Shelf stable, chewy snack food product

Abstract

Shelf stable, chewy snack food products meeting kosher standards are described that include a pliable binder, including kappa carrageenan, which binds a plurality of liquid permeable particulates. Also described are methods of making the shelf stable, chewy snack food product.

Description

SHELF STABLE, CHEWY SNACK FOOD PRODUCTRELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 662,812, filed June 21, 2024, the entire contents of which are incorporated herein by reference in their entirety.BACKGROUND

[0002] Consumers enjoy snack foods that provide a variety of eating experiences. Convenient, shelf stable snack foods are available in various forms, such as snack mixes, bites and bars. These known shelf stable snack foods provide a number of benefits to consumers. They are generally ready-made without requiring refrigeration or preparation; they can often be consumed without needing utensils; and they can be readily provided in a variety of flavors and textures to satisfy a wide array of cravings.

[0003] One popular type of shelf stable snack food product is a chewy snack food product formed from food particulates which are bound together with a binder. When one or more liquid permeable particulates, such as pieces of cereal, are employed in making a chewy snack food product, these particulates are generally low in density and referred to as “sponges” because they tend to absorb the binder over the shelflife of the snack food product. For this reason, the binder for this type of chewy snack food product almost invariably employs gelatin which assures the desired soft and chewy texture over the shelf life. However, typical gelatin based binders are not kosher so cannot be employed in making a Kosher chewy snack food product from liquid permeable particulates. Unfortunately, starch based binders are considered to leave chewy snack food products employing liquid absorbing / permeable particulates with an unacceptable dry, gritty texture. In addition, true kosher gelatin, pectin and other hydrocolloids are either not cost effective binder materials or considered to fail in producing an acceptable food product of this type. Based on theseconstraints, acceptable kosher chewy snack food products are simply not considered to be currently available but rather a need exists for these specific products.SUMMARY

[0004] The present disclosure relates to a shelf stable, ready-to-eat snack food product including an aggregate made from liquid permeable particulates which are bound together by a pliable binder including kappa carrageenan.

[0005] In some embodiments, the kappa carrageenan is provided in an amount of about 0.2% - 0.6% by dry weight of the pliable binder.

[0006] In some embodiments, the binder is provided in an amount of about 40% to 60% by weight of the aggregate.

[0007] In some embodiments, the liquid permeable particulates are provided in an amount of 60% to 40% by weight of the aggregate. In particularly preferred embodiments, the liquid permeable particulates constitute cereal pieces. In certain embodiments, additional particulates, such as protein crisps are provided. In a specific embodiment, the ratio of cereal pieces to protein crisps is in the range of about 65:35 to 40:60 by weight, while at least 85% by weight of all the particulates are liquid permeable.

[0008] In some embodiments, the binder can include other ingredients, such as: about 5% - 15% by dry weight of a protein ingredient; about 50% - 75% by wet weight of a syrup ingredient; and about 8% - 20% by weight moisture.

[0009] In some embodiments, a binder can include about 2% - 5% by dry weight of an oil.

[0010] In some embodiments, the binder can have a sugar content of up to 50%, preferably 25% - 45%, by dry weight of the binder.

[0011] In some embodiments, the binder further includes up to about 8% by dry weight of nut butter and up to about 5% lecithin.

[0012] In some embodiments, a coating, such as a chocolate or compound coating, is provided on at least a portion of a surface of the aggregate.

[0013] In certain embodiments, the binder includes one or more of a soluble fiber syrup (e.g., inulin, soluble com fiber, or the like), a sugar syrup (e.g., com syrup, maple syrup, honey, or the like), glycerin, one or more oils, a protein ingredient (e.g., soy protein, pea protein, milk protein, whey protein, or the like), powdered or granulated sugar (e.g., fructose, sucrose, or the like), salt, fruit and / or vegetable powder, peanut butter, cocoa, cinnamon, and various potential flavorings, including fruit, vanilla, nut and cinnamon.

[0014] In connection with making shelf stable, ready-to-eat chewy snack food products in accordance with the invention, a pliable binder including kappa carrageenan is formed, the binder is employed to bound a plurality of liquid permeable particulates to create a dough, and the dough is formed into the shelf stable, ready-to-eat chewy snack food products.

[0015] In some embodiments, forming the binder also includes combining, in addition to the kappa carrageenan, a plurality of distinct liquid ingredients and a plurality of distinct dry ingredients.

[0016] In some embodiments, forming the pliable binder includes combining the kappa carrageenan with the plurality of distinct liquid ingredients at a temperature and for a time required to at least partially hydrate the kappa carrageenan and, after at least partially hydrating the kappa carrageenan, then adding the plurality of distinct dry ingredients.

[0017] In a particular embodiment, the temperature is approximately 120° F.

