STECK NATHAN (US)
O'CONNOR SEAN FRANCIS (US)
STECK NATHAN (US)
| US6863917B2 | 2005-03-08 | |||
| US5858440A | 1999-01-12 | |||
| US20040033291A1 | 2004-02-19 | |||
| US20040033300A1 | 2004-02-19 |
CLAIMS
What is claimed is"
I A method of preparing a bakable food product, comprising' (a) blending a plurality of dry i ngredi ents;
Cb) adding water and one or more preservatives to the dry ingredients to form a batter,
(c) storing the baiter in an inert atmosphere; and
(d) loading the batter and a gas composition into a sealed pressurized dispenser, wherein one or more of steps (a)-(d) the temperatures is below between: a lower limit of approximately 3 °C {38 0 Fj, and an upper limit of approximately 6 "C (42 4 T); and wherein bacteria does not grow in the pressurized batter when stored at said temperature range for up to approximately 120 days.
2. The method of claim I , wherein the gas composition includes a water-soluble gas
3 The method of claim 1 , wherein the gas composition acts to change the bakable food product a brown color during baking
4. The method of claim 1. wherein the gas composition ia selected to allow phase stability of the bakable food product over a temperature range between: a lower limit of approximately ••• 5 "C (23 0 F), and an upper limit of approximately 35 C (95 4 T).
5. The method of claim L where the gas composition includes carbon dioxide.
6. The method of claim 1, where in the gas composition acts to adjust the color of the bakable food product upon baking
7 The method of claim 1, where in the gas composition acts to adjust the viscosity of the bakable food product to between: a lower limit of approximately 12000; and an upper limit of approximately 14000, for up to approximately 120 days.
8. A method of preparing a bakable food product, comprising- (a) blending a plurality of dry ingredients; (b) adding water to the dry ingredients to form a batter, wherein the batter temperature is kept between a lower limit of approximately 2 X (36 T), and an upper limit of approximately 7 0 C (44 0 F);
(c) loading the batter and a gas composition into a sealed pressurized dispenser; wherein bacteria does not grow in the pressurized batter for up to approximately 120 days when stored between a lower limit of approximately 2 X. (36 0 F), and an upper limit of approximately 7 °C {44 °¥\.
9. The method of claim 8, wherein step (b) the water temperature is kept between; a lower limit of approximately I X (33 ^F); and an upper limit of approximately 3 X (38 0 F).
10. The method of claim 8, wherein the batter temperature is kept between; a lower limit of approximately 2 X (36 0 F); and an upper limit of approximately 8 0 C (47 0 FV
! i The method of claim 8, where the gas composition includes carbon dioxide.
12. A bakable food product comprising:
(a) mixing a plurality of dry ingredients including Hour and one or more preservatives with water, wherein the dry ingredients are not homogenized prior to mixing, wherein the ingredients are blended into a batter using a cold process, and
(b) sealing the batter in a pressurized dispenser with one or more gasses including carbon dioxide, wherein the gasses assist dispensing the batter from the pressurized dispenser; wherein bacteria does not grow in the pressurized batter for approximately 180 days when stored between a lower limit of approximately 2 X (36 0 F); and an upper limit of approximately 7 0 C (44 0 F).
13 The bakable food product of claim 12, wherein the temperature of the batter during the cold process ia kept between. a lower limit of approximately 3 0 C (38 0 F), and an upper limit of approximately 7 "C (44 0 F).
14 The bakable food product of claim 12, wherein step (a) the water temperature is kept between: a lower limit of approximately 1 0 C (33 0 F); and an upper limit of approximately 3 "C (38 'TK
15 The bakabie food product of claim 12, wherein the bakabie food product has a shelf life when stored between, a lower limit of approximately 2 °C {36 0 Fj, and an upper limit of approximately 7 0 C (44 0 F); of up to approximately 120 days.
16. The food product of claim 12, wherein the carbon dioxide acts to increase the rate of browning of the bakable food product during baking.
17 The bakable food product of claim 12, wherein the food product is selected from the group consisting of waffles, pancakes, muffins, cup calces, ginger bread, cookies and brownies.
18 The bakable food product of claim 12, wherein the carbon dioxide acts to increase one or both viscosity and aeration of the bakable food product for approximately ! 80 days
19. The bakable food product of claim 12, wherein the bakable food product is organic
20 The bakable food product of claim ! 2, wherein the dry ingredients are dried whole egg, soybean powder, sodium bicarbonate, salt, sodium lactate, dicalcium phosphate, rice bran, sugar and wheat flour. |
REFRIGERATOR STABLE PRESSURIZED BAKING BATTER
PRIORITY CLAIM The present application claims priority to U.S. Provisional Patent Application No 60/812,674, entitled "REFRIGERA TOR STABLE PRESSURIZED BAKING B ATr ER " . inventors: Sean Francis O'Connor and Nathan Steck, filed June 9, 2006, and to U.S. Utility Patent Application No. 11/760.647. entitled "REFRIGERATOR STABLE PRESSURIZED BAKiNG BATTER", inventors. Sean Francis O'Connor and Nathan Steck, filed June 8, 2007, which applications are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is directed to food products, specifically pre-mixed or ready to cook batters and dough.
BACKGROUND OF THE INVENTION
A number of different types of food products come in pressurized dispensers, including decorative icings, dessert toppings, whipping cream, whipped cream substitute and Cheez
Whiz®, a thick sauce product made by Kraft Foods®.
Consumers have come to find foods provided in pressurized cans to be convenient to use.
Hence, different foods provided in such a manner are advantageous. Typically, dough, and batter used in baking comes in dry form or must be assembled from component ingredients from scratch.
SUMMARY OF THE INVHNTlON
Although a number of inventors have proposed bakabie batters in a pressurized can, there is no commercially successful product currently on the market This reflects the problem in developing a batter that has an acceptable shelf storage life in a pressurized can, the ability to freeze store the product without deleterious separation of components, obtaining an attractively browned appearance, a palatable taste and light and fluffy texture when baked.
lii various embodiments of the present invention, a cold process of preparing a food product to be provided in a pressurized can without the need for pasteurization of the ingredients results in a refrigeration stable product, In various embodiments of the present invention, a cold process of preparing a food product Io be provided in a pressurized can without the need for pasteurization of all of the ingredients results in a refrigeration stable product. In various embodiments of the present invention, the ingredients include a browning agent which is used to control the appearance and texture of the product, In various embodiments of the present invention, the ingredients enable freezing and thawing of the product without phase separations. In various embodiments of the present invention, a browning agent is used which is compatible with the cold process and pressurized can application of the product. In various embodiments of the present invention, the ingredients used to allow freezing and thawing are compatible with one or more of the browning agent the cold process preserv ation and pressurized can application of the product In various embodiments of the present invention, the ingredients stored in the can include one or more preservative In various embodiments of the present invention, different baking products including waiϊies, pancakes, muffins, cup calces, ginger bread, cookies and brownies are formulated using the cold process into a ready to use pressurized can and dispensed directly into the cooking apparatus In various embodiments of the present invention, the batter in the can be combined with, gasses and a water-mixed dry batter recipe under pressure.
BRIEF DESCRIPTION OF THE FIGURES
This invention is described with respect to specific embodiments thereof Additional aspects can be appreciated from the Figures in which;
Figure t shows a flow chart outlining the steps involved in preparing the batter for dispensing.
Figure 2 shows the Change in Pressure in Un -pressurized Cans (Dots - 0.15% Sorbates, no N; Cap; Vertical Lines - 0.15% Sorbates, Ni Cap; Horizontal Lines ~ 0 15% Sorbates. 1.0% Lactic acid, no N; Cap, Black - 0.15% Sorbates, 1 0%- Lactic acid, N : Cap),
Figure 3 shows the Change in Pressure in CCb Pressurized Cans (Dots - 1.0% Sorbates, Vertical Lines - \ .0% Sorbates, 200 ppm EDTA, Horizontal Lines - 1 0% Sorbates, 500 ppm
1
EDTA; Diagonal Stripes LtoR - 1.0% Sorbates, 0.1% Sodium benzoate. Black - 1 .0% Sorbates, 0 075% Propyl Parahen, 0.025% Methyl Paraben; Diagonal Stripes RtoL - 1 0% Sorbates, 0.5% Lactic acid; White - 1.0% Sorbates, 1.0% Lactic acid);
Figure 4 shows the Change in Pressure in N2 Pressurized Cans (Dots - 1.0% Sorbates, Vertical Lines ••• I 0% Sorbates, 200 ppm KDTA, Horizontal Lines ••• 1.0% Sorbafes, 500 ppra EDTA; Diagonal Stripes LtoR - ! ,0% Sorbates, 0 1% Sodium benzoate. Black - 1 0% Sorbates, 0.075% Propyl Paraben, 0.025% Methyl Paraben; Diagonal Stripes RtoL - 1 0% Sorbates, 0 5% Lactic acid; White - 1.0% Sorbates, 1 .0% Lactic acid); and
Figure 5 shows a comparison between waffles ( H) and 30) and pancakes (20 and 40), where the waffles and pancakes are baked using batter mixed and dispensed with carbon dioxide from a pressurized canister { 10 and 20) or the batter is not mixed or dispensed with carbon dioxide but applied directly to the waffle iron or frying pan (30 and 40).
DETAILED DESCRIPTION OF THE INVENTION
In an embodiment of the present invention, a batter mix such as that which can be useful for making pancakes, waffles, muffins, cup cakes, ginger bread, cookies and brownies can be mixed with water and transferred to a can ϊn an embodiment of the present invention, an antibacterial agent can be added to the batter and transferred to a can. in an embodiment of the present invention, a can or container can be sealed and pressurized with a mixture of water soluble and non water-soluble gasses. ϊn an embodiment of the present invention, the pressurized gasses are a mixture of N2 arid CO3. In an alternative embodiment of the invention, the pressurized gas is 100% CX) 2 . In an embodiment of the present invention, the antibacterial agent can be cultured dextrose In an alternative embodiment of the invention, the antibacterial agent is sodium lactate. In various embodiments of the present invention, the ingredients include a browning agent which is used to control the appearance and texture of the product. In various embodiments of the present invention, the ingredients enable freezing and thawing of the product without phase separations, in various embodiments of the present invention, a browning agent is used which is compatible with the cold process and pressurized can application of the product In various embodiments of the present invention, the ingredients used to allow freezing and thawing are compatible with one or more of the
browning agent, the cold process preservation process and the pressurized can application of the product A dispenser suitable for use in storing and dispensing the batter provided therein is well known in the industry and to consumers alike, and includes a spout, which releases pressurized contents when an individual depresses the spout to expend the contents of the can. There are numerous variations on the shape and type of dispenser, suitable for use with the present invention. The inventors have empirically determined that providing a refrigeration- stable, bakable batter in a pressurized can. using the specified gas and pressure combinations set forth herein, produces a superior quality baked good when the product is cooked in a manner similar to current dry mix products stored in boxes or bags
The mix recipe can be used to create pancakes (single sided grilling) or waffles {double sided, patterned grilling). The resultant product yields fluffy pancakes and light crisp waffles. In an embodiment of the present invention, the fluffy nature of the pancakes can be a result of the partial pressures of the gasses used to pressurize the can In an embodiment of the present invention, the fluffy nature of the pancakes can be a result of the partial pressure of the water soluble gasses used to pressurize the can. In an embodiment of the present invention, the fluffy nature of the pancakes can be a result of the incorporation of the water-soluble gas into the batter mix In an embodiment of the present invention, the fluffy nature of the pancakes can be a result of the ratio of the water to batter mix
In an embodiment of the present invention. Figure 1 shows a flow chart for assembling a charged batter-filled food in a pressurized container Generally, the batter recipe will be blended at step 10, mixed with water and preservatives at step 12, inserted into a pressurized scalable container at step 14, the container sealed at step 16, and the container pressurized in accordance with well-known techniques at step 18 In an embodiment of the present invention, steps 10-14 are earned out in an inert atmosphere. In an embodiment of the present invention, steps 10- J 4 are carried out at between 32-48 "1 F In an alternative embodiment of the present invention, steps 12-14 are carried out at between 38~ψ : i °F.
In an embodiment of the present invention, the ingredients of the mix include wheat flour, sugar, nonfat dry milk, whole dried egg, salt, sodium bicarbonate, di calcium phosphate dihydrate, xanthan gum, cultured dextrose and water. This recipe is mixed by blending all the dry ingredients, adding water at approximately 1 0 C (34 0 F) to the cultured dextrose and then
this solution to the dry blend in an appropriate amount (set forth below) depending osi the desired batter product while keeping the temperature of the batter below approximately 4 °C (40 °F). The batter can be stored in an inert atmosphere while being transferred to piston fillers used to dispense the batter into the aerosol line for filling the pressurized cans.
hi an alternative embodiment of the invention, the ingredients ate certified organic The organic ingredients of the mix include wheat flour, sugar, whole dried egg. powdered soy, salt sodium bicarbonate, dicalcium phosphate dehydrate, sodium lactate and water. This recipe is mixed by blending all the dry ingredients, adding water at approximately I °C (34 0 F) to the sodium lactate and then this solution to the dry blend in an appropriate amount (set forth, below) depending on the desired batter product while keeping the temperature of the batter below approximately 4 0 C (4 1 °F). The batter can be stored in an inert atmosphere while being transferred to piston fillers used to dispense the batter into the aerosol line for filling the pressurized cans.
in an embodiment of the present invention, the pressurized gas (100% VOz) is used as a preservative of the ingredients stored in the can. In an embodiment of the present invention, sodium lactate can be used as a preservative of the ingredients stored in the can In an embodiment of the present invention, the pressurized gas (J 00% CCb) and sodium lactate can be used as preservatives of the ingredients stored in the can. In an alternative embodiment of the present invention, sorbic acid can be used as a preservative of the ingredients stored in the can. In an embodiment of the present invention, potassium sorbate can be used as a preservative of the ingredients stored in the can In an embodiment of the present invention, propionic acid can be used as a preservative of the ingredients stored in the can,
In an embodiment of the present invention, the mix utilized for the present invention can be a specially blended mix. In an embodiment of the present invention, the mix utilized for the present invention can be an organic batter blended mix. In an embodiment of the present invention, the product produced with an organic batter blended mix can be an organic product. In an embodiment of the present invention, other dry mix can be utilized for the present invention. In an embodiment of the present invention, other dry-mix products can be utilized with the present invention. In an embodiment of the present invention, the dry mix can be activated by a combination of water, milk or other fluids
Table 1.0 outlines the breakdown of the total calories in a 100 g (3.53 oz.) serving of the mixed pancake batter.
Table 1.0 Nutritional Analysis per !0Og
Processing Procedure hi an embodiment of the present invention, a dry mixing vessel can be used to blend all the ingredients. In an embodiment of the present invention, water at approximately 1 °C (34 'T) can be added to the dry mix. In an embodiment of the present invention, the batter can be blended for approximately 5 to 7 minutes on a high sheer mixer In an embodiment of the present invention, the batter can be blended until smooth without lumps on a high sheer mixer. In an embodiment of the present invention, the batter can be blended at less than 4 °C (40 0 F) on a high sheer mixer In an embodiment of the present invention, the batter can be stored in an inert atmosphere directly after mixing until being loaded in pressurized cans In an embodiment of the present invention, the batter can be stored under nitrogen to prevent the sodium bicarbonate reaction for early leavening. Jn an embodiment of the invention, the batter is not stored under nitrogen because the sodium bicarbonate is encapsulated. Encapsulated sodium bicarbonate does not release until it reaches 58 - 61 0 C ( 136 ~ 142 0 F) directly after mixing and before being loaded in the pressurized cans In an embodiment of the present invention, the batter can be pumped to piston fillers on an aerosol line prior to being loaded in the pressurized cans
Cpj.d..Process. Procedure In an embodiment of the present invention, the blending of the ingredients can be carried out in a refrigerated production room. In an embodiment of the present invention, the blending of the water and the dry ingredients can be carried out in a chilled production room. In an embodiment of the present invention, the blending of the water and the dry ingredients can be carried out with refrigerated production equipment In an embodiment of the present invention, the blending of the water and the dry ingredients can be carried out with refrigerated production equipment in a refrigerated production room In an embodiment of the present invention, the batter temperature can be controlled to not exceed approximately 10 0 C (50 0 F) Jn an alternative embodiment of the present invention, the batter temperature can
be controlled to not exceed approximately 4 -'C (40 0 F). In an embodiment of the present invention, in a jacketed mixing tank the water coolant can be introduced at approximately 1± 2 °C (34± 2 °F). In an embodiment of the present invention, full scrape mix agitator can be utilized in mixing the ingredients. In an embodiment of the present invention, high shear cage agitator cars be utilized in mixing the ingredients. In an embodiment of the present invention, the dry blend of ingredients can be slowly pumped into the mixing vessel with slow agitation for approximately 10 minutes. In an embodiment of the present invention, batter can be mixed for approximately 5 to 7 minutes on high shear speed, where the batter temperature is not allowed to exceed approximately 4 0 C (40 0 F).
