Food product

Abstract

The invention pertains to food product comprising a core and a coating covering the core, the coating comprising starch and fat, wherein the food product comprises at least 1 wt% fat, based on the total weight of the food product, and wherein the fat has a Totox value of at most 25.

Description

[0001] FOOD PRODUCT

[0002] The present invention relates to food products comprising a core and a coating.

[0003] Food products having a core and a coating have been described in the art. An example such food products includes French fries which have a separately applied coating, a so-called clear coat or batter. Clear coats bring about a crispy outer layer to the fries. A drawback of conventional clear coats is that after freezing of the French fries the clear coat generally exhibits cracks. When the frozen fries are subsequently fried in hot oil, fat is taken up through the cracks and reaches the inner core of the French fries. The overall fat content substantially increases during the frying process to levels well exceeding 15 wt%. Such high fat levels are undesirable for consumers. During (par-)frying of potato fries the frying oil is absorbed by the potato fries. The absorbed oil or fat is prone to chemical change, e.g. by oxidation, during the frying process. Moreover, the frying oil is used for up to 17 hours before it needs to be replaced, and in this time the chemical changes to the absorbed frying oil is generally more progressed. Due to this oil deterioration the variety of frying oils is rather limited. The present invention seeks to overcome these disadvantages.

[0004] The objective of the present invention is to provide novel food products.

[0005] The invention pertains to a food product comprising a core and a coating covering the core, the coating comprising starch and fat, wherein the food product comprises at least 1 wt% fat, based on the total weight of the food product, and wherein the fat has a Totox value of at most 25. The food product of the invention allows for consumption without the food product being exposed to oil frying conditions. The inventors have found that applying fat in the batter or coating composition enables frying or baking of the food product under alternative baking conditions such as baking in an air fryer, an oven, microwave and / or steam oven. Without fat being present in the coating composition, the coating of the food product is generally not uniformly heated, uniformly colored and / or forms a crunchy crust. The inventive food product generally has a crunchy crust, remains at a higher temperature after baking and / or the core has a higher water content. Generally, the fat remains in the coating rather than migrates to the core of the food product. In addition, the amount of fat in the food product can be controlled better and kept at lower concentrations, and even allows for low fat food products (i.e. a fat content below 3 wt%, based on the total weight of the food product). A further advantage is that the food product comprises fat of a higher quality (i.e. less fat degradation). In frying oil, the fat degrades over time and generally the fat which is taken up in the food product has a significantly higher Totox value and / or a higher amount of free fatty acids. As in the present invention fat is introduced in the batter, this fat is generally exposed to a pre-bake and a bake process which renders a short time exposure to higher temperatures and hence the degradation of fat is minimal or even absent. This also allows for use of (vegetable) fats that degrade easier at elevated temperatures such as olive oil, which in turn enables the use of fats with different compositions, e.g. oils with a more favorable a>6 fatty acid over a>3 fatty acid weight ratio.

[0006] The food product of the invention comprises a core and a coating covering said core. With the wording “covering” is meant that the core is covered on all sides by the coating. In one embodiment of the invention the coating is intact and does not comprise pores or cracks. The presence of pores or cracks may lead to migration of fat to the core, which is undesirable. In one embodiment, the coating may comprise air pockets or bubbles. It is noted that despite the presence of such air pockets the integrity and coverage of the coating is not negatively impacted.

[0007] In one embodiment, the food product comprises at least 1 wt% fat, based on the total weight of the food product. The fat can be any fat known in the art, and includes free fatty acids, monoglycerides, diglycerides, triglycerides, phospholipids and any other lipid originating from plants and / or fruits. In one embodiment, fat can be a plant-based fat or an animal-based fat. Preferably, fat is a plant-based fat. Examples of suitable fats includes sunflower oil, olive oil, flaxseed oil, avocado oil, coconut oil, corn oil, canola or rapeseed oil, cottonseed oil, grape seed oil, hemp seed oil, palm oil, peanut oil, rice bran oil, sesame oil, soybean oil, walnut oil, and (partially) hydrogenated fats thereof. In one embodiment, when a low amount of a>6 fats are desired, fat is selected from high oleic sunflower oil, olive oil, rapeseed oil, canola oil and palm oil. Preferably, fat is selected from high oleic sunflower oil, olive oil and rapeseed oil.

[0008] Preferably, the inventive food product comprises at least 1.1 wt% fat, more preferably at least 1 .2 wt% fat, even more preferably at least 1 .5 wt% fat and most preferably at least 2 wt% fat, and preferably at most 5 wt% fat, more preferably at most 4 wt% fat and most preferably at most 3 wt% fat, based on the total weight of the food product. In one embodiment, the inventive food product comprises at most 3 wt%, which constitutes a low-fat food product. The total weight is defined as the total weight of the food product including water. The amount of fat can be determined with methods known in the art including organic solvent extraction. An example of such a technique is the ISO 6492 method.

[0009] The food product of the present invention comprises fat which has a Totox value of at most 25. The Totox value is defined as the product of twice the peroxide value and the anisidine value. The Totox value is a measure for the degradation of the fat or oil by oxidation and / or subsequent aldehyde formation. Preferably, the Totox value of the fat in the inventive food product is at most 20, more preferably at most 18 and most preferably at most 15, and preferably at least 0.1 , more preferably at least 0.5 and most preferably at least 1.

[0010] In one embodiment, the food product comprises fat which comprises at most 3 wt% of free fatty acids, based on the total weight of fat. The term “free fatty acids” or “FFA” refers to the concentration of (free) fatty acids in fat; such fatty acids generally form by hydrolysis of mono-, di- or triglycerides. For instance, fresh rapeseed oil has a FFA value of about 0.05 wt%, based on the total weight of fat, and fresh olive oil has a FFA value of about 0.21 wt%, based on the total weight of fat. The FFA value can be determined using any method known in the art including titration. An example of such a method is the ISO 660 method.

[0011] Preferably, the food product comprises fat which comprises at most 2.5 wt% of free fatty acids, based on the total weight of fat. More preferably, the food product comprises fat which comprises at most 2 wt% of free fatty acid, even more preferably at most 1 wt% of free fatty acid, even more preferably at most 0.5 wt% of free fatty acid and most preferably at most 0.3 wt% of free fatty acid, and preferably at least 0.001 wt% of free fatty acid, more preferably at least 0.01 wt% of free fatty acid and most preferably at least 0.05 wt% of free fatty acid, based on the total weight of fat.

[0012] In an embodiment, the inventive food product has an anisidine value of at most 20. Preferably, the inventive food product has an anisidine value of at most 15, more preferably at most 10, even more preferably at most 5, even more preferably at most 2 and most preferably at most 1 , and preferably at least 0.1 , more preferably at least 0.2 and most preferably at least 0.5. The anisidine value can be determined using any suitable method in the art. An example of such method is ISO 6885.

[0013] In an embodiment, the inventive food product has a peroxide value of at most 30 meq / kg. Preferably, the inventive food product has a peroxide value of at most 20 meq / kg, more preferably at most 10 meq / kg and most preferably at most 5 meq / kg, and preferably at least 0.1 meq / kg, more preferably at least 0.2 meq / kg and most preferably at least 0.5 meq / kg. The peroxide value can be determined using any suitable method in the art. An example of such method is ISO 3960:2017.

[0014] Preferably, the inventive food product comprises at most 2 ppm hexanal, based on the weight of the potato starch composition, more preferably at most 1.5 ppm, even more preferably at most 1 .2 ppm, even more preferably at most 1 ppm, even more preferably at most 900 ppb, even more preferably at most 800 ppb, even more preferably at most 700 ppb, even more preferably at most 600 ppb, such as at most 500 ppb, at most 450 ppb, at most 400 ppb, at most 350 ppb or at most 300 ppb. Hexanal is considered a marker for fat oxidation. The concentration of hexanal can be determined using gas chromatography-mass spectrometry with solid phase microextraction (GC- SPME-MS).

[0015] In one embodiment, the inventive food product comprises fat comprising at most 0.25 wt% trans fatty acid. Preferably, the fat comprises at most 0.2 wt% trans fatty acid, more preferably at most 0.15 wt% trans fatty acid, even more preferably at most 0.10 wt% trans fatty acid and most preferably at most 0.05 wt% trans fatty acid, and preferably at least 0.001 wt% trans fatty acid, more preferably at least 0.005 wt% trans fatty acid and most preferably at least 0.01 wt% trans fatty acid. The trans fatty acid content can be determined using any suitable method in the art including gas chromatography. An example of such method is ISO 15304:2002.

[0016] In one embodiment, the food product comprises fat which comprises at most 15 wt% of total polar compounds, based on the total weight of fat. The term “total polar compounds” or “TPC” refers to the concentration of hydrocarbon compounds containing nitrogen, sulphur or oxygen, and includes free fatty acids, mono- and diglycerides, oxidized products, dimeric and polymeric triglycerides in fat. For instance, fresh soybean oil has a TPC value of about 2.5 wt%, based on the total weight of fat, and fresh rapeseed oil has a TPC value of 0.8-1 .5 wt%, based on the total weight of fat. With the term “fresh” or “fresh oil” is meant that the oil is obtained as such and has not been exposed to frying or baking conditions during which oil degradation generally occurs. The TPC value can be determined with methods known in the art including liquid chromatography or silica gel column chromatography. An example of such a technique is the ISO 17025 method.

[0017] Preferably, the food product comprises fat which comprises at most 10 wt% of total polar compounds, based on the total weight of fat. More preferably, the food product comprises fat which comprises at most 7 wt% of total polar compounds, even more preferably at most 5 wt% of total polar compounds, even more preferably at most 3 wt% of total polar compounds and most preferably at most 2 wt% of total polar compounds, and preferably at least 0.01 wt% of total polar compounds, more preferably at least 0.1 wt% of total polar compounds and most preferably at least 0.2 wt% of total polar compounds, based on the total weight of fat.

[0018] In one embodiment, the food product comprises fat having an acid number of at most 12 mg KOH / g fat. The term “acid number” or “acid value” is a measure of the carboxylic acid groups which can be neutralized by the base KOH; it is generally a measure of the free fatty acids present in fat. For instance, fresh rapeseed oil has an acid value of about 0.11 mg KOH / g oil, and fresh olive oil has an acid value of about 0.41 mg KOH / g oil. The acid value can be determined using any method known in the art including titration. An example of such a method is the ISO 660 method.

[0019] Preferably, the food product comprises fat having an acid number of at most 10 mg KOH / g fat. More preferably, the food product comprises fat having an acid number of at most 5 mg KOH / g fat, even more preferably an acid number of at most 2 mg KOH / g fat, even more preferably an acid number of at most 1 mg KOH / g fat and most preferably having an acid number of at most 0.5 mg KOH / g fat, and preferably an acid number of at least 0.01 mg KOH / g fat, more preferably an acid number of at least 0.05 mg KOH / g fat and most preferably having an acid number of at least 0.1 mg KOH / g fat.

[0020] In a further embodiment, the inventive food product comprises fat having a weight ratio of a>6 fatty acids and a>3 fatty acids of at most 200. The term “a>6 fatty acids” refers to polyunsaturated fatty acids with a double bond in the 6-position taken from the methyl end. Examples of a>6 fatty acids include linoleic acid and y-linolenic acid. The term “a>3 fatty acids” refers to polyunsaturated fatty acids with a double bond in the 3-position taken from the methyl end. Examples of a>3 fatty acids include hexadecatrienoic acid and a-linolenic acid. The amount of a>6 over a>3 fatty acids includes free fatty acids as well as these fatty acids in ester form, e.g. in mono-, di- and triglycerides. Preferably, the a>6 over a>3 fatty acids weight ratio is at most 150, more preferably at most 100, even more preferably at most 50, even more preferably at most 20 and most preferably at most 15, and preferably at least 0.1 , more preferably at least 0.5 and most preferably at least 1. The amount of a>6 fatty acids and a>3 fatty acids can be determined with methods known in the art including gas chromatography, GC-MS and HPLC. An example of such a technique is the ISO 12966-2 / 4 method.

[0021] In a further embodiment, the food product of the invention comprises at most 500 ppm acrylamide. Preferably, the inventive food product comprises at most 300 ppm acrylamide, more preferably at most 200 ppm acrylamide, even more preferably at most 150 ppm acrylamide and most preferably at most 100 ppm acrylamide, and preferably at least 0.1 ppm acrylamide, more preferably at least 1 ppm acrylamide and most preferably at least 5 ppm acrylamide. The acrylamide content can be determined using any suitable method. An example of such a method is LC-MS. Preferably, acrylamide is determined using NEN-EN 16618. In one embodiment of the invention, the food product comprises fat of which at least 40% is located in the coating. Preferably, the coating comprises at least 50% of the fat in the food product, more preferably at least 60%, even more preferably at least 70% and most preferably at least 80% of the fat in the food product, and preferably at most 99% of the fat in the food product, more preferably at most 95% and most preferably at most 90% of the fat in the food product. The inventive coating of the food product enables only fat uptake in the coating or no fat uptake during frying or frying in fat. Penetration of fat during frying or frying in fat to the core of the food product does not or does hardly proceed.

[0022] The food product can be any food product known in the art comprising a coating. Examples of such food products include potato-based snacks such as potato fries, potato croquettes, hash browns or rdsti and sweet potato wedges; vegetable snacks such as vegetable croquettes, vegetable fries, cheese-based snacks and vegetable balls, meat-based snacks such as bitter balls and meat croquettes, fish-based snacks such as shrimp croquettes and fish sticks; vegetarian or vegan food product, preferably a vegetarian or vegan meat substitute or alternative such as a vegan burger or fish substitute or alternative; and meat-based food products such as Wiener schnitzel or cordon-blue.

[0023] In one embodiment, the food product comprises at least 5 wt% coating, based on the total weight of the food product. Preferably, the inventive food product comprises at least 10 wt% coating, more preferably at least 20 wt% coating, even more preferably at least 30 wt% coating and most preferably at least 40 wt% coating, and preferably at most 90 wt% coating, more preferably at most 80 wt% coating and most preferably at most 70 wt% coating, based on the total weight of the food product. This value is determined by separating the coating from the core, e.g. by using a knife, and weighing the coating.

[0024] In one embodiment of the invention, the starch in the coating is at least 60 wt% gelatinized. With “gelatinization” or “gelatinized” reference is made to the phenomenon occurring when starch is exposed to water and heat in which starch granules primarily absorb water, swell and eventually burst out to form a gel. Preferably, the inventive coating comprises starch which is at least 70 wt% gelatinized, more preferably at least 80 wt% gelatinized and most preferably at least 90 wt% gelatinized, and preferably at most 100 wt% gelatinized, more preferably at most 99 wt% gelatinized and most preferably at most 95 wt% gelatinized. The degree of gelatinization can be determined using any suitable method known in the art. Examples of suitable methods include light microscopy and electron microscopy. The advantage of gelatinized starch is that amylopectin may form a glassy structure which contributes to the crispiness of the coating of the food product.

[0025] In one embodiment, the coating comprises at least 1 wt% fat, based on the total weight of the coating. Preferably, the inventive coating comprises at least 2 wt% fat, more preferably at least 3 wt% fat, even more preferably at least 4 wt% fat and most preferably at least 5 wt% fat, and preferably at most 50 wt% fat, more preferably at most 45 wt% fat and most preferably at most 40 wt% fat, based on the total weight of the coating. The total weight is defined as the total weight of the coating including water. The amount of fat can be determined with methods known in the art including organic solvent extraction. An example of such a technique is the ISO 6492 method. This value is determined by separating the coating from the core e.g. by using a knife, and using the coating.

[0026] In one embodiment, the inventive coating comprises at least 20 wt% starch, more preferably at least 30 wt% starch, even more preferably at least 40 wt% starch and most preferably at least 50 wt% starch, and preferably at most 99 wt% starch, more preferably at most 95 wt% starch, even more preferably at most 90 wt% starch and most preferably at most 80 wt% starch, based on the total weight of the coating. The amount of starch can be determined using any suitable method known in the art. Examples of a suitable method include spectrophotometric methods such as the method of NEN-EN-ISO 15914. This value is determined by separating the coating from the core e.g. by using a knife, and using the coating.

[0027] In one embodiment, the inventive coating comprises starch and fat in a weight ratio of starch to oil of at least 1 . Preferably, the weight ratio of starch to fat is at least 1.1 , more preferably at least 1.2 and most preferably at least 1.5, and preferably at most 10, more preferably at most 5 and most preferably at most 3.

[0028] In one embodiment, the inventive coating comprises at least 0.1 wt% protein, based on the total weight of the coating. Preferably, the inventive coating comprises at least 0.2 wt% protein, more preferably at least 0.5 wt% protein, even more preferably at least 1.0 wt% protein and most preferably at least 15 wt% protein, and preferably at most 40 wt% protein, more preferably at most 30 wt% protein, even more preferably at most 25 wt% protein and most preferably at most 20 wt% protein, based on the total weight of the coating. Various methods have been described in literature to determine the protein content. For the purposes of this application, the Kjeldahl method is used to determine the nitrogen content, which is then converted to protein content. The Kjeldahl is well established and well known to the person skilled in the art. In this application the Kjeldahl method is performed by hydrolyzing a sample using H2SO4at 420°C for 2 hours, during which the proteins will be converted to ammonia. The generated ammonia is distilled off and the amount of nitrogen is measured by titration. The amount of protein is calculated by multiplying the nitrogen content by the conversion factor of 6.25 (nitrogen to protein factor).

[0029] In one embodiment, the inventive coating comprises at most 10 wt% water, based on the total weight of the coating. Preferably, the inventive coating comprises at most 9 wt% water, more preferably at most 8 wt% water, even more preferably at most 6 wt% water and most preferably at most 5 wt% water, and preferably at least 0.1 wt% water, more preferably at least 0.2 wt% water, even more preferably at least 0.5 wt% water and most preferably at least 1 wt% water, based on the total weight of the coating.

[0030] In a further embodiment, the coating of the invention comprises at most 500 ppm acrylamide. Preferably, the inventive coating comprises at most 250 ppm acrylamide, more preferably at most 150 ppm acrylamide, even more preferably at most 100 ppm acrylamide and most preferably at most 75 ppm acrylamide, and preferably at least 0.1 ppm acrylamide, more preferably at least 1 ppm acrylamide and most preferably at least 5 ppm acrylamide. The acrylamide content can be determined using any suitable method. An example of such a method is LC-MS. Preferably, acrylamide is determined using NEN-EN 16618.

[0031] In an embodiment, the coating has a peroxide value of at most 30 meq / kg. Preferably, the coating has a peroxide value of at most 20 meq / kg, more preferably at most 10 meq / kg and most preferably at most 5 meq / kg, and preferably at least 0.1 meq / kg, more preferably at least 0.2 meq / kg and most preferably at least 0.5 meq / kg. The peroxide value can be determined using any suitable method in the art. An example of such method is ISO 3960:2017.

[0032] In one embodiment, the coating comprises an additive. The additive can be any additive known in the art. Such additives include other starch, pigments, (inorganic) fillers, flavouring agents, antioxidants, preservatives, herbs, salt, sugars and colouring agents.

[0033] In one embodiment of the invention, the coating comprises at least 1 wt% of the additive. Preferably, the inventive coating comprises at least 2 wt% additive, more preferably at least 5 wt% additive, even more preferably at least 10 wt% additive and most preferably at least 15 wt% additive, and preferably at most 60 wt% additive, more preferably at most 50 wt% additive and most preferably at most 40 wt% additive, based on the total weight of the coating. The amounts of starch, fat, water, additives and any other components add up to 100% by weight of the coating.

[0034] The food product of the invention comprises a core. The core is generally edible and can be any core known in the art. Preferably, the core is vegetarian or vegan, fish-based, meat-based or a combination thereof. The core can have any shape and form known in the art such as a mash, a paste or a solid food substrate. In one embodiment, the core is potato. Preferably, the potato is a potato suitable for use in potato-based food products such as French fries and potato wedges.

[0035] In one embodiment, the food product comprises at least 5 wt% core, based on the total weight of the food product. Preferably, the inventive food product comprises at least 10 wt% core, more preferably at least 20 wt% core, even more preferably at least 30 wt% core and most preferably at least 40 wt% core, and preferably at most 90 wt% core, more preferably at most 80 wt% core and most preferably at most 70 wt% core, based on the total weight of the food product. This value is determined by separating the coating from the core e.g. by using a knife, and weighing the core.

[0036] In one embodiment, the core comprises at least 10 wt% water, based on the total weight of the core. Preferably, the core comprises at least 20 wt% water, more preferably at least 30 wt% water, even more preferably at least 35 wt% water and most preferably at least 40 wt% water, and preferably at most 80 wt% water, more preferably at most 70 wt% water, even more preferably at most 60 wt% water and most preferably at most 50 wt% water, based on the total weight of the core. The core generally comprises a higher amount of water than the coating of the inventive food product. The coating enables a significantly lower water loss during frying or frying, which generally renders a more juicy food product with an improved texture. Moreover, the food product may maintain its heat for a longer period of time.

[0037] In one embodiment, the core comprises at most 10 wt% fat, based on the total weight of the core. Preferably, the core comprises at most 8 wt% fat, more preferably at most 5 wt% fat, even more preferably at most 3 wt% fat and most preferably at most 2 wt% fat, and preferably at least 0.1 wt% fat, more preferably at least 0.2 wt% fat and most preferably at least 0.5 wt% fat, based on the total weight of the core. The inventive coating allows for a relatively low fat content in the core, which fat content will not increase during frying or frying in fat. The total weight is defined as the total weight of the core including water. The amount of fat can be determined with methods known in the art including organic solvent extraction. An example of such a technique is the ISO 6492 method. A piece of the core is taken to use in the method. The invention further pertains to a coating comprising starch, fat and water wherein the coating composition comprises at least 5 wt% fat, based on the total weight of the coating composition. In a further embodiment, the coating composition is an emulsion. The embodiments for the coating and its ingredients are presented above and apply here as well.

[0038] The invention further pertains to a process for preparing a food product comprising a core and a coating covering the core, the coating comprising starch and fat, wherein the food product comprises at least 1 wt% fat, based on the total weight of the food product, and wherein the fat comprises at most 15 wt% of total polar compounds, based on the total weight of fat comprising the steps of:

[0039] (a) providing a first coating composition comprising starch, fat and water;

[0040] (b) applying the first coating composition to a core of food product to form a coated food product;

[0041] (c) optionally applying a second coating composition comprising a starch which is at least 60 wt% gelatinized and optionally water to the singly coated food product to form a double coated food product;

[0042] (d) frying the coated food product, and optionally the double coated food product, at a temperature between 120 and 300°C to form the food product; and

[0043] (e) optionally freezing the food product.

[0044] With the process of the invention the inventive food product can be prepared. The process is simple and can be easily implemented in existing production facilities of for example battered potato fries. A further advantage is that the inventive food product does not have to be fried in frying oil. The pre-bake (or par-frying) and baking of the food product can be performed in oil-free (pre-)baking apparatus such as an air fryer, an oven, microwave and / or steam oven.

[0045] The first coating composition of step (a) can be any conventional coating composition known in the art and which can be suitably used in coated food products according to the invention. The starch present in the first coating composition may be any starch known in the art and suitable for use in such coating compositions. Examples of such starches include starch from rice, wheat, maize, potato and peas. The starch may be modified or unmodified. It is also envisaged to use two or more starches. In one embodiment, the first coating composition comprises a partially cross-linked starch such as a starch crosslinked using metaphosphate. In another embodiment, the starch is cold water swelling (CWS). With “cold water swelling” is meant that the potato starch composition will absorb water at room temperature. It is also envisaged to use a combination of two or more starches selected from a native starch, a (partially) gelatinized starch, a modified starch and a cold swelling starch.

[0046] In one embodiment, the first coating composition comprises at least 20 wt% starch, more preferably at least 30 wt% starch, even more preferably at least 40 wt% starch and most preferably at least 50 wt% starch, and preferably at most 99 wt% starch, more preferably at most 95 wt% starch, even more preferably at most 90 wt% starch and most preferably at most 80 wt% starch, based on the total weight of the first coating composition. The amount of starch can be determined using any suitable method known in the art. Examples of a suitable method include spectrophotometric methods such as the method of NEN-EN-ISO 15914.

[0047] In one embodiment, the first coating composition comprises at least 1 wt% fat, more preferably at least 2 wt% fat, even more preferably at least 5 wt% fat and most preferably at least 10 wt% starch, and preferably at most 40 wt% fat, more preferably at most 30 wt% fat, even more preferably at most 25 wt% fat and most preferably at most 20 wt% fat, based on the total weight of the first coating composition.

[0048] In one embodiment, the first coating composition comprises at least 10 wt% water, based on the total weight of the first coating composition. Preferably, the first coating composition comprises at least 20 wt% water, more preferably at least 30 wt% water, even more preferably at least 35 wt% water and most preferably at least 40 wt% water, and preferably at most 80 wt% water, more preferably at most 70 wt% water, even more preferably at most 60 wt% water and most preferably at most 50 wt% water, based on the total weight of the first coating composition.

[0049] In one embodiment, the first coating composition may further comprise a food-grade additive. Examples of such food-grade additives includes protein, sugars, (dietary) fibers, cross-linking agents, preservatives, flavouring agents and colouring agents.

[0050] In one embodiment of the invention, the first coating composition comprises at least 1 wt% of the food-grade additive. Preferably, the first coating composition comprises at least 2 wt% food-grade additive, more preferably at least 5 wt% food-grade additive, even more preferably at least 10 wt% food-grade additive and most preferably at least 15 wt% food-grade additive, and preferably at most 50 wt% food-grade additive, more preferably at most 40 wt% food-grade additive and most preferably at most 30 wt% food-grade additive, based on the total weight of the first coating composition. The amounts of starch, food-grade additives and any other components add up to 100% by weight of the first coating composition.

[0051] In step (b) of the inventive process, the first coating composition is applied to the core to form a singly coated food product. The core can be any core known in the art. Examples of such a core and embodiments thereof are described above. In one embodiment, the core can be pre-treated. The pre-treatment can be performed using any method known in the art. Examples of such pretreatment include blanching (i.e. heating in water of a temperature between 65 and 95°C), steam treatment, microwave treatment or IR heating. Application of the first coating composition can be performed using any method known in the art. Examples of such methods include dipping, spraying, electrostatic coating and soaking.

[0052] In one embodiment, the temperature in step (b) is maintained at a temperature above 10°C. Preferably, the temperature is at least 15°C, more preferably at least 20°C, more preferably at least 25°C and most preferably at least 30°C, and preferably at most 80°C, more preferably at most 75°C, and most preferably at most 70°C.

[0053] In optional step (c), a second coating composition is applied to the singly coated food product of step (b) to form a double coated food product. In one embodiment, the second coating composition is a powder. Application of a powder can be performed using any method known in the art. Examples of such methods include spraying and contacting the singly coated food product with the powder such as crumb-master.

[0054] In another embodiment, the second coating composition is a suspension or solution. Liquid coating compositions can be applied in a similar way as the first coating composition.

[0055] The second coating composition comprises a starch which is at least 60 wt% gelatinized. Preferably, the inventive composition comprises starch which is at least 70 wt% gelatinized, more preferably at least 80 wt% gelatinized and most preferably at least 90 wt% gelatinized, and preferably at most 100 wt% gelatinized, more preferably at most 99 wt% gelatinized and most preferably at most 95 wt% gelatinized.

[0056] In one embodiment, the starch is cold water swelling (CWS). With “cold water swelling” is meant that the potato starch composition will absorb water at room temperature.

[0057] The starch present in the second coating composition may be any starch known in the art and suitable for use in such coating compositions. Examples of such starches include starch from rice, wheat, maize, potato and peas. The starch may be modified or unmodified. It is also envisaged to use two or more starches. In an embodiment, the starch is a potato starch composition comprising at least 1 wt% fat, based on the total weight of the potato starch composition, and starch which is at least 60 wt% gelatinized, and the composition not being rancid. Preferably, the potato starch composition originates from a (pre)fried potato starch-containing food product such as potato fries, rdsti or potato crisps. In another embodiment, the starch in the second coating composition is a pea starch such as Empure® E Jel 100.

[0058] In one embodiment, the temperature in step (c) is maintained at a temperature above 10°C. Preferably, the temperature is at least 15°C, more preferably at least 20°C, more preferably at least 25°C and most preferably at least 30°C, and preferably at most 80°C, more preferably at most 75°C, and most preferably at most 70°C. Preferably, the temperature in step (c) is the same as the temperature in step (b).

[0059] In one embodiment, the second coating composition comprises at least 20 wt% starch, more preferably at least 30 wt% starch, even more preferably at least 40 wt% starch and most preferably at least 50 wt% starch, and preferably at most 100 wt% starch, more preferably at most 99 wt% starch, even more preferably at most 95 wt% starch and most preferably at most 90 wt% starch, based on the total weight of the second coating composition. Preferably, the second coating composition comprises starch in a powder form (without additional water).

[0060] In one embodiment, the second coating composition comprises at least 10 wt% water, based on the total weight of the second coating composition. Preferably, the first coating composition comprises at least 20 wt% water, more preferably at least 30 wt% water, even more preferably at least 35 wt% water and most preferably at least 40 wt% water, and preferably at most 80 wt% water, more preferably at most 70 wt% water, even more preferably at most 60 wt% water and most preferably at most 50 wt% water, based on the total weight of the second coating composition. In a preferred embodiment, the second coating composition does not comprise additional water.

[0061] In one embodiment, the second coating composition may further comprise a food-grade additive. Examples of such food-grade additives includes protein, sugars, (dietary) fibers, cross-linking agents, preservatives, flavouring agents, herbs, salt and colouring agents.

[0062] In one embodiment of the invention, the second coating composition comprises at least 1 wt% of the food-grade additive. Preferably, the first coating composition comprises at least 2 wt% food- grade additive, more preferably at least 5 wt% food-grade additive, even more preferably at least 10 wt% food-grade additive and most preferably at least 15 wt% food-grade additive, and preferably at most 50 wt% food-grade additive, more preferably at most 40 wt% food-grade additive and most preferably at most 30 wt% food-grade additive, based on the total weight of the second coating composition.

[0063] The amounts of starch, food-grade additives and any other components add up to 100% by weight of the second coating composition.

[0064] In one embodiment, the weight ratio of the first coating composition and the second coating composition is at least 0.01 , preferably the weight ratio is at least 0.1 , more preferably at least 0.2 and most preferably at least 0.5, and preferably at most 100, more preferably at most 50, even more preferably at most 20 and most preferably at most 10.

[0065] In one embodiment, the weight ratio of the first coating composition and the second coating composition is at least 0.01 , preferably the weight ratio is at least 0.1 , more preferably at least 0.2 and most preferably at least 0.5, and preferably at most 100, more preferably at most 50, even more preferably at most 20 and most preferably at most 10. The weight ratio refers to the weight ratio of the first and second coating composition without water.

[0066] In step (d) of the invention, the (double) coated food product is fried or prepared at a temperature between 120 and 300°C to form the food product. In this step (d) the temperature at which the food product is fried is generally above the glass transition temperature of the glassy amylopectin rendering starch to be fluid and able to flow and form the coating of the inventive food product. When a powder is used as a second coating composition, the surface of the double coated food product is generally rough. After step (d) the coating is generally less rough and can even be smooth. Moreover, starch that is not gelatinized or is retrograded is converted to a gelatinized state during step (d). Upon cooling the coating converts to a solid, glassy state which moreover brings about crispiness. It was further observed that fat generally remained in the coating during step (d), and does not migrate into the core. While not being bound by theory, fat appears to be homogeneously and uniformly distributed throughout the coating, while fat concentrations or fat droplets are absent. In addition, air pockets may be generated during step (d), which pockets are supported by the glassy structure of the starch.

[0067] In one embodiment, the coated food product is (par)fried or (pre-)baked in any method known in the art. Such methods include frying oil, an air fryer, an oven, impingement oven, microwave and / or steam oven. The inventive food product is specifically suitable for baking or pre-baking using electromagnetic waves such as a microwave, RF (radio frequency) heater or an IR (infrared) heater and / or in hot air or hot steam such as an air fryer, oven or steam oven, and without the use of frying oil. In one embodiment, step (d) is performed in an air fryer, an oven, microwave and / or steam oven. In one embodiment of step (d), the coated food product is par-fried or prebaked so as to form the inventive food product. In another embodiment, the par-fried or pre-baked food product is subsequently fried or baked before consumption. The methods, the residence times and the temperatures may be the same or different during the pre-baking and the baking step.

[0068] In one embodiment, the temperature in step (d) is maintained at a temperature above 120°C. Preferably, the temperature is at least 140°C, more preferably at least 150°C, even more preferably at least 155°C more preferably at least 160°C and most preferably at least 165°C, and preferably at most 300°C, more preferably at most 250°C, and most preferably at most 220°C.

[0069] In one embodiment, the residence time of the (double) coated food product at the elevated temperature is at least 20 seconds. Preferably, the residence time is at least 30 seconds, more preferably at least 45 seconds and most preferably at least 60 seconds, and preferably at most 15 minutes, more preferably at most 12 minutes and most preferably at most 10 minutes. A shorter residence time is desirable as it is technically and economically more attractive.

[0070] In optional step (e) of the inventive process, the food product is frozen. The freezing process can be performed using methods known in the art. In one embodiment, the temperature in step (e) is maintained at a temperature of at most 0°C. Preferably, the temperature is at most -5°C, more preferably at most -10°C, more preferably at most -15°C and most preferably at most -18°C, and preferably at least -40°C, more preferably at least -30°C, and most preferably at least -25°C.

[0071] The invention is exemplified in the following Examples.

[0072] Examples

[0073] Comparative Example A: battered potato fries par-fried and fried in sunflower oil

[0074] A batter was prepared using a standard batter powder and water (41 wt% dry matter) were mixed to form a liquid batter.

[0075] 11 mm potato fries from Fontane potatoes were pre-cooked and coated with a standard batter composition (41 wt% dry matter). The coated potato fries were fried in sunflower oil at 175 °C for 60 seconds. The pre-fried potato fries were subsequently cooled and frozen.

[0076] The frozen potato fries were fried in sunflower oil at 175 °C for 3.5 minutes. The fried potato fries were uniformly yellow in colour and had a crispy outside layer. No off-flavours were smelled or tasted.

[0077] Comparative Example B: battered potato fries par-fried in sunflower oil

[0078] A batter was prepared using a standard batter powder and water (41 wt% dry matter) were mixed to form a liquid batter.

[0079] 11 mm potato fries from Fontane potatoes were pre-cooked and coated with a standard batter composition (41 wt% dry matter). The coated potato fries were fried in sunflower oil at 175 °C for 60 seconds. The pre-fried potato fries were subsequently cooled and frozen.

[0080] The frozen potato fries were fried in an air fryer at 200 °C for 10 minutes. The fried potato fries were uniformly yellow in colour and had a crispy outside layer. No off-flavours were smelled or tasted.

[0081] Example 1 : battered potato fries

[0082] A batter was prepared using a standard batter powder with 15 wt% of sunflower oil and water (41 wt% dry matter) were mixed to form a liquid batter.

[0083] 11 mm potato fries from Fontane potatoes were pre-cooked and coated with the liquid batter. The coated potato fries were fried in a steam oven (moisture level of 70%) at 150 °C for 7 minutes. The pre-fried potato fries were subsequently cooled and frozen.

[0084] The frozen potato fries were fried in an air fryer at 200 °C for 10 minutes. The fried potato fries were uniformly yellow in colour and had a crispy outside layer. No off-flavours were smelled or tasted. Example 2: battered potato fries

[0085] A batter was prepared using a standard batter powder with 15 wt% of olive oil and water (41 wt% dry matter) were mixed to form a liquid batter.

[0086] 11 mm potato fries from Fontane potatoes were pre-cooked and coated with the liquid batter. The coated potato fries were fried in a steam oven (moisture level of 70%) at 150 °C for 7 minutes. The pre-fried potato fries were subsequently cooled and frozen.

[0087] The frozen potato fries were fried in an air fryer at 200 °C for 10 minutes. The fried potato fries were uniformly yellow in colour and had a crispy outside layer. No off-flavours were smelled or tasted.

[0088] Example 3: battered potato fries

[0089] A batter was prepared using a standard batter powder with 15 wt% rapeseed oil and water (41 wt% dry matter) were mixed to form a liquid batter.

[0090] 11 mm potato fries from Fontane potatoes were pre-cooked and coated with the liquid batter. The coated potato fries were fried in a steam oven (moisture level of 70%) at 150 °C for 7 minutes. The pre-fried potato fries were subsequently cooled and frozen.

[0091] The frozen potato fries were fried in an air fryer at 200 °C for 10 minutes. The fried potato fries were uniformly yellow in colour and had a crispy outside layer. No off-flavours were smelled or tasted.

[0092] The par-fried and fried potato fries were analysed for various properties, which are tabulated in the Table below.

[0093] Table 1: Various properties of fat in par-fried and fried potato fries

[0094] The inventive potato fries of Examples 1 to 3 exhibit a lower Totox value compared to potato fries fried in sunflower oil (Comparative Examples A and B). Additionally, the anisidine value, the free fatty acid content and the trans fatty acid content is significantly lower for the potato fries of the present invention. Moreover, the overall fat content of the potato fries is lower for the potato fries in accordance with the invention; even below 3 wt%, which constitute low fat potato fries.

Claims

CLAIMS1. Food product comprising a core and a coating covering the core, the coating comprising starch and fat, wherein the food product comprises at least 1 wt% fat, based on the total weight of the food product, and wherein the fat has a Totox value of at most 25.

2. Food product according to claim 1 wherein the food product comprises at most 5 wt% fat, based on the total weight of the food product.

3. Food product according to any one of claim 1 and 2 wherein the fat comprises at most 3 wt% of free fatty acids, based on the total weight of fat.

4. Food product according to any one of the preceding claims wherein the fat has an anisidine vale of at most 20.

5. Food product according to any one of the preceding claims wherein the fat comprises at most 0.25 wt% of trans fatty acid, based on the total weight of the fat.

6. Food product according to any one of the preceding claims wherein at least 40 % of the fat is located in the coating.

7. Food product according to any one of the preceding claims wherein the starch in the coating is at least 60 wt% gelatinized.

8. Food product according to any one of the preceding claims wherein the core is potato.

9. Food product according to any one of the preceding claims comprising at most 5 wt% fat, preferably at most 3 wt% fat, based on the total weight of the food product.

10. Coating composition comprising starch, fat and water wherein the coating composition comprises at least 5 wt% fat, based on the total weight of the coating composition.

11. Coating composition according to claim 10 wherein the weight ratio of starch and fat is at least 1 .

12. Coating composition according to any one of claims 10 and 11 wherein the coating composition is an emulsion.

13. A process for preparing a food product comprising a core and a coating covering the core, the coating comprising starch and fat, wherein the food product comprises at least 1 wt% fat, based on the total weight of the food product, and wherein the fat has a Totox value of at most 25, comprising the steps of:(a) providing a first coating composition comprising starch, fat and water;(b) applying the first coating composition to a core of food product to form a coated food product;(c) optionally applying a second coating composition comprising a starch which is at least 60 wt% gelatinized and optionally water to the singly coated food product to form a double coated food product;(d) frying the coated food product, and optionally the double coated food product, at a temperature between 120 and 300°C to form the food product; and(e) optionally freezing the food product.

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