[0018] In some embodiments, a resting stage is purposely established between creating the dough and forming the dough into the shelf stable, chewy snack food products.

[0019] In some embodiments, a coating, such as a chocolate or compound coating, is provided on at a portion of a surface of the shelf stable, chewy snack food product.

[0020] In some embodiments, the permeable particulates include cereal pieces.

[0021] In some embodiments, one or more sources of protein are added, such as including protein particulates, in making the shelf stable, chewy snack food product.

[0022] In some embodiments, the protein particulates include protein crisps. In a particular form of these embodiments, the ratio of cereal pieces to protein crisps is in the range of about 65:35 to 40:60 by weight.

[0023] These and various other features and advantages will be apparent from a reading of the following detailed description.DETAILED DESCRIPTION

[0024] Important in connection with the invention is employing a pliable binder including kappa carrageenan for binding liquid permeable particulates to establish a shelf stable, chewy snack food product meeting kosher standards.

[0025] In various embodiments of the invention, the liquid permeable particulates are constituted by breakfast cereal pieces either alone or in combination with other snack pieces, protein crisps such as soy protein crisps, and / or puffed grain such as puffed wheat, rice, corn and the like. In some embodiments, at least 85%, but potentially up to 100%, by weight of all the particulates are liquid permeable. In connection with certain embodiments of the invention, the liquid permeable particulates are provided in an amount of 40% to 60% by weight of the shelf stable, chewy snack food product. In one preferred embodiment, cereal pieces are combined with protein crisps in order to provide a high protein bar. In this situation, the ratio of cereal pieces to protein crisps is in the range of about 65:35 to 40:60 by weight. Although various types of cereal pieces can be employed, those sold under the brand names CHEERIOS™ (e.g., chocolate peanut butter, Honey Nut, and berry flavors), TRIX™, CINNAMON TOAST CRUNCH™ and REESE’S PUFFS™ represent particularly preferred cereal pieces.

[0026] It was discovered, as disclosed herein, that a shelf stable, chewy food product including an aggregate containing a food binder containing kappa carrageenan and particulates which are liquid permeable provides an eating experience previously only attributed to employing a gelatin based chewy binder, while satisfying kosher standards. In connection with the invention, it should be recognized that not all gelling agents / thickeners are interchangeable. Surprisingly, it was found that employing kappa carrageenan results in a shelf stable food advantageously exhibiting a chewy texture over shelf life even though kappa carrageenanhas a reputation as being more brittle and typically only relied on for viscosity purposes versus even the softer, more elastic, less brittle iota carrageenan which is known for use as a gelatin replacement. By way of examples regarding non-interchangeable gelling agents, the use of iota carrageenan actually resulted in an unsatisfactory, crumbly product; pectin would simply not hold the particulates together when used at low levels, and when used at high enough levels was cost prohibitive and suffered from poor texture; and agar was unsatisfactory and additionally required an undesired heating process (hot bloom). In connection with the invention, the binder includes between about 0.2% - 0.6% kappa carrageenan.

[0027] As used herein in connection with an amount, “about” is to be interpreted to mean ±5%, while “approximately” equates to ±10%. The phrase “shelf stable, chewy” should be interpreted to mean the aggregate is maintained as a bound aggregate that can be hand-held without falling apart yet having a soft, chewy texture for a shelflife of at least 6 to 9 months in a package exposed to room temperature. As to the particulates being “liquid permeable”, this means the particulates must tend to soak up / absorb liquid materials like a sponge, yet not to the point where they become soggy. In addition, when referring to the binder including kappa carrageenan, this excludes other known binder materials, such as gelatin, agar, pectin, etc., but does not preclude the inclusion of contaminant amounts, less than 5% of the total carrageenan, particularly of iota carrageenan.

[0028] As indicated above, the binder employed in the invention can include the kappa carrageenan in the range of 0.2% - 0.6% dry weight, preferably 0.25% - 0.5%, most preferably about 0.45%. In addition, the binder can include various other ingredients, including additional protein, preferably in the order of 5% - 15% dry weight, such as due to the inclusion of soybean protein and / or nut butter. Surprisingly, the effective amount of kappa carrageenan is not altered with the inclusion of nut butter, e.g., nut butter up to 8% dry weight. The binder can also include lecithin, preferably about 1.5% - 4%, although up to 5% if nut butter is included.

[0029] The pliable binder can also include a syrup ingredient in the range of about 50% - 75% wet weight, where the syrup ingredient comprising soluble fiber syrup, sugar syrup and / or glycerin. By way of example, the soluble fiber can constitute inulin syrup which has lowviscosity while adding fiber, while the sugar syrup can comprise com syrup which adds viscosity while adding sugar. The moisture of each of these ingredients is generally less than 30%, with glycerin being less than 2%. One potential combination is glycerin between 5% - 10% and fiber and / or sugar syrup totaling 45% - 70%.

[0030] A pliable binder provided herein typically has a moisture content of about 8% - 20%, preferably about 10% - 18%. Moisture content in the pliable binder can be contributed by the inclusion of water as an ingredient and / or water content in any of the other included ingredients. A moisture content can contribute to a water activity within the desired range, and chewiness over shelf life without resulting in sogginess of particulates within an aggregate. In addition, a moisture content in the desired range can enable the pliable binder to be used in an aggregate without requiring drying and / or baking to achieve effective binding.

[0031] Oil can also be included in a pliable binder (e.g., 2% - 5% dry weight). Various known oils can be employed, including canola, coconut, peanut, soybean or the like oils.

[0032] In addition to those discussed above, the pliable binder can contain further ingredients, such as a protein ingredient (e.g., soy protein, pea protein, milk protein, and the like), sweeteners (e.g., powdered and / or granulated sugars, sugar alcohols, and the like), flavorants (e.g., salt, fruit and / or vegetable powder, cocoa, cinnamon, natural and / or artificial flavors, seed or nut extracts or oils, and the like), nut butter (e.g., peanut butter, almond butter, and the like), and the like.

[0033] For the sake of completeness, exemplary binder formulations to the different cereal particulates listed in paragraph 0025 are represented in Table 1.Table 1Main Particulate Cheerios CheeriosIngredient: Choc PB Berry Trix CTC Reese'sBinder Ingredients(wet weight)Inulin 32-35% 30-32% 30-32% 30-32% 32-35%Corn syrup 18-20% 30-32% 30-32% 30-32% 18-20%Glycerin 7-9% 7-9% 7-9% 7-9% 7-9%Canola oil 3-4% 2-3% 2-3% 2-3% 3-4%Water 0.3-0.35% 0.3-0.35% 0.3-0.35% 0.3-0.35% 0.3-0.35%Lecithin 3-3.5% 2-2.5% 2-2.5% 2-2.5% 3-3.5%Kappa carrageenan 0.25-0.4% 0.25-0.5% 0.3-0.5% 0.3-0.5% 0.3-0.5%Soy protein isolate 8-8.5% 9.5-10% 9.5-10% 9.5-10% 8-8.5%Fructose 10-12% 10-12% 10-12% 10-12% 10-12%Salt 0-0.5% 0.1-0.5% 0.1-0.5% 0.1-0.5% 0-0.5%Fruit powder 0% 2-3% 0% 0% 0%Nut butter 6-7% 0% 0% 0% 6-7%Cocoa 2-3% 0% 0% 0% 2-3%Cinnamon 0% 0% 0% 0.2-0.5% 0%Flavors 2.5-3% 1.5-2% 1-2% 3-3.5% 2.5-3%

[0034] A method of making a shelf stable chewy food product according to the invention is also provided herein based on the ingredient percentages set forth above. In connection with making shelf stable, ready-to-eat chewy snack food products in accordance with the invention, the pliable binder, including the kappa carrageenan, is formed (such as in a batch mixer) and employed to bind the plurality of liquid permeable particulates (i.e., the cereal pieces alone or in combination with one or more other snack pieces, protein crisps and puffed grain) to create a dough upon setting of the fluid binder, after which the dough is formed into the shelf stable, ready-to-eat chewy snack food products (e.g., bites, bars or the like) and then the binder is set to form a pliable binder. In general, forming the binder includes combining, in addition to the kappa carrageenan, a plurality of distinct liquid ingredients (e.g., the syrup ingredient, oil, water) and a plurality of distinct dry ingredients (e.g., protein ingredient, granulated sugar, salt, nut butter, and the like). More preferably, forming the pliable binder includes combining the kappa carrageenan with the plurality of distinct liquid ingredients at a temperature (e.g., about 110° F to about 135° F, or approximately 120° F) and for a time required to at least partially hydrate the kappa carrageenan and then, after at least partially hydrating the kappa carrageenan, adding the plurality of distinct dry ingredients. Although a temperature of about 140° F is lower than generally recommended for hydrating kappa carrageenan by ingredient suppliers, it is believed that a hold time at about 110° F to about 140° F, or approximately 120° F for a time (e.g., at least 5 minutes, at least 10 minutes, about 15 minutes to about an hour, or about 20 minutes) initiates at least partial hydration. In some embodiments, a temperature of abinder can be adjusted (e.g., to a temperature of less than 100° F, or from about 80° F to about 95° F) before combining with particulates to form a dough. In some variants, a resting stage is purposely established between creating the dough and forming the dough into the shelf stable, chewy snack food products. In some embodiments, a resting stage between creating a dough and forming the dough can include adjusting the temperature of the dough (e.g., to a temperature of less than 100° F, or from about 80° F to about 95° F).