In an embodiment of the present invention, cultured dextrose (0.10 - 3.00 %) can be added to the water to be mixed with the dry ingredients In an embodiment of the present sodium lactate (below approximately 1 %) can be added to the water prior to agitation with the dry- mix to minimize v off-flavor\ in an embodiment of the present invention, cultured dextrose (greater than approximately 0.5 %) can be added to the water prior to agitation with the dry mix to insure 120 day refrigerated v shelf life " in an embodiment of the present invention, cultured dextrose (0 50 ••• 1.00 %) can be added to the water prior to agitation with the dry- mix. In an alternative embodiment of the present invention, sodium lactate and carbon dioxide can be added to the batter prepared with the cold process to a insure 120 day refrigerated ' shelf iiiV .
In various embodiment of the present invention, the water ranges from approximately 20 % to approximately 80 % of the dry batter weight (on a % by weight basis) for waffles, pancakes, muffins, cup cakes, and ginger bread, cookies and brownies formulations, in an embodiment of the present invention, a cookie mix can be made by mixing approximately 20% water with approximately 80% dry mix. In an embodiment of the present invention, a brownie mix can be made by mixing approximately 30% water with approximately 70% dry mix. In an embodiment of the present invention, a cup cake mix can be made by mixing approximately 30% water with approximately 70% dry mix. In an embodiment of the present invention, a pancake mix can be made by mixing approximately 50% water with approximately 50% dry- mix in an embodiment of the present invention, a waffle mix can be made by mixing approximately όθ% water with approximately 40% dry mix in an embodiment of the present
invention, a moose mix can be made by mixing approximately 80% water with approximately 20% dry mix. In an alternative embodiment of the present invention, the water can be 43% by weight of the mix for waffles, pancakes, muffins, cup cakes, ginger bread, cookies and brownies
hi various embodiments of the invention, the ratio of water to dry mix varies depending on the nature of the dry mix All-purpose flour has lower levels of gluten and as a result requires less water, hi contrast, pastry flour has higher levels of gluten, which requires more water to generate the same consistency mix. In an embodiment of the present invention, the water is 60% by weight for waffles using an -organic * batter mix. In an embodiment of the present invention, the water is 40% by weight for waffles using a non-organic dry mix containing all- purpose flour.
In an embodiment of the present invention, the water varies depending on the required consistency of the product. In an embodiment of the present invention, a pancake mix can be made by mixing approximately 50% water with, approximately 50% dry mix, In an embodiment of the present invention, the pancake mix can vary between 40.5 - 52.5% by weight water depending on the required consistency In an embodiment of the invention, one mix can be used for both waffles and pancakes.
In an embodiment of the present invention, the dry mix ingredients are greater than 95% organic ϊn an embodiment of the invention, there ate no available substitute organic ingredients for the non-organic ingredients in the dry mix in an embodiment of the invention, where the dry mix ingredients are greater than 95% organic and there are no available substitute organic ingredients for the non-organic ingredients, the food product can be certified as organic.
In an embodiment of the present invention, an amount of sorbic acid can be used to adjust the pH of the batter mix. ϊn an embodiment of the present invention, an amount of potassium sorbate can be used to adjust the pH of the batter mix. In an embodiment of the present invention, the inclusion of one or more ingredients to control the pH in the batter provides a stable product, requiring refrigeration at approximately 4+ 2 ;j C (40± 2 °F). In an
embodiment of the present invention, the watei to be added to the dn > mix can be provided with approximate!! 0 !% potassium sorbate and approximate!) 0 05% sorbic acid (b\ \\ eight)
In an embodiment of the present invention, an amount of potassium sorbate contro!s the growth of yeast and mold to keep the pioduct stable In an embodiment of the piesent invention, sodium lactate controls the growth of yeast, mold lactic acid and Listeria to keep the product stable In an embodiment of the present invention, an amount of cultured dextrose controls the growth of \ east and mold to keep the product stable In an embodiment of the present invention, the inclusion of one or more ingredients to control the growth of mold and bacteria in the batter provides a stable product, requiring refrigeration at approximately 4- 2 T (40± 2 0 F)
In an embodiment of the present invention, batter can be pumped to a jacketed holding \essel, where the batter temperature is not allowed to exceed 4± 2 J C (40± 2 C F) In an embodiment of the present invention, batter can be pumped to a series of filling heads In an embodiment of the present invention, samti/ed lined cans can be introduced to the series of filling heads and filled with the batter In an embodiment of the present invention, cans can be \ ahed with tilt valve 2 x 0 0022 or vertical action valv e 2 x. 0 033x0 090 valves and the cans can be crimped and gassed to approximate^ 150 r 3 psl Cans can be tipped, capped, packed and stored in cold storage at 4+ 2 °C <40+ 2 '¥}
In various embodiments of the present invention, different baking products including waffles, pancakes, muffins, cup cakes, ginger bread, cookies and brownies are formulated using the cold process into a ready to use pressurized can and dispensed directly into the cooking apparatus
The pressurizing step pi ox ides with different mixtures of a pressurized gas. depending on the particular application for the batter in the can If the batter is to be used as a waffle mix, the gas can be nitrogen (N^) and carbon dioxide (CO;) mixed in a ratio of approximately 10% N; and approximately 90% COi by weight, pressurized at 150 pounds per square inch (psi) For a pancake mix, the gas can be N ; and CO 2 mixed in a ratio of approximately 50% each gas bv
weight. For a cup cake mix, the gas can be N 2 and CO 2 mixed in a ratio of approximately 55% N 2 and approximately 45% CO 3 by weight. For a brownie mix, the gas can be N 3 and CO 2 mixed in a ratio of approximately 85% N; and approximately 15% CO; by weight.
In an alternative embodiment of the invention, if the batter is to be used as a waffle mix, the iias can be 100% carbon dioxide (CO 2 X pressurized at 150 pounds per square inch (psi). See ' fable 14.2 for the weight of gas added in the can.
Different batter mixtures require various pressurizing reagents and compositions in order to provide the optimal consistency for baking of the food product. For example, the batter in a gas container can be pressurized with carbon dioxide (CO;). CCb is a water miscibie or soluble gas. After sealing the can, the pressure drops considerably {up to approximately 40%) after canning because the C Qa dissolves into the mixed batter in the can. For a waffle mix where the gas is 90% CO 2 this can have a significant impact on the final pressure For a pancake mix, the gas composition can include both nitrogen (N;) and CO?. In contrast, to CO?, N; is largely a non water-soluble gas. When N2 and CCH are mixed in a ratio range of approximately 00% nitrogen and approximately 10% carbon dioxide to approximately 80% nitrogen and approximately 20% carbon dioxide, the N 2 will not be significantly absorbed by the batter mix, and the resulting total pressure can remain higher. By having approximately 10% to approximately 20% of the gas as CO 2 , this combination gives sufficient gas emulsifi cation of the batter to generate a light and fluffy pancake or waffle, while maintaining sufficient gas pressure for the entire life of the can. Gas composition and ratios for muffins are similar to waffles. Gas compositions and ratios for ginger bread, cookies and brownies formulations are similar to pancakes.
The foregoing detailed description of the invention has been presented for purposes of illustration and description, it is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The described embodiments were chosen in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated, it is intended that the scope of the invention be defined by the claims appended hereto.
A bakahie food product is any food product which requires heating prior to serving. Bakable includes processes such as frying, poaching, grilling, bar-b-q-ing, heating in a waffle iron, heating in a sandwich maker, heating in a boiler, heating in a conventional oven, healing m a gas convection oven, heating in a microwave oven and heating in a toaster.
Example J.
Aim: Io determine an acceptable pancake powder mix to water ratio; and determine suitable prapellant(s) to make an aerosol packaged pancake batter.
Mix; 50/50 Elite Spice Pancake MLvDl Water (-50'C; ~ l20 f 'F); Preservatives (0.05% Potassium sorbate and 0.05% sorbic acid); Fill; 16oz; Can; 2 1 -4 x 804, 3-piece, lined; Propeilants Tested: (i ) Sg Carbon Dioxide {CO?}, (ii) 2.8g Nitrogen (Nj)
Although different amounts of batter were dispensed with the different propetlants (see Tables 1 1 and I 2), the samples made similar diameter pancakes. This is due to the CO^ dissolved (in water) in the (X); sample that gave the batter more volume.
Initial tests showed that the ratio of 50/50 Elite Spice powder rnix-to-water ratio made a batter that produced good pancakes and waffles The consistency was typical of a pancake batter.
These samples were used to cook pancakes and waffles (using waffle iron). The sample gassed with COa was more suitable to make waffles. The waffles produced were light and crispy Because CO 2 is more soluble in water than Nj. the batter dispensed from the CO 2 - gassed sample had dissolved CO2 in it. When cooked in the waffle iron, the CO; escaped making the waffle light thin and crispy. When this sample was used to make pancakes, the dissolved CO 2 escaped the batter during the cooking process making the pancakes flat and thin. The sample gassed with N 2 made better pancakes than the one gassed with CO;. The N 2 pressurized the can, but did not really get absorbed or mixed in the water/batter. The batter dispensed was therefore denser and made thicker, sponge-like pancakes similar in appearance and texture to normal pancakes. When this sample was used to cook waffles, the waffles produced were thicker and denser. The test candidate preferred the thin and crispy waffles over the denser ones On the other hand, they preferred the denser pancakes over the thin and Oat ones. Summary of trial" samples gassed with CO? made good waffles; samples gassed with N 2 made good pancakes
Example 2.
Aim: to fine-tune the powder mix-to-water ratio and the amount of compressed gas to be used as propellant.
The following samples were prepared: (i) 50 powder mix/50 water; in 214x804 can; filled at lόoz; gassed with 3.9g N; at 130 psi; (ii) 45 powder raix/55 water; in 205x604 can; filled at 4oz; gassed with 2.7g N? at 130 psi; and (iii) 40 powder mix/60 water; in 214x804 can; filled at !2Oz; gassed with 4.6 N> at 130 psi. Additionally, the following samples were prepared for test candidate testing: (iv) 50 powder mix/50 water; gassed with CO?; (v) 47.5 powder rmx/52.5 water; gassed with N;.
Results
As in Example i, sample (iv) that was 50/50 and gassed with CO; made thin, light and crispy waffles. Sample (v), that was 47.5% powder mix and 52.5% water was found to be less dense than sample (iv) and was easier to mix Sample (v) also flowed faster and easier from the can gassed with N; and still made pancakes with attractive appearance, taste and texture. The quality of the pancake was comparable to sample (i) where the 50/50 formula was gassed with Nj. Test candidate test result: sample (iv) 50/50 with CO 2 - good for waffles; sample (v) 47.5/52.5 with N? - good for pancakes.
Table 2,1 Cook Test Results on N^-Pressured Pancake Baiter with Varying Powder Mix-to- Water Ratio.
EXAMPLE S
Aim: to conduct preliminary tests on different preservatives.
Mix: Pancake Batter: 47.5/52.7 Elite Spice Pancake Mix/DI Water. Screw cap glass vials. Primary Preservatives used, (i) 0.05% Sorbic Add and 0.10% Potassium Sorbate; (it) 0.10% Sorbic Acid and 0.20% Potassium Sorbate. Additional preservatives: ED 1 TA, Sodium Benzoate, Methyl Paraben, Propyl Paraben and Lactic Acid All the samples were aseptically prepared. One set of vials were capped with Na and one set was not. AH the vials were stored in the dark at room temperature for 1 week.
Results
The evaluation of the samples was limited to visual and ol factors- testing. Based on these results, no preservative was suitable for the required barter applications. The results were almost identical in all the samples regardless of the preservative system used. All samples showed signs of phase separation, pressure built up and a sour odor was detected after a week.
The phase separation was expected in such suspension with high level of water insoluble solids. The barter mixture can require an emulsifier or a suspending agent. The pressure build-up can have been due to. generation of CO; from bicarbonate leavening agent and/or microbial growth and/or possible fermentation. The souring of odor could have been due to fermentation or other microbial growth. The microorganisms can have come from powder mix.
Table 3.1 Preservative Test Results on Pancake Batter in Glass Vials with 0.05% Sorbic Acid and 0.10% Potassium Sorbate After 1 Week
Tabte 3.2 Preservative Test Results on Pancake Batter in Glass Vials with 0, 10% Sorbic Acid and 0.20% Potassium Sorbate After 170 Hrs.
pressure build-up pressure build-up sour røilk odor sour milk odor beginning of phase
1.00% Lactic Acid phase separation separation pressure build-up pressure build-up no off odor sour miik odor
Note' Pressure build-up was characterized by an audible pressure exhaust when the vial cap was unscrewed.
EXAMPLE 4
Aim: to study the pressure build-up in pressurized and un-pressurized cans.
Propellents: (i) None; (ϋ) CO 2 ; (iϋ) N 2 . Fill: Soz. Hot process, 5O 0 C (12O 0 F) Dl water + Elite Spice pancake mix. Preservative trials.
Un-pressurized crimped 2O5κ.6O4 3-pc steel, EP coated cans with 0.05% Sorbic Acid and 0.10% Potassium Sorbate combo 0.05% Sorbic Acid and 0.10% Potassium Sorbate combo with N 2 cap 0.05% Sorbic Acid and 0.10% Potassium Sorbate combo + 1.00% lactic acid (88%) 05% Sorbic Acid and 0 10% Potassium Sorbate combo + ■ 1.00% lactic acid (88%) with N2 cap
Pressurized crimped 205x604 3-pc steel, EP coated cans with
1.0 % Sorbates (combination of 0.40% Sorbic Acid and 0.60% Potassium Sorbate) a + 200 ppm KDTA a + 500 ppm EDTA a + 0.1 % Sodium Benzoate a -■ ■ 0.075% Propyl Paraben í 0.025 % Methyl Paraben a + 0.5% Lactic Acid (88%) a + ■ 1.0% Lactic Acid (88%)
Results
There was a significant pressure build-up in both un-pressurized samples (Dots - 0.15% Sorbates.. no N? Cap; Horizontal Lines - 0.15% Sorbates.. 1 .0% Lactic acid, no N ? Cap) and ^-pressurized samples (Vertical Lines - 0.15% Sorbates, N 2 Cap; Black - 0.15% Sorbates, 1 .0% Lactic acid, N2 Cap) after 60 days. On the contrary, COj-pressurized samples dropped in pressure in the same time frame (Tables 4,1 and 4.2 and Figure 3). The pressure build-up was more pronounced in the υn-pressurized samples (Figure 2; -40 psi average after 60 days) than in the N^-pressuάzed samples ( - 13 psi average after 60 days) (Figure 4). And for the un- pressurized set, the samples with sorbates only (Dots - 0 15% Sorbates, no N? Cap) result in
more than double the final pressure compared to the sample with sorbates í lactic acid preservative system (Horizontal Lines - 0.15% Sorbates, i .0% Lactic acid, no N 2 Cap) (Figure 2).
For the samples pressurized with CO: (Dots - 1.0% Sorbates; Vertical Lines - 1.0% Sorbates, 200 ppm KDTA, Horizontal Lines - 1.0% Sorbates, 500 ppm KDTA; Diagonal Stripes LtoR - 1.0% Sorbates, 0 1% Sodium herrzoaie; Black - 1.0% Sorbates, 0 075% Propyl Paraben,
0 025% Methyl Paraben; Diagonal Stripes RtoL - 1 ,0% Sorbates, 0.5% Lactic add, White -
1 0% Sorbates, 1 0% Lactic acid), the average pressure drop after 60 days was about 20 psi (Figure 3}
As discussed in Example 3, the probable causes for the build up of pressure in the ιm- piessυrized and N; pressurized cans can have been (i) evolution of CO: from the bicarbonate leavening agent and/or (ii) microbial growth/fermentation.
