Background This invention relates to food binder matrices which are useful in providing formed food products of any desired shape. The formed food products, on cooking, have a very pleasing appearance, texture and taste.

A variety of food binder matrices have been used to bind various food sources into desired shapes, particularly in the field of convenience foods, fast foods, snack foods and the like. It is well understood that various forms of unprocessed red meat and poultry, when ground in the presence of salt, can be formed into various shapes for cooking purposes. The salt draws proteins from within the ground meat particles to the surfaces of the particles to form a protein matrix. When cooked, this matrix becomes firm and remains intact.

However, there are several other food sources which cannot be bound or formed in this manner, such as vegetables, fish and cooked/denatured meats. Current binder systems for such food sources produce pasty or gummy products which typically fail to maintain the texture of the substrate. There is a need for a binder matrix which can be used to bind these food sources into desired shapes for providing appealing cooked food products which are not gummy or pasty but rather parallel the texture of the substrate.

Edible formed food products are becoming very popular because of public demand for healthy alternatives to the more common forms of high fat, high carbohydrate, high cholesterol food products. By use of the food binder matrix of this invention, fruits, vegetables, cereals, fish, shellfish, dairy products and various forms of processed meats may be formed into food product shapes, such as burgers, nuggets, cylinders, bars, and the like, and then coated or left uncoated, to provide a variety of convenience foods which may be home cooked by

oven or microwave, deep fried with or without coatings, served up at fast food outlets or sold as packaged snack products. The food binder system of this invention has the ability to bind a variety of foods while providing excellent texture and taste. Further, a clear binder can be formulated so that the individual substrate pieces are readily apparent to the consumer.

The food binder matrix of the present invention overcomes the problems with existing food binder matrices and, in turn, gives a food product which, when cooked, has excellent appearance, taste and texture.

SUMMARY The present invention is directed to formed food products and more particularly to unique new food binder matrices for making formed food products which, when cooked, have a pleasing appearance, texture and taste.

The food binder matrices of the present invention comprise a combination of a functional protein, a cereal, and a hydrocolloid. The functional protein is present at a level of about 5 to 50% by weight and preferably about 10 to 30% by weight. The cereal is present at a level of about 50 to 90% by weight and preferably about 60 to 85% by weight. The hydrocolloids are present at a level of about 0 to 25% by weight and preferably about 2 to 20% by weight.

Typical useful functional proteins include one or more of the following as well as combinations thereof: vital wheat gluten, soya protein, egg albumen, milk powder, whey protein, and caseinate. Examples of cereals useful in the practice of the present invention include one or more of the following as well as combinations thereof: potato starch, modified corn starch, and wheat flour. Finally, typical hydrocolloids which may be used in the binder matrix include one or more of the following as well as combinations thereof: methyl cellulose,

xanthan gum, hydroxypropylmethyl cellulose, and carrageenan. Methyl cellulose is particularly preferred. The food binder matrix makes up approximately 2 to 10% by weight of the formed product. In a preferred embodiment, the food binder matrix makes up approximately 3 to 9% by weight of the formed product. Normally, the food binder matrix is mixed with a small amount of water, seasonings, and oil (preferably vegetable oil) , and then combined in a non-shear type of mixer with the food product and then the mixture is compressed or formed into the desired food product shape.

The food source may include vegetables, cereals, nuts, seeds, fish, shellfish, cooked/denatured meats, dairy products and the like, as well as combinations thereof. In a preferred embodiment, the food source includes vegetables, fish or shellfish or combinations thereof. One combination product which has been prepared in accordance with the present invention used a combination of cheese, ham and sauerkraut. The various food sources which may be formed into food products include a variety of vegetables, such as carrots, cauliflower, broccoli, peas, peppers, corn, water chestnuts, ethnic blends of vegetables and the like. Cereals may also be used which include various forms of grains with or without nuts and seeds. Fish meat is particularly important as are various types of shellfish. Normally fish and shellfish products do not bind very well; however, in the use of the binder in accordance with this invention, a very acceptable product is provided. Various forms of dairy products, including cheeses and the like, may be bound by use of the binder of this invention with vegetables, cereals, fish, ham and other types of processed meats. Various fresh or dried fruits may also be bound by use of this binder. It is also understood that within the range of meats are various organ meats, such as liver, kidney, heart and

the like. More exotic specialty combinations could include a high fiber, liver and onion burger or burgers of barley, carrots and cooked beef. Meatless food products such as burgers and nuggets can also be made by use of this food binder matrix where the substrate normally comprises vegetables and/or cereal.