[0035] In some embodiments, a coating, such as a chocolate or compound coating, is provided on at least a portion of a (e.g., an upper surface and / or a lower surface) of the shelf stable, chewy snack food product. The shelf stable, chewy snack food products of the invention can be packaged individually or in combination with one or more additional food ingredients, such as a drizzle, to produce a shelf stable food product. A shelf stable food product can be packaged in any appropriate packaging material, such as a plastic, foil, or paper-based wrapper.

[0036] The implementations described above and other implementations are within the scope of the following claims. One skilled in the art will appreciate that the present disclosure can be practiced with embodiments other than those disclosed. Therefore, the disclosed embodiments are presented for purposes of illustration and not limitation.

Claims

What is claimed is:

1. A shelf stable food product comprising a chewy aggregate, the aggregate including: a pliable binder including kappa carrageenan; and a plurality of liquid permeable particulates bound by the pliable binder.

2. The shelf stable food product of claim 1, wherein the binder is provided in an amount of about 40% to 60% by weight of the aggregate.

3. The shelf stable food product of claim 1 or 2, wherein the plurality of liquid permeable particulates is provided in an amount of 60% to 40% by weight of the aggregate.

4. The shelf stable food product of claim 3, wherein the plurality of liquid permeable particulates include cereal pieces.

5. The shelf stable food product of claim 4, wherein the plurality of liquid permeable particulates further includes protein crisps, with a ratio of cereal pieces to protein crisps being in the range of about 65:35 to 40:60 by weight.

6. The shelf stable food product any of claims 1-5, wherein the binder includes between about 0.2% - 0.6% kappa carrageenan.

7. The shelf stable food product of claim 6, wherein the binder includes between about 0.25% - 0.5% kappa carrageenan.

8. The shelf stable food product of any of claims 1-7, wherein the binder further includes: about 5% - 15% by dry weight of a protein ingredient; about 50% - 75% by wet weight of a syrup ingredient comprising soluble fiber, sugar, glycerin, or any combination thereof; about 2% - 5% by dry weight of an oil; anda moisture content of about 8% - 20% by weight of the binder.

9. The shelf stable food product of claim 8, wherein the binder has a sugar content of up to 50% by dry weight of the binder.

10. The shelf stable food product of any of claims 1-9, wherein the binder further includes up to about 8% by dry weight of nut butter and up to about 5% dry weight lecithin.

11. The shelf stable food product of any of claims 1-10, further comprising additional particulates, wherein at least 85% by weight of all of the plurality of liquid permeable particulates and the additional particulates are permeable.

12. The shelf stable food product of any of claims 1-11, further comprising a coating on at least one of an upper surface and a lower surface of the aggregate.

13. A shelf stable food product comprising a chewy aggregate, the aggregate including: a pliable binder including:0.2% - 0.6% kappa carrageenan; about 5% - 15% by dry weight of a protein ingredient; about 50% - 75% by wet weight of a syrup ingredient comprising soluble fiber, sugar, glycerin, or any combination thereof; sugar content of up to 50% by dry weight of the binder; about 2% - 5% by dry weight of an oil; and a moisture of about 8% - 20% by weight of the binder; and a plurality of particulates bound by the pliable binder, with at least 85% of the said plurality of particulates are liquid permeable.

14. The shelf stable food product of claim 13, wherein the plurality of particulates include cereal pieces and protein crisps, with a ratio of cereal pieces to protein crisps being in the range of about 65:35 to 40:60 by weight15. A method of making shelf stable, chewy food products comprising: forming a pliable binder including kappa carrageenan; binding a plurality of liquid permeable particulates with the pliable binder to create a dough; and forming the dough into the shelf stable, chewy food products.

16. The method of claim 15, wherein the forming the pliable binder includes, in addition to the kappa carrageenan, a plurality of distinct liquid ingredients and a plurality of distinct dry ingredients and wherein forming the pliable binder includes combining the kappa carrageenan with the plurality of distinct liquid ingredients at a temperature and for a time required to hydrate the kappa carrageenan and, after hydrating the kappa carrageenan, adding the plurality of distinct dry ingredients.

17. The method of any one of claims 15 and 16, further comprising establishing a resting stage between creating the dough and forming the dough into the shelf stable, chewy snack food products.

18. The method of claim 17, wherein forming the dough into the shelf stable, chewy snack food products includes sheeting the dough and subsequently cutting the dough into the shelf stable, chewy snack food products.

19. The method of any of claims 15-18, further comprising coating on at least one of an upper surface and a lower surface of each of the shelf stable, chewy snack food products.