In fermentation of sugars, one of the ingredients of the powder mix, the byproducts are etlumol and CO?. Some of the CO 3 is released to the headspace of the can However, a portion of the CO; is dissolved in the water which, in effect, acidifies the batter. Additionally, other microorganisms such as lactic acid bacteria which can possibly be present in the mix (see Example 6), can produce acid byproducts such as lactic acid. Such byproducts can cause the batter to acidify. This acidification can then caused the sodium bicarbonate to release further
CO;
The COj due to microbial activity or bicarbonate decomposition in the un-pressurized cans produced the headspace pressure (Figure 2). But when the headspace of the can already had a positive pressure as in the N; pressurized samples (Dots ~ 1.0% Sorbates, Vertical Lines -
1.0% Sorbates, 200 ppm EDTA; Horizontal Lines - I 0% Sorbates, 500 ppm EDTA;
Diagonal Stripes LtoR - 1.0% Sorbates, 0.1% Sodium benzoate; Black - 1.0% Sorbates,
0.075% Propyl Paraben. 0.025% Methyl Paraben; Diagonal Stripes RtoL - I 0% Sorbates, 0.5% Lactic acid; White - 1.0% Sorbates, 1.0% Lactic acid) (Figure 4), the production of COj can have been restricted such that the pressure-build up was less than that in the un- pressurized samples
On the other hand, un- pressurized and N^-pressurized samples preserved with sorbates combined with lactic acid had the least pressure build-up And the more lactic acid added, the lower the pressure build-up (Figures 2 and 4), Although the lactic acid efficacy cannot completely offset the bicarbonate decomposition due to acidify, it was significantly better as a preservative, in combination with sorbates, than the other preservative systems used
The COrpressurized cans exhibited reversed results and the pressure decreased after 60 days (Figure 3). One explanation is that some of the CCh molecules that were injected in the can were dissolved in the water in the mix over time. This explains why the pressure decreased from the day the samples were made. The CO 2 generation in these samples cannot have been enough to overcome the amount of CO? dissolved in the sample. ' Therefore, the pressure effects of CO; dissolution were more evident than the effects of CO; generation. Alternatively, the CO^ can have natural anti-microbia! action which impeded or slowed down microorganism growth. For fermentation, the CO: injected can have saturated the system retarding further CO; production from yeast. For aerobic microorganisms, CO; made the environment undesirable for microbial growth.
EXAMPLE 5 Aim: to study the pressure changes in the can pressurized with 50/50 CO/N2 as a follow-up to Example 4
Ta C
"Samples were stored at room temp for the duration of the study
Results
The pressure build up was similar to the NVpressurized samples in Example 4 (see Fig 4.6), but the amount of product in the cans was increased in this trial. Some of the injected CCb dissolved in the water but more CO 2 (or other gaseous microorganism byproducts) can be generated, caυ si ng the pressure i nerease .
EXAMPIJE 6
Aim: to determine the shelf stability of the batter using trial preservatives. The tests were conducted by BETA Food Consulting, Inc.
Mix: Pancake Batter: 47,5/52.7 Elite Spice Pancake Mix/Dϊ Water. Screw cap glass vials. Primary Preservatives used:
-MG510 gassed with CO 2 -CS ! -50 gassed with CO 2 -MG510 gassed with N 2
-CSl -50 gassed with N 3
Inocuiants:
Y - yeast
LAB ••■ lactic acid bacteria SA - StaphUυcoccus Aureus LM - Lysteήa Monocytogenes BC ~ Havillus Cerem
Results
Following is a study conducting a microbiological challenge on aerosolized food product. The pH of the aerosol food product is approximately 6.0 and the water activity is 0.96.
Growth of Selected Spoilage and Pathogenic Organisms in an Aeroso! Food Product
Purpose
The purpose of the study is to determine the fate of selected spoilage and surrogates for pathogenic microbial agents when inoculated into an aerosolized food product. Outgrowth of lactic acid bacteria and Listeria monocytogenes was problematic in a previous study completed in January. 2006. For this reason, they will be the only organisms studied on this formulation. A surrogate organism that is non-pathogenic will be used for L. monocytogenes to avoid the potential for contamination of your new facility. Listeria innocua will be used instead.
Product Variables
The product variables to be studied include:
I ) MicroGard 510 with CO 2 (waffle) 2} MicroGard CS 150 with CO; (waffle) 3) MicroGard 510 with N 2 (pancake) 4) MicroGard CSI 50 with N 2 (pancake).
The intended shelf life is 45-60 days, minimum. No previous stability information had been gathered on the products. The study was continued for 105 days to determine whether a longer shelf life was possible.
Process
The pre-cooled batter was loaded into the cans after filling to minimize shifts in microbial loads. Empty cans were submerged in a 200 ppm chlorine solution for a minimum of 60 seconds prior to draining and permitting to air dry, for the purpose of disinfection. Cans were filled, inoculated, capped with valve tops and pressurized, chilled in an ice bath, and
immediately placed into refrigeration temperatures of 40 0 C (41° F). Finished cans were stored for ! .5 days and transported in a refrigerated tmck.
Organisms The organisms for challenge represented those of potential safety and spoilage concern. The only pathogen of potential conceπi that was not represented was C botulinum. The test organism categories included:
-Bacillus cereus (gram positive spore former, therm o labile toxin)
-Staphylococcus aureus (gram positive non-spore former, thermo stable toxin) -Listeria monocytogenes (gram positive non-spore former, psychrotroph)
-Zygosaceharomyces rouxii (yeast)
-Lactobacillus formenturø, Lactobacillus plantarum (combined inoculum of gram positive non-spore formers).
Culture Preparati on
Lactic acid bacteria was grown in sterile MRS broth. Other bacteria were grown in sterile trypticase soy broth. Yeast extract was added for the I... monocytogenes culture Bacteria were cultured for 24 hours at 35C, then streaked on trypticase soy agar and incubated for 48 hours at 35 *C. Yeast were cultured for 5 days at 24 0 C on potato dextrose agar Cell suspensions were prepared by harvesting cells into sterile 0. 1% peptone water. Inoculum was adjusted to deliver a target initial load of 103- 104 cfu/g (minimum 590,000 cfu/'can in each 20 fl oz. can), inoculation was delivered with a 1 mL inoculum volume. Tbe cans were inoculated in the " in-house ' R & D laboratory bench top capping unit at Follmer Development, located away from the processing area and not used for production. A Food Safety Solutions represen tati ve conducted the i nocul ation .
Sixteen cans for each inoculum group were prepared. ' Two uninoculated controls were additionally prepared for each of the 4 product variables. Swabs of the bench, utensils, and rinsate from the filler unit were collected after cleaning and sani fixation was complete to determine adequacy of cleaning The unit was not be used before results were available.
Test Method
Test methods for quantitation will be per FDA-B λ\l or AOAC The changes in loads for each inoculum group will be measured at each test interval Testing will be done in duplicate Trend information about growth, death, or stasis will be available from the data
Test lnteπ. al
Test intervals v\eie spaced appropriately to iepiesent the 105 day stomge pemxl Testing was conducted on inoculated \ariabies 1. 2, and 4 at day 2, ! 5. 30, 45, (>(>, 75, 0 O. and 105 Testing foi inoculated \ariable 3 was conducted at day 2, 1 5. 30, and 45 Later test intervals for \ ariabie 3 were discontinued because inoculum loads significantly increased L'ninoculated controls were analyzed alter 2 and 105 for variables 1 and 2 An additional 45 day test inter\ al was added for variables 3 and 4 to determine midpoint shifts in background flora levels
Uninocuiated contiol samples were anal) zed foi B ccieus, S auteus, L monocytogenes, lactic acid bacteria, yeast, mesophilic aerobic plate count, and mcsophilic anaerobic spore former counts
Storage Conditions
Products stored at 4 0 C (40 - 41 0 F)
The Pathogenic Organisms detected in the product after 2-105 days are shown in Fables 6. 6.9.
Ai day ! 5, no appreciable changes in inoculum loads were observed, with the exception of L. monocytogenes in variables 3 and 4. A small (1 log 10) increase occurred between 2 and 15 days. All sample variable results remained acceptable
At day 30. variable 1 experienced an approximate 2 logjo increase in lactic acid bacteria levels since the last interval (Day 15). AI! other results did not appreciably change The net increase in lactic acid bacteria from the initial inoculum levels was about 2 logs, which was still considered acceptable Variable 2 similarly experienced an increase in lactic acid bacteria, but only by approximately 1 log t o- Listeria monocytogenes and lactic acid bacteria exhibited spikes (approximately 2 log) in counts in variables 3 and 4 (packaged in nitrogen). In order to determine whether the cause was related to background flora activity, the decision was made to test the uninocuiated controls at the next test interval (Day 45) All results were considered acceptable after 30 days storage
After 45 days storage, variable 1 sustained an approximate 2 log overall increase in lactic acid bacteria levels, with 45 day average loads of 5.0 logm The changes in populations were not unacceptable. Variable 2 experienced a 1 log increase in L. monocytogenes and sustained a 2 log increase in lactic acid bacteria loads Overall results were acceptable after 45 days storage. Variable 3 experienced an increase of approximately 5 logs in lactic acid bacteria since Day 2, which was considered unacceptable. Listeria monocytogenes increased by 2-3 logjo since initial!) inoculated, Counts in inoculated samples for Variable 4 did not change appreciably since the last interval (Day 30) Uoinoeulated control lactic acid bacteria levels were higher in uninocuiated control variable 4 than in sample inoculated with laetics, reflecting that previous withdrawal of product from the container ( uninocuiated control) likely caused elevated counts due to fouling of the nozzle, not changes in the internal product itself. Since the results for Variable 3 were poor, testing of the inoculated sample was discontinued Testing of the uninocuiated control was continued, as for other controls. Testing for Variables 1. 2, and 4 were continued, as scheduled.
After 60 days of storage, a 2.5 and 2.0 login increases in lactic acid bacteria levels were observed in variables i and 4, respectively. Results were not indicative of a product failure. No other appreciable changes in microbial loads were observed.
No appreciable changes occurred in microbial loads between 60 and 75 days storage.
After 90 days storage, 0.5 log lactic acid bacteria increase was observed in variable 1. No other changes occurred.
Between 90 and J 05 days of storage, L. monocytogenes increased by 1 logic in variable 2 and lactic acid bacteria increased by more than 2 logio- Staphylococcus aureus increased by approximately 1 logic within the same timeframe.
None of the uninoculated controls had detectable pathogens isolated from them over the 105 day storage period.
Chief flora associated with uninoculated controls were lactic acid bacteria. Mesophilic anaerobic spore former counts did not change during the 105 storage period, indicating no need to conduct a follow-up C botulinum inoculation study.
Aroma defects observed in uninoculated controls after 105 days storage were associated with variables 3 and 4, which had higher loads. Lactic acid bacteria, aerobic plate counts, and anaerobic plate counts in the variables with N? used as a propellant were extremely high. In the control variables containing COj as a propellant, aroma defects were not observed after 105 days storage. Indicator microbe loads were also markedly lower in those variables { I and 2)
The sum of observation results for aroma indicates the organoleptic endpoint for variables 1 and 2 was beyond 105 days and for variables 3 and 4 it was less than 105 days. The apparent microbiological endpoints are discussed below.
None of the variables supported outgrowth of toxigenic pathogens over the 105 day storage period (S. auneus, B cereus). Variables with N^ propellant permitted faster outgrowth of L.
monocytogenes, to higher levels Use of C0> as a propellant appears to suppress Listeria growth, reducing risk of hazard from end-user under cooking.
Overall, the formulation for Variable 2. containing MicroGard CS 150 with CO; (waffle), was most stable against spoilage organisms (uninoculated controls) and L monocytogenes
(inoculated samples). Spoilage bacteria! levels never exceeded 104 efu/g during the 105 day storage period in uninoculated controls. The marked spike (approximately 2 logu>) between 00 days and 105 days in L. monocytogenes levels for the inoculated sample variable 2 reflect the microbiological endpomt for variable 2 could conservatively be set at c) 0 days.
The spike in lactic acid bacteria < 2.5 lognt) between 45 and 60 days for variable 1 indicates stability begins to decline. Since the organoleptic endpoint (uninoculated control) was beyond 105 days, a conservative endpoint for variable I could be set at 60 days
The microbiological shelf life endpoint for inoculated variable 3 was 30 days, based on marked changes in lactic acid bacteria levels after that time.
The aroma for uninoculated variable 4 was objectionable after 105 days storage. The endpoint would have been sooner, but was not determined. Based on the microbiological results, a con sen' alive endpoint for the lactic acid bacteria might be 60-75 days, based on substantial increases at those intervals
A mix of propellant gases (N 2 and CO;} would likely result in better stability than N; alone
The resident organism in the batter using Elite Spice Pancake Mix is lactic acid bacteria This organism is not pathogenic and the only concern is aroma defect when present in high loads.
Based on the data, Variable #2 (CS 150 gassed with CO;} was the most stable against spoilage organisms None of the variables supported outgrowth of toxigenic pathogens over the 105 clay storage period (5. aureus, />". cerens). Variables with N; propellant permitted faster outgrowth of L monocytogenes, to higher levels but the use of CCb as a propellant appears to suppress listeria growth, reducing risk of hazard from end-user under baking the product while cooking.
EXAMPLE 7
Aim: to monitor the weight losses in samples The samples tested were pancake and waffle formulations with the pancake gassed with 3 5g gas (30% CO? and 70% N 2 ) and the waffle gassed with 7.0 g CO; Ail the samples were in 2 S 4 x 804 cans. The samples were kept at room temperature throughout the test
Results
After 13 days, there was no significant weight loss (or leak) from the can. The weight loss observed can have been due to leakage of gas when pressure readings were taken. The packaged batter does not pose any leaking problem The valve, crimp and can specifications are appropriate for use in this application
EXAMPLE S
Aim: to determine the density of the batters
Formula' 47.5 powder nύx/52.5 water; Cold process (water temperature is 50 0 F: finished batter is 61"P), Preservatives: 0.05% Sorbic Acid and 0.10% Potassium Sorbate combo. Graduated cylinder method
Results
Calculated density. 1.33g/mL at - 16 0 C (61 0 F). The suspended solids made the product denser A cold process ia more appropriate for the batter preparation Higher temperature will cause the sodium bicarbonate to decompose and the leavening effect lost.
KXAM P Li: 9
Aim: to determine the effect of mixing time on the viscosity of the batter
Formula. 50/50 Elite Spice Pancake Mix 18636AO/Water. Viscosity measurements were taken throughout the mixing time of the batter The viscometer used was Broσkfieid DV-IH viscometer
Table 9.1 Effect of lime of Mixing to the Viscosity of the Batter
*RV Spindle #6 at 20rpm, 1 minute
Results
The data show that the batter exhibits a non-Newtonian property which is thixotropic. As a result, shear (mixing) decreases the viscosity but recovers its original viscosity after the applied shear is reduced or removed. Accordingly, extended mixing of the batter to achieve homogeneity during process cannot be detrimental to the final mix
EXAMPLE IO
Aim: to determine delivery weight of bailer in pressurized container.
Fill 22oz, Pressure- 130 psi (2 6g N2V, Can. 214x804, Valve S63 3x022" Summit Whipped Cream Valve (Summit) - ) - Whipped Cream Actuator, the spray -out was not intermittent.
Results
Total delivery weight from a 22oz filled 214x804 can is approximately I8oz. Spraying the product out of the can at once leaves approximately 18% in the can. This high retention weight is due to the viscosity of the batter. The flow of the product is slow and has the tendency to cling to the sides of the can. The propellant is exhausted even before most of the product is expelled from the can.
EXAMPLE 1 1 Aim: to determine the delivery weight of baiter from a 2 M x7 J 3 can be filled at 18oz
Formula. Waffle (50/50 Elite Spice Pancake Mix/Water); Can: 21 1x713, 3-ρiece Valve: S63 3x0,022"' (tilt action) (SurnroU) Whipped Cream Valves + ■ Whipped Cream Actuator; fill: 18oz; Propellant: 3g (50/50 €Cb/Nj): Order of gassing. CCb first to achieve 1.5g 5 then Ni with regulator set at 140 psi. At this pressure, 1 5g N; is injected in the can; Storage. Refrigerator at 4± 2 0 C (4Oi 2 ύ ψ) for 2 days. The product was dispensed while cold until gas starts to come out of the nozzle. ' The can was shaken to dispense more product.
Table 11.1 Delivery Weight of an i8oz Batter Filled 21 1x713 Can
Total delivery weight from an 18oz filled 2 ! 1x713 can is approximately 44Og or ! 5.5oz. Retention weight is approximately 2,Soz.
Results
Contrary to the procedure carried out in Example 10, the delivery was maximized by shaking the can, the retention is still approximately 13%. This is due to the viscous characteristic of the batter (as discussed in Example 10).
EXAMPLE 12
Aim: to determine the delivery weight of Batter from a 2 ! 1x713 can with a S63 3x0,030" tilt action valve filled with 23oz high water ratio batter.
Base formula: 40/60 Elite Spice Pancake Mix 18636AO/Water; Fill; 23oz in 214x804 3-piece can; Valve: S63 3x 0.030 " tilt action valve f Whipped Cream Actuator (Summit)
Propellant <i) Pancake is gassed with -2,2g (50/50 CO 2 ZN 2 ); Order of gassing: CO2 first to achieve 1. Ig, then N? with regulator set at 125 psi. At this pressure, 1.1 Nj is injected in the can, (ii) Waffle is gassed with 4.3g CO; with the regulator set at 570psi
Table 12.1 Delivery Weight of High Water Ratio Batter in a Can with a S63 3x0.030" Valve Filled at 23oz
Results Less viscous halter flowed better inside the can such that more product is expelled before the propellent is exhausted This in effect increased the product yield from the can.
EXAMPLE 13
Aim: to determine the spray rate of product using different valves.
Can: 214x804, 3-piece; FiU: ISoz
Valves Tested: (i) SV-77/HF 2x0.035"x0.0W (vertical action) (Summit) + Whipped Cream Actuator: (it) S63 3xO.O3O"(tilt action) Whipped Cream Valve (Summit) + Whipped Cream
Actuator; (iii) Sό3 3x0 022 M (tiit action) Whipped Cream Valve (Summit) -'- Whipped Cream Actuator.
Formulas: (i) for Valve I , Waffle (50/50 Elite Spice Pancake Mix/Water) with 0.75% Microgard MG 510; (ii) for Valve 2, Sample Code 06-1 59, 40/60 Elite Spice Pancake Mix. 18636A()/Water; , for Valve 3, Waffle (50/50 Elite Spice Pancake Mix/Water) with 0.75% Microgard MG510.
Propeiiant: (i) for Valve I, 4g (50/50 CO 2 ZN 2 ); Order of gassing: CO 2 first to achieve 2g, then
10 N3 with regulator set at 125 psi. At this pressure, 2g N^ is injected in the can; (ii) for Valve 2, approximately 7.Og CCb; regulator pressure set at 170 psi; {iii) for Valve 3, 4g {50/50 COyN 2 ), Order of gassing. CO 3 first to achieve 2g, then N 2 with regulator set at 125 psi. At this pressure, 2g N 2 is injected in the can.
i S Storage: Refrigerator at 4± 2 0 C (4Oi 2 °F) for 3 days. Spray rates were taken at 10 seconds per spray.
Table 13.1 Spray Rate of Waffle batter (i) Using the Valve SV-77/HF 2x0.03 S"x0.090" (vertical action) (Summit)
Spray Rate, g/s
First spray 21.7
Second spray * 21.2
The delivery weight for this sample is 12.5oz** 0
* Second spray lasted for only 6.5 seconds until air started to come out.
** The delivery rate was not maximized. More product could be yielded by shaking the can.
This was not done in this trial. 5 Table 13.2 Spray Rate of Waffle batter (ii) Using the Valve 8633x0.030" (tilt action) whipped cream vaive (Summit)
Table 13,3 Spray Rate of Waffle batter (ii) Using the Valve S63 3x0.022" (tilt action) Whipped Cream Valve (Sumrnit)_
Spray Rate, g/s
First spray 9.2
Second spray 7.6
Third spray 6.7
Fourth spray 6.0
** Fifth spray was lOrnins apart from the fourth spray while the cars is left at room temperature.
*** Sixth spray was l Omins apart from the fifth spray while the can is left at room temperature. Sixth spray lasted for only 5 seconds until air started to come out.
***** As in Table 13. i, the delivery rate was not maximized. More product could be yielded by shaking the can. This was not done in this trial.
Results
The wide open valve SV-77/HF 2x0.035 " x0.090 " (Table 13 1) delivered a faster spray rate but yielded only j 2.5oz of product (although this amount was not maximized by shaking the can) The spray rate through the valve overcame the product flow inside the can The valve S63 3x0,022 " (Table 13.3) had a smaller orifice therefore having a slower spray rate but yielding around I02 more in delivery weight (also not maximized) The valve with slightly wider the orifice size to 3x0.030' " (Table 13 2) delivered a faster spray rate. This test only had one data point and no other parameters were tested.
EXAMPLE 14
Aim: to set the filling parameters of products using the gasser-crimper.
Pancake and waffle products were filled at different fill weights and ran through the gasser- crimper (Terco, Inc.) varying gassing pressure and time and crimping pressure. The valves used were (i) S63 3x0.030 " Tilt Action Valve í Whipped Cream Actuator (Summit); (ii) 3400 2x0.045"x0.037" Whipped Cream Valve and Actuator (Clayton); (iii) 5477 Unrestricted Flow Whipped Cream Valve and Actuator (Clayton).
Table 14.1 Gasser-Cάmper Data for Pancake batter (High Fill) Gassed with CO2 at 150»$t for 2 to 4 seconds with a Crimper Pressure of About lOO si
Results
As the flH weight of the product is reduced, the more gas is accommodated in the can (Tables
14 ] and 14 2) The gassing capability of the plant niax.es at around 5.2g CO 2 for can filled with 20oz of batter. The desired fast/high delivery weight is achievable by using a high How valve such as Clayton ' s 5477 1 Table 14.4).
The mechanism of the gasser-cήmper depends highly on the pressure of the propellant injected, the length of time of gassing, the headspace in the can available for the propellant and the crimping pressure Some of these parameters were varied and the results were very conclusive.
( Y^> Pressure
Due to the gasser-criniper ' s limitation, the CO 2 injection pressure was niaxed at 150 psi to introduce the maximum amount of CO; into the headspace of the batter.
Length off /me of Gassing
This parameter was varied from 2 to 4 seconds. As the point of entry of the gas is through the wide-open 1-inch mouth of the can, there was no restriction in gassing and extending the length of time of gassing hardly increased the amount of CO2 injected (Tables 14. ! and 14.3)
Hei hispace of the ( "an
In any can, the lesser the product contained in the can, the higher the headspace available. For the 214x804 can, filling the can with 18oz of batter leaves about 40OmL headspace and filling it with 20oz reduced the headspace by about 10% (355ml). This is why 18oz filled cans can hold about 5.7g CO 2 while 20αz filled cans can hold about 5,Og CO 3 (Table 14 2)
( ηmping Pressure
This is the pressure that counters the CO^ or gassing pressure. Increasing the crimping pressure will prevent some of the CO? already situated in the headspace of the can from escaping. If this pressure is lower, some of the CO2 will evacuate the headspace until the countering crimp pressure is able to descend and fasten the valve on. the can (See Table 14 2 2 Qoz and table 14 4V
EXAMPLE 15.
It was observed that a sample gassed with COa was also suitable to make light and fluffy pancakes. Previously (see Example 1 ) it was observed that the dissolved CQj escaped the batter during the cooking process making the pancakes flat and thin Previously, the sample gassed w ith N? made better pancakes than the one gassed with CGj The Ni pressurized the can, but did not really get absorbed or mixed in the water/batter. The batter dispensed was therefore denser and made thicker, sponge-like pancakes similar in appearance and texture to normal pancakes By changing the recipe, including the water to powder ratio (43 % water by weight) and charging the can with more carbon dioxide (5,5 g) it has been possible to obtain light and fluffy pancakes and light and crispy waffles with the same mix The test candidate
preferred the light and fluffy pancakes over the denser pancakes raade with the nitrogen filled can and the older mix.
Process Parameters Product was prepared as shown in Table 15.1. Product was stored at under 4 0 C (40° F). Sampling occurred everyday for 14 days. On the 13 lh day the product had a sour taste, off flavor, odor and a foamy texture.
Product was prepared as shown in Table 15.2. Product was stored at under 4 °€ (40° F). Sampling occurred everyday for 14 days. On the 1 19 lh day the product did not have a sour taste, off flavor, odor and a foamy texture.
