Food or edible material: processes – compositions – and products – Surface coated – fluid encapsulated – laminated solid... – Isolated whole seed – bean or nut – or material derived therefrom
Reexamination Certificate
2000-05-25
2001-04-17
Bhat, Nina (Department: 1761)
Food or edible material: processes, compositions, and products
Surface coated, fluid encapsulated, laminated solid...
Isolated whole seed, bean or nut, or material derived therefrom
C426S559000, C426S560000, C426S602000
Reexamination Certificate
active
06217920
ABSTRACT:
The invention relates to a process for preparing an edible laminated dough comprising combining a pre-dough with a lamination dispersion and subjecting the combination to rolling and folding to obtain a plurality of layers, wherein the lamination dispersion is a water continuous dispersion. It also relates to an edible lamination dispersion suitable for use in the process. Lamination dispersions are dispersions suitable for use in the preparation of laminated doughs, for example for making croissants, danish pastry and other laminated pastry, especially puff pastry. The typical lamination dispersion is a fat continuous product often having a dispersed aqueous phase, e.g. pastry shortening or margarine.
According to Bailey's Industrial Oil and Fat Products vol. 3 (1985), pp 109-110, puff pastry requires the use of a very specialized shortening. The fat is placed on top of the (pre-)dough and folded and rolled to form many alternating layers of dough and fat. The shortening has a tough waxy body over a wide temperature range. It must approximate the consistency of the dough to remain in a continuous unbroken layer as it stretches and becomes thinner. Puff pastry shortening almost always contains an aqueous phase. The fat keeps the layers of dough separate and flaky, and the moisture attributes the “puff” as it turns to steam during the baking process. Commonly 90% fat shortenings or 80% fat pastry margarines are used. For the preparation of other laminated doughs, similar types of lamination shortenings and margarines are used.
Lamination dispersions that do not have a continuous fat phase are known.
U.S. Pat. No. 5,190,776 discloses a low
o fat ingredient for use in producing laminated baked goods. It is prepared by mixing 40-70% cake crumbs, 9-30% sugar, 5-20% sugar syrup and 10-30% of a starch containing creme filling. The starch containing creme-filling consists of the same composition as this “low
o fat ingredient” but further includes flavouring ingredients such as flavours, spices and/or fruit material. The low
o fat ingredient has a moisture content of 2-20%, preferably 4-10%. Disadvantages of this ingredient are that it requires the availability and processing of cake crumbs and that it is very sweet. In view of the low moisture contents this ingredient will not have a continuous aqueous phase.
DOS 1442001 describes an O/W lamination dispersion. A purpose is to provide a product that can be prepared without the use of equipment required for making margarine or shortening. A further target is to avoid the use of high melting fats that can give a waxy mouthfeel to the baked product. The use of high melting fats is often required when using conventional margarine or shortening to obtain a proper consistency over a wide temperature range. The products illustrated in the examples consist of 75-82% fat, 16-21% water, 1.6-3.8% emulsifier and in some cases 0.08% carboxy methyl cellulose. The dispersion must have a firmness characterised by a minimum value for a parameter which is calculated from a given equation using data obtained with a cone-penetrometer.
EP 327 120 discloses oil-in-water type emulsions for lamination purposes (“rolling in”) comprising 2-20% protein, 30-75% fat, 18-65% water and 0,1-5% phospholipid. The primary objective of EP 327120 is to reduce the fat content of the lamination dispersion, for nutritional reasons. It is essential that at least 40% preferably at least 50% of the phospholipids are mono acyl glