The present invention relates to the foodstuffs industry, in particular to flavoured food products, and more particularly to baked products, freeze-dried products and powder products to be reconstituted.

It is known from traditional gastronomic culture to use granules to flavour foods including, for instance, the various types of bread flavoured with granules of poppy and sesame seeds, salt, onion, garlic, cheese, aromatic herbs, tomato, etc.

The foodstuffs industry produces various types of food flavoured on the surface or internally with various types of granules ranging from salt to the above-mentioned seeds.

Various problems connected with the packaging and distribution of products must nevertheless be taken into account in industrial production.

Conserving the flavouring throughout the period of production, distribution, sale and consumption of the products is a first problem. This is particularly problematic in the case of volatile flavourings.

A further example is provided by those flavouring granules which are spread over the surface of products, for instance baked products such as breadsticks, crackers and various types of bread, which have to be produced and distributed to points of sale. These products are inevitably subject to mechanical stresses during distribution which cause the granules to become detached. Once consumers open the packaging, they may discover that the product has lost all or part of the granules, which have become dispersed in the packaging, with the result that the foodstuff product loses any attractiveness that it had because of the presence of the flavouring granules on the surface of the product.

When the product is being stored, moreover, the granule may lose part of its flavour because of the natural drying out of the product and the volatility of the substances providing the flavour. This is a particular problem with baked products such as breadsticks, crackers and various types of bread, and with freeze-dried products to be reconstituted such as coffee or milk. Conserving flavour is also a problem from the point of view of flavourings for cakes.

The prior art proposes to resolve this problem by coating the baked product with a solution of water and starch, after which flavouring granules are sprinkled on the product and it is cooked. This solution is unsatisfactory as up to 50% of the granules become detached from the surface of the product during its subsequent packaging and distribution.

The object of the present invention is to resolve the known problems of the prior art.

It has now been discovered that the flavouring granule remains attached to the baked product if it is provided with a double coating of an edible glue, in particular gum arabic, and a heat-resistant food material, in particular bentonite.

A method of encapsulating a granule of a flavouring or a flavoured food has also been discovered and makes it possible to preserve the flavour in the long term, as well as to improve its organoleptic properties in general and to ensure that the flavour is more permanent.

US Patent Specification 2443138 discloses the incorporation of bentonite into the dough of baked products with a view to conserving them for longer and reducing the development of a stale taste. This use is reiterated in Application WO 00/01241.

US Patent Specification 5204102 discloses a granule of fluffy cotton seed coated with a binder, for instance gum arabic, and a filler, for instance bentonite, for the production of animal feed.

An object of the present invention is therefore to provide a food product, in particular a baked product with flavouring granules sprinkled on its surface or incorporated in the product, characterized in that the granules are coated with a first layer of edible glue, in particular gum arabic, and with a second layer of a heat-resistant food material, in particular bentonite or another edible clay.

A further object of the present invention is to provide a method for the preparation of said flavouring granule.

A further object of the present invention is to provide a method for the encapsulation of powdered flavoured food products.

All these objects are characterized by the use of said heat-resistant food material, in particular bentonite, as an encapsulating agent.

As regards the aspect of the present invention relating to products, in particular baked products, where the flavouring granules are sprinkled on the surface, the granules described here remain attached to the surface of the product, despite the mechanical stresses to which they are normally subject during baking, packaging, distribution, conservation and use of the product.

A further advantage of the present invention lies in the fact that the flavouring granules retain their flavour for a considerable time and in any case for longer than known products. A general aspect of the present invention is that the granules enable smaller amounts of raw flavouring material to be used.

A further object of the present invention is to provide a method for the preparation of said baked product.

A further object of the present invention is also to provide methods for the preparation of said flavouring granules and their use in the foodstuffs industry.

These and other objects of the present invention are described in detail below and illustrated in the accompanying drawings, in which: Fig. 1 shows a diagram of the production of an embodiment of the invention taking the form of a baked product;

Fig. 2 shows a flavouring granule on the surface of a baked product, for instance a breadstick, according to the prior art;

Fig. 3 shows a flavouring granule on the surface of a baked product, for instance a breadstick, according to the invention;

Fig. 4 shows a diagram of a method for the encapsulation of a flavouring granule according to further embodiments of the present invention.

In general, the granule of the present invention is shown in Fig. 3, in which the surface of the granule 8 is coated with a first inner layer 12 of said edible glue, in particular gum arabic, and with a second outer layer 10 of said heat-resistant food material, in particular bentonite.

In the embodiment of the present invention relating to a baked product, the surface of the granule 8 is coated with an outer layer 10 of said heat-resistant food material, in particular bentonite, in a substantially uniform manner and interacts with the layer of water and starch 11 provided during the preparation of the product (left-hand side A of Fig. 3). After cooking, micro- fissures are created in the bentonite 10 enabling the gum arabic 12, which is liquid in the cooking stage, to emerge and become stably attached to the baked product 7 (right-hand side B of Fig. 3).

Edible glues, in particular gum arabic, and heat-resistant food materials, such as silicon dioxide, magnesium sulphate, potassium sorbate and in particular bentonite and other edible clays, are widely used in the foodstuffs, pharmaceutical and cosmetics industries and are entirely harmless in the doses and manner in which they are currently used. For the purposes of the present invention, the term "food material" is also understood as a "food additive" in its general meaning in the sector.

The flavouring granules of the present invention are of the very wide range of types known in the foodstuffs industry. A non-exhaustive list of examples includes salt, poppy and sesame seeds, onion, garlic, cheese, aromatic herbs and tomato.

In the same way, the powdered flavoured food products encapsulated in accordance with the present invention may be of any known type, for instance freeze-dried powdered coffee and milk and any other powdered food to be reconstituted. The present invention also applies to fruit juices. The flavourings used in the confectionery industry are also covered by the present invention.

The baked products on which the granules of the present invention are sprinkled may be of any kind, and a non-exhaustive list of such products includes the group made up of breadsticks, crackers, bread and various snacks. According to an embodiment of the present invention, the preparation of the flavouring granules takes place by means of a method comprising the following stages:

a. adding a solution of edible glue, in particular gum arabic, in water to a plurality of granules;

b. mixing said granules until they are disaggregated and obtaining granules coated with edible glue, in particular gum arabic;

c. adding a heat-resistant food material, in particular bentonite, to the granules of stage b) until they are disaggregated and obtaining coated granules;

In the method described above, there is preferably full disaggregation.

In stage c), the heat-resistant food material, in particular bentonite, is preferably added as powder.

In an embodiment of the invention, the weight ratio between gum arabic and bentonite is 1:6. The bentonite may be increased in order to improve the adhesion of the granules. The ratios may nevertheless be readily determined by a person skilled in the art.

The flavouring granules of the present invention may be used to dust baked products. As an alternative, the flavouring granules may be incorporated in any food product, exploiting the advantage that the present invention offers in terms of preserving the characteristic flavour of the granule and the possibility of using a smaller quantity of flavouring material.

A further object of the present invention is therefore also to provide a flavouring granule for a food product, in particular a baked product, characterized in that said granule is coated with a first layer of edible glue, in particular gum arabic, which may preferably be dissolved or dispersed in water, and with a second layer of a heat-resistant food material, in particular bentonite. In a particularly preferred embodiment of the invention, the flavouring granule for a baked product is coated with a first layer of gum arabic and a second layer of bentonite.

Said granule is prepared by a method comprising the following stages:

a. adding a solution or suspension of edible glue, in particular gum arabic, in water to a plurality of granules;

b. mixing said granules until they are completely disaggregated and obtaining granules coated with edible glue, in particular gum arabic;

c. adding a heat-resistant food material, in particular bentonite, to the granules of stage b) until they are completely disaggregated and obtaining coated granules; d. sprinkling the coated granules on the product to be baked;

e. baking and obtaining the baked product.

A further object of the present invention is to provide a food product comprising said flavouring granules. In an embodiment of the invention, said granules are incorporated in the food product, in particular a baked product, for instance in the product dough. In a further embodiment of the invention, said granules are also sprinkled on the surface of the product. In the context of the present invention, a food means any food which, in keeping with consumers' tastes, may comprise said granules. Non-limiting examples of foods are flour-based products, for instance pasta in all its forms, ready-to-eat soups, for instance frozen or freeze-dried preparations, for instance coffee and milk and their mixtures. The granules of the present invention may also be used on their own as a condiment or flavouring.

The present invention also relates to a method for the preparation of said baked product, comprising the following stages:

a. adding a solution or suspension of edible glue, in particular gum arabic, in water to a plurality of granules;

b. mixing said granules until they are completely disaggregated and obtaining granules coated with edible glue, in particular gum arabic;

c. adding a heat-resistant food material, in particular bentonite, to the granules of stage b) until they are disaggregated and obtaining coated granules;

d. incorporating said coated granules in the dough of the product to be baked, and possibly sprinkling said granules on the surface of the product;

e. baking and obtaining the baked product.

A further object of the present invention is the use of said granules for the preparation of food products.

In an embodiment of the invention, a mixture of 30-40% gum arabic and water is separately prepared.

The flavouring granules are placed in a dough mixer to which the mixture of gum arabic and water is slowly added while the mixer is in operation. In an embodiment of the invention, the mixture is formed by 50 g of gum per 300 ml of water for each 10 kg of granules, for instance sesame, to be coated. The quantity of gum arabic is also a function of the size of the granule, and the smaller the granule, the greater the surface area to be coated. Mixing is continued in alternating directions until the granules coated with gum arabic are completely disaggregated.

The powdered bentonite is then added, if desired in the same mixer, and in any case with mixing in operation, and mixing is continued until the granules are again fully disaggregated.

The granules now have a double coating, where the first coat is gum arabic, in contact with the granule, and the second outer coat is bentonite.

The granules of the present invention are ready for use and may be sprinkled on the food product according to known methods, or may be incorporated in the product itself.

In an embodiment of the invention, and with reference to Fig. 1, the baked product is prepared according to conventional methods.

The preparation of breadsticks is described by way of example. The ingredients are placed in a dough mixer 1 and processed. The dough is then passed through an extruder 2 in order to form breadsticks. The extruder is connected to the oven by transport means, for instance a belt 3. The breadsticks are caused to move from the extruder and, while they are being conveyed, their surfaces are treated with a bath of water and starch 4a and then sprinkled 4b with granules according to the present invention. The surface treatment with water and starch is preferably carried out by spraying, using an appropriate diffuser 4a and the sprinkling may be carried out by means of a hopper 4b, possibly provided with a vibrating screen.

The water and starch solution is for instance a 7% solution of corn starch. The starch concentration is not critical and depends on the baked product to be prepared.

The breadsticks are then placed in a conventional oven 5 to cook by means of known methods and are then conveyed for packaging 6. By way of example, the oven input temperature may be approximately 480°C and the output temperature approximately 120°C.

It will be appreciated that a person skilled in the art may make use of any appropriate method or plant variants depending on the desired product, for instance crackers, snacks or various types of bread, as these variants are well-known in the sector.

In a further embodiment of the invention, the flavouring granules are of onion and/or garlic. These granules must be appropriately treated so as not to compromise the friability of the final baked product.

The Applicants have discovered that the optimum size for granules of onion and/or garlic in baked products such as breadsticks, crackers and snacks is 1-2 mm, rather than the conventional 0.01 mm.

A further object of the present invention is therefore to provide a flavouring granule for foods, in particular baked foods, of garlic or onion of a size of 1-2 mm and coated as described above.

It will be appreciated that the present invention is applicable irrespective of the form and dimensions of the granules, which will be compatible with the use of the food product selected.

The method described up to now provides for dry encapsulation at ambient temperature. In a further embodiment of the present invention, the method for the encapsulation of the flavouring granule or flavoured powdered food uses different temperatures so that the capsule of heat-resistant bentonite also adheres externally in the case of thin granules.

According to this embodiment of the invention, the method comprises the following stages:

a. cooling a plurality of granules to -20°C; b. mixing said plurality of granules until it is frozen;

c. adding by spraying a solution or suspension of an edible glue, in particular gum arabic, in water, mixing until the granules are disaggregated and obtaining granules coated with said glue, in particular gum arabic;

d. adding a heat-resistant food material, in particular bentonite, to the granules of stage c), discontinuing cooling, mixing until the granules are disaggregated and obtaining coated granules;

With reference to Fig. 4, the granules to be encapsulated are placed in a cooling plant, for instance a plant for the production of ice cream 17, working at a temperature of -20°C, with continuous stirring.

When the whole mass is frozen, but still in powder form, a solution of water and edible glue, in particular gum arabic, is gradually sprayed, while continuing to stir the powder which, at - 20°C, almost immediately freezes the thin layer of glue, in particular gum arabic, and water.

While continuing to stir the product frozen in this way, the powdered bentonite is then added, cooling is discontinued and stirring is continued until the bentonite is fully absorbed and the capsule is formed. The granules encapsulated in this way are then separated, for instance by screening, and dried, for instance at 72°C or at any temperature compatible with the encapsulated flavouring granule or flavoured food. The final product, for instance coffee, milk and various flavourings, may be used as such.

In a further embodiment of the present invention, applicable to volatile flavourings, for instance mint, the method comprises the following stages:

a. dissolving a flavouring in double-distilled water;

b. distilling said flavouring in steam;

c. condensing at -2°C to a plurality of droplets containing said flavouring;

d. cooling said plurality of droplets of stage c) to -270°C to provide a plurality of ice crystals containing said flavouring;

e. bringing the plurality of crystals of stage d) to -20°C;

f. adding by spraying a solution of an edible glue, in particular gum arabic, in water, mixing until the granules are disaggregated and obtaining a plurality of granules coated with said glue, in particular gum arabic;

g. adding a heat-resistant food material, in particular bentonite, to the granules of stage f), discontinuing cooling, mixing until the granules are disaggregated and obtaining coated granules.

In this embodiment, the flavouring, dissolved in double-distilled water, is distilled in steam in an appropriate plant 13 and conveyed 14 to a condenser 15 at -2°C; at this stage, droplets containing the flavouring nucleus are formed, which acts as a condensation nucleus. The droplets are brought into a liquid nitrogen cooling plant 16 at a temperature of -270°C, where crystals of flavouring coated with ice are formed, which are then immediately introduced without interruption into the above-mentioned cooling plant 17 at -20 °C and this is followed by the steps of the previous method of encapsulation with the first layer of gum arabic or other edible glue and then the second layer of the heat-resistant material, in particular bentonite.

The following examples illustrate the invention in further detail.

Example 1 - Prior art

A dough for breadsticks having the following composition was prepared:

Manitoba flour 0 100 g

Soft wheat flour 0 150 g

Table salt 4.3 g

Vegetable fat 50 g

Bread yeast 3 g

After extrusion and formation of the breadsticks, a 7% water and corn starch solution was spread on the surface.

The surface of the breadsticks was also sprinkled with medium-grain salt granules or with hulled sesame seeds.

After rising, the breadsticks were placed in an oven and cooked initially for four minutes at 390°C and then at 220° for a further fifteen minutes.

The result was evident: a large proportion of the grains and seeds (forming the granules overall) became detached during handling, leaving only 50% of the product initially used on the breadsticks.

Microscopic analysis showed that the water mixed with the starch 9a on the surface of the breadstick 7 caused the granules 8 to adhere by surface tension (left-hand side A of Fig. 2). After cooking, the granules became detached because the adhesion point was much smaller and was formed by the single layer of starch 9b which was not sufficient to keep the granules attached to the surface of the product (right-hand side B of Fig. 2).

Example 2 - preparation of sesame granules

10 kg of hulled sesame seeds were placed in a dough mixer.

50 g of gum arabic was mixed in 300 ml of water.

The mixer was started and the mixture of water and gum arabic was slowly added. The mixer was kept in operation, alternating the direction of rotation, until the seeds were disaggregated.

While mixing continued, 300 g of powdered bentonite was added in portions and mixing continued until they were completely disaggregated.

Granules of salt and poppy seeds were prepared in the same way.

Example 3

Breadsticks were prepared as in Example 1, except that they were sprinkled with granules according to the invention.

After cooking and packaging, all the granules remained stably attached to the surface of the breadsticks even when subject to mechanical stresses.

Microscopic analysis showed that prior to cooking the surface of the granule 8 was coated with the layer of bentonite 10 in a substantially uniform manner and interacted with the layer of water and starch 11 (left-hand side A of Fig. 3). After cooking, micro-fissures were created in the bentonite 10 enabling the gum arabic 12, which was liquid in the cooking stage, to emerge and become stably attached to the breadstick (right-hand side B of Fig. 3).