The formed food products of this invention are usually stored in the refrigerated or frozen state and are cooked normally with either the use of a microwave oven, conventional oven, grill, or deep frying to prepare the food products for consumption. Various types of coating systems may be used in combination with the formed food products of this invention to enhance their presentation, particularly when they are to be deep fried.

Wheat flour, when used, preferably will be precooked so that it is pregelatinized. It is normally used in greater amounts in the meat matrix, particularly with fish and shellfish, to absorb water that is released from the meat during processing. This ensures that the food product will form properly and gives in its final cooked form, the proper texture and taste. It is appreciated that, in the use of the higher amounts of flour, the binder takes on a cloudy appearance. This is acceptable with meat products because the clarity is not as important as with vegetables. Furthermore, with darker meats or fish substrates, it can have a whitening effect, making the food product more appealing. With a vegetable form of food product, it is desirable to use little if any flour because this composition provides a binder matrix which is clear so that the individual pieces in the formed food product are clearly evident to the consumer.

In one preferred embodiment, particularly good gel strength is provided by the combined use of potato starch, modified corn starches or other quick gelling

starches. The potato starch has the property of forming a firm gel and gelling quickly, although it is understood that other forms of starches which set up quickly and which would function in a manner equivalent to the potato starches may be employed. The modified cornstarch gives body to the gel, particularly when used in conjunction with the native potato starch. One preferred commercially available waxy modified cornstarch is sold under the trademark FIRMTEX by National Starch. FIRMTEX starch has been found to provide good water binding capacity, low gelatinization temperature and swelling power making it ideal for the present food matrix application. This modified waxy cornstarch has also been found to impart a smooth texture to the food products and to protect the product from the syneresis (weeping) effect after cooking.

The gums, particularly in the preferred form of methyl-cellulose, in conjunction with the other components of this food binder matrix, provide a binder which, when cooked, yields a food product for consumption which retains its shape, has good presentation and is of the right texture when eaten. The superior texture is achieved by the firm short gel aspect of the composition which is readily sheared during the eating process. The use of the food binder matrix of the present invention provides the necessary viscosity and binding capacity for the substrate (e.g., vegetables, fish, shellfish, etc.) so that the formed food product, when dropped from the forming mechanism, can be conveyed intact to go through further processing, such as coating, parfrying, etc. The desired shape is retained in the food product during the cooling, freezing cycle.

The following examples illustrate various facets of the invention. It should be understood, however, that these examples are meant to be illustrative of the invention which is not intended to be limited thereto.

EXAMPLES 1. Four food binder matrices for vegetables were prepared in accordance with the invention with levels in percent by weight of the components as follows:

1 2 3 4

Vital wheat gluten 8 8

Soya protein 8

Egg albumen 33 27 15

Potato starch (native) 21 20 18

Modified corn starch

(FIRMTEX) 44 65 43

Wheat flour (heat processed) 60

Methyl-cellulose 8 7 8

Xanthan gum 7

These binder systems were found to provide very presentable products.

2. Next, a shellfish food binder matrix was prepared as follows (components in percent by weight) as follows:

Vital wheat gluten 11

Potato starch (native) 20

Modified corn starch (FIRMTEX) 13 Wheat flour (heat processed) 35

Methyl-cellulose 21

3. In this example, food binder matrices for fish were prepared as follows (components in percent by weight) : £ 1 8.

Milk powder 20 16 Vital wheat gluten 17 15 15 Caseinate 11

Potato starch (native) 9 8 47 Modified corn starch 25 23 22

Wheat flour (heat processed) 38 34

As noted with the meat types of matrices, a higher wheat flour content was used. With the higher wheat flour content, the amount of modified cornstarch was reduced, yet a very desirable bound meat matrix

J 5 particularly with fish or shellfish was obtained. Again, the formed food product was cooked either with or without a coating to provide a very pleasing, consumable product.