Conclusion: the temperature that the samples thai were packed at materially affects the integrity of the product when stored for long durations at beiow 40° F We speculate that the cold processing inhibits the transfer and or growth of bacteria prior to packaging in the cans.
Table 15.1 Process Preparation for integrity of storage study
-1 i 5 (overniuht no shaking) I — 1 15 {overnight no shaking)
EXAMPLE 16.
Product was prepared as shown in ' Table 16 1 Product was stored at under 4 0 C (40° F). 20 oz. Cans 567,0 g product and 5.5 g COj. Report from BETA Food Consulting, inc.
Following is a study conducting a microbiological challenge study on the revised formula of the aerosolized food product ( Table 16.1 ) The pH of the aerosol food product is approximately 6.57.5 and the water activity is 0.96.
Growth of Selected Spoilage and Pathogenic Organisms in an Aerosol food Product
Purpose
The purpose of the study is to determine the fate of selected spoilage and surrogates for pathogenic microbial agents when inoculated into an aerosolized food product. Outgrowth of lactic acid bacteria and Listeria monocytogenes was problematic in Example 4. For this reason, these organisms are studied in this formulation A surrogate organism (Listeria iiwocua) that is non-pathogenic will he used instead of L. monocytogenes to avoid potential contamination of facility.
Product Variable
The product to be studied is given in Table 16 j ■ . the variable addressed is the use of sodium lactate with CO;.
The intended shelf life is 45-60 days, minimum The study will assess stability for as long as 120 days.
Process
The batter temperature is 7 ° C (45 ° F) or below at the time of filling the cans. Empty cans will be disinfected per the process set-up, with chlorine at 50-200 pprn Filled cans will be removed from the line before installation of the gas valves. They will immediately be transported to the in-house laboratory for inoculation, before having the valve tops installed
and gas applied Finished cans will be stored and transported to Food Microbiological Laboratories by Kolimer in a refrigerated truck
Organisms The organisms for challenge should represent those of potential safetv and spoilage concern, as demonstialed in the pieύous study No mesopliiϊic spoie foπnei activity was noted in the prev ious study, indicating C botulinum should not be problematic
The test organism categories will include i Listeria innocua {non-pathogenic surrogate organism for L monocytogenes (gram positive non-spore former. ps\ chrotroph)
2 Lactobacillus fermentism, Lactobacillus plantarum (combined inoculum of gram positive non-spoie formers)
Culture Preparation
Lactic acid bacteria will be grown as a lawn on sterile MKS agar Listeria innocua will be giown on sterile trypticasc sov, agar with yeast extract Bacteria will be cultured foi 24 hows at 35 %"\ then streaked again on trypticase soy agar and incubated for 48 hours at 35 0 C lhe cells will be prepared by harvesting cells into sterile 0 1 % peptone water
Inoculum will be adjusted to deliver a target initial load of 103-104 cfu/g (minimum 590,000 cfulcan in each 20 ft αz can) Inoculation will be deiiv eied with a 1 ml inoculum volume The cans will be inoculated in the in-house laboratory at Kollmer Development on the R & D laboratory bench top capping unit that is i emote from the processing area and not used for production λ Food Safetv Solutions representative will assist with inoculation at the facility in Thousand Oaks, CA
Sixteen cans for each inoculum group will need to be prepared Sixteen Uninoculated control cans are also necessary The customer wi 11 be responsible foi adequate cleaning and samtizatiυn of the bench top filling unit Swabs of the bench, utensils, and rinsate from the valve application and gas charging unit will be collected after cleaning and sanitization is complete- The unit should not be used before results reflect inoculum organisms have been adequately ridded
Test Method
Test methods for quantitation will be per FDA-BAM or AOAC. The changes in loads for each inoculum group will be measured at each test interval. Testing will be done in duplicate Trend information about growth, death, or stasis will be available from the data
Test Inierva!
Test intervals will be spaced appropriately to represent a 120 day storage period. Testing will be conducted on inoculated variables at day 2, 30, 45, 60, 75, 90, 105 and 120. IJninoculated controls will be analyzed at 2, 45, 60, 75, 90, 105 and 120.
Uninoculated control samples will be analyzed to determine background spoilage flora response, and also for absence of Listeria inπocua. They will be analyzed for L. innocua, lactic acid bacteria, yeast, mesophilic aerobic plate count, and mesophilic anaerobic spore former counts.
Storage Conditions
Products will be stored at 4 0 C (40 - 41 0 F).
Product
The constituents of the Product to be tested are shown in Table 16.
Table J 6 J Product Constituents
The Pathogenic Organisms detected in a product spiked with the organism and tested after a given number of days is shown in Table 16.2. The Pathogenic Organisms detected in a control sample not spiked with the organism and tested after a given number of days is shown in Table 16.3.
Table 16.2 Pathogenic Organisms detected in spiked product
Table .16.3 Pathogenic Organisms detected in un spiked product
[Variable 1 Listeria Lactic jAerobie MesophilJc jControl genus/2: jacid jpiate anaerobic jbacteria jcouot spore former kcfa/g) Kcfu/g) count (ctu/g)
|Day 2 Negative 1280 ϊ30 <10
!Dav 2 Negative |290 1160 c !0
EXAMPLE 17. Viscosity Enabier Product was prepared in 20 oz cans, 567.0 g product and 5.5 g COi) or alternatively was a commercially available (Aunt jemima) batter prepared according to the directions. Both products were stored at under approximately 4 0 C (4O" F).
The batter needs to flow at a certain rate for an optimal product. Thus it needs a certain viscosity. In an embodiment of the invention, the CCb is used to insure that the product does not separate or degrade and the viscosity remains relatively stable as shown in Table 17.1.
EXAMPLE 18. Browning of Product
Product was prepared as shown in. Table 15 1 (20 oz cans 567.0 g product and 5 5 g CO>) or alternatively was a commercially available (Aunt Jemima) batter prepared according to the directions. Both products were stored at under approximately 4 0 C (40° F),
Figure 5 shows a waffle (!O) and a pancake (20) which were dispensed from a pressurized canister containing carbon dioxide, hi comparison, the same batter applied directly to the waffle iron (30) or frying pan (40) was baked for the same length of time at the same temperature. The carbon dioxide gas allows for the easy flow of the batter from the pressurized canister and also aerates the batter mix. Unexpectedly, the carbon dioxide results in a brownish appearance, crunchy texture and attractive taste to the food product. The carbon dioxide's attractive browning of the waffle or pancake thereby allows the food product to be baked more rapidly and efficiently. The carbon dioxide improves the taste experience of the person consuming the food product.
It is to be understood that other embodiments of the invention can be developed and fall within the spirit and scope of the invention and claims
Definition of Terms: (layton: Clayton Corporation; supplier of valves and caps.
Delivery Weigh?: the total amount of product sprayed after all the pressure in the can is exhausted Bakabk: including frying, steaming, toasting, boiling, grilling and cooking including cooking on a waffle iron, cooking on a frying pan and cooking in an oven.
Brownmg: refers to the color of the bakable food product upon baking and corresponds with the oxidation of one or more of the carbonaceous components in the composition.
IJghf uncf J- friffyr easily cut with a plastic, knife. Pancake or food product retains shape and form after being compressed. Does not require metal knife or excessive force to cut or slice food product. Food product is not heavy or dense and plastic knife does not permanently compress food product at a distance of 2 mm from the knife blade when cutting food product. Food product does not result in heavy feeling in stomach or other discomfort when eaten. See also sponge-like.
Propellam(s): compressed gas Carbon Dioxide (CO 2 ) or Nitrogen (H 2 ) or a combination of both
Resident Mu roorg<ιm\m: chief microbial flora 01 the microorganism normally costing in the product
Retention or Retention Weight: the amount of product remaining in the can after all the pressure in the can is exhausted
Sponge-like: having the characteristics of a sponge, bread with consistent size of air pockets as in sponge cake, a desirable characteristic of a pancake Spray RaU 1 : amount of product sprayed out of a can at a given amount of time, typically in grams per 1 second spray
Summit- Summit Packaging Systems, lnc , supplier of vaives and actuators Water: de-ionized isatβr
Next Patent: PATIENT INTERFACE AND HEADGEAR CONNECTOR