% of all dry ingredients present in the extrusion composition have a particle size range of from about 25 micrometers to about 75 micrometers; or at least about 75% of all dry ingredients present in the extrusion composition have a particle size range of from about 40 micrometers to about 60 micrometers.

5. The process of any one of claims 1-3, wherein from about 20% to about 50% of all dry ingredients present in the extrusion composition have a particle size range of from about 25 micrometers to about 50 micrometers, and from about 20% to about 50% of all dry ingredientspresent in the extrusion composition have a particle size range of from about 50 micrometers to about 75 micrometers.

6. The process of any one of the above claims, wherein the components of the extrusion composition are selected so the total protein present in the puffed, egg white-containing snack food is from about 6 to about 20 % by weight on a dry weight basis; or from about 6 to about 17 % by weight on a dry weight basis; or about 6 to about 15 % by weight on a dry weight basis; or from about 6 to about 12 % by weight on a dry weight basis.

7. The process of any one of the above claims, wherein the extrusion composition comprises a flour made from whole grain corn that is ground and sized to have a mean particle size of about 175-425 micrometers.

8. The process of any one of the above claims, wherein the extrusion composition comprises a flour having a protein content of less than 20%, or less than 15%, or less than 10% protein, or less than 5%, all on a dry weight basis.

9. The process of any one of the above claims, wherein the extrusion composition further comprises an added protein component; wherein the added protein component comprises at least 65 wt% protein and is selected from the group consisting of corn protein, rice protein, cassava protein, soy protein, whey protein, or mixtures thereof.

10. The process of claim 9, wherein the added protein component in the extrusion composition is present in an amount of up to 10% by weight of the extrusion composition.

11. The process of claim 9 or 10, wherein the added protein component and the flour source are from different species sources.

12. The process of claim 9 or 10, wherein the added protein component is sourced from rice and the flour is sourced from corn.

13. The process of any one of the above claims, wherein the extrusion composition further comprises an added dry egg white component, wherein the added dry egg white component comprises at least 95 wt% egg white protein and is present in an amount of up to 10% by weight of the puffed, egg white-containing snack food.

14. The process of any one of the above claims, wherein the extrusion composition further comprises added polysaccharide that is in addition to polysaccharide that may be present in the flour.

15. The process of claim 14, wherein the added polysaccharide is selected from the group consisting of starches, gums, or mixtures thereof.

16. The process of claim 1, wherein the puffed, egg white-containing snack food has a moisture content of no more than about 3% water by weight, or wherein the puffed, egg white-containing snack food has a moisture content of from about 1% to about 3% water by weight.

17. The process of claim 1, wherein the puffed, egg white-containing snack food has a PDCAAS value of 1.0.

18. The process of claim 1, wherein the puffed, egg white-containing snack food has an average hardness value of from about 1900g to about 2600g, or an average hardness value of from about 2000g to about 2500g.

19. The process of claim 1, wherein the extrusion composition comprises: a) liquid egg white present in an amount of from about 6% to about 12% by weight of the extrusion composition, b) com flour present in an amount of from about 65% to about 78% by weight of the extrusion composition, c) rice protein present in an amount of from about 6% to about 12% by weight of the extrusion composition, and d) tapioca starch present in an amount of from about 6% to about 12% by weight of the extrusion composition.

20. The process of claim 1, further comprising the step of applying a surface seasoning composition to the puffed, egg white-containing snack food to form a seasoned puffed, egg white-containing snack food.

21. The process of claim 20, wherein the surface seasoning composition has a protein content of from about 5wt% to about 45wt%; from about 5 to about 40wt%; or from about 8wt% to about 30 wt%.

22. The process of claim 21, wherein the surface seasoning composition is applied to the puffed, egg white-containing snack food in a coating weight sufficient to provide a seasoned puffed, egg white-containing snack food having a total protein content of from about 8 to about 40 wt%.

23. The process of any one of claims 20-22, wherein the surface seasoning composition comprises a dairy component selected from cheese, sour cream or mixtures thereof.

24. The process of any one of claims 20-23, wherein the seasoned puffed, egg white-containing snack food has a 30g pellet count of from about 80 to about 100; or wherein the seasoned puffed, egg white-containing snack food has a 30g pellet count of from about 40 to about 80.

25. The process of any one of claims 20-24, wherein the surface seasoning composition contributes from about 5 to about 45wt% of the total protein content of the seasoned puffed, egg white-containing snack food; or from about 5 to about 30wt% of the total protein content of the seasoned puffed, egg white-containing snack food; or from about 5 to about 15wt% of the total protein content of the seasoned puffed, egg white-containing snack food; or from about 1 to about 45wt% of the total protein content of the seasoned puffed, egg white-containing snack food; or from about 20 to about 45wt% of the total protein content of the seasoned puffed, egg white-containing snack food.

26. The process of any one of claims 20-25, wherein the seasoned puffed, egg white-containing snack food is free of one or more of nuts, gluten, added leavening agent, and added sugar.

27. The product made according to the process of any one of the above claims.

Images