4. Finally, examples of the food binder composition used with vegetables, fish, and shellfish

10 binder matrix were prepared as set out in these examples:

A B C

Vegetable seasoning 3 4 4 Vegetable binder matrix

(1, 2 or 3) 7

15 Vegetable binder matrix

(4) 7 7

Mixed vegetables 80 52 53

Rice (cooked) 24 24

Potato (flakes) 2 2

20 Vegetable oil 7 7 3

Water 3 4 7

The mixed vegetables were small chopped pieces of carrots, cauliflower, broccoli, peas, peppers, corn, water chestnuts and the like. First, the product was

25 mixed by making a slurry of the binder in water. The vegetable seasonings and the vegetable oil were included in the slurry. The slurry was then slowly and gently mixed without shear into the vegetable pieces to the extent that there was a reasonably uniform dispersion of

30 the binder about the vegetable pieces.

The mixture was then transferred to a forming device to form the material into the desired food shapes, in this case a patty. By compressing the material and forming the patty the voids were filled with the binder

35 to complete the formed food product. The product may then be coated with a traditional adhesion or cohesion

batter and breading and/or precooked, chilled/frozen or cooked and served.

The frozen vegetables were previously blanched in the normal way and frozen for later use. The frozen vegetables were mixed with the binder at a temperature in the range of 0° to 5°C. A short mixing time in the range of 3 to 5 minutes took place in a mixer having a controlled temperature achieved in a jacketed mixer or by dry ice or the like which was injected during the mixing process. Similarly during the compression molding of the product in its desired food shape, the molding temperature was normally around 0°C to 5°C.

D E

Shellfish binder matrix 8 8

Shellfish seasoning 1

Cooked shellfish

(whole or chopped) 64 64

Cooked shellfish (minced) 22 21

Vegetable oil 3 3

Water 3 3

The shellfish binder matrix was mixed with the vegetable oil, water, shellfish seasoning and minced or chopped shellfish to form a slurry which was then mixed with the cooked shellfish. The cooked shellfish was at temperatures in the range of -2°C to 0°C. However, as needed, the temperature could rise to 5°C. After the mixing was completed, the product was then formed into the desired shape by compression molding, carried out at a lower temperature in the range of -2°C to 0°C. £ G H I J

Fish binder matrix 6 4.5

Fish binder matrix 7 5 Fish binder matrix 8 3 3 3 Fish seasoning 0.5 0.5 0.5 1 0.5 Fish (raw minced) 37.5 87 17.5 Fish (raw whole pieces) 84 84 50 70

Vegetable oil 4 4 4 Water 11 10.5 5 5 5

In examples F and G, the fish flesh was bound together with the binder matrix, seasoning and water by blending the dry ingredients with the water and tumbling this slurry together with the fish flesh for approximately 90 seconds, then compression forming into blocks, freezing and then cutting into the desired shapes from the frozen state.

In examples H and J, the fish binder matrix, seasoning, water, oil and a portion of the fish flesh was chopped or minced to form a finer homogeneous mass. This mixture was then blended with the remainder of the fish pieces at a temperature of 0 to 5°C, preferably 0 to 2°C. After mixing, the product was then formed into the desired shape, preferably by compression molding, at a temperature from -2 to 0°C, and then frozen.

Alternately, in example I, the binder matrix, seasoning, oil, water and all of the fish flesh were chopped or minced and subsequently formed and frozen under similar temperatures. All of these products can then be coated with a traditional adhesion or cohesion batter and breading if so desired.

The food binder matrix, according to this invention, has therefore a variety of uses in forming varous types of formed food products. The binder has the capability of presenting vegetable pieces in clear, readily identifiable form and also be adaptable for use in binding meat products.

While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention and, therefore, it is intended in the appended claims to cover all such changes and modifications which fall within the true spirit and scope of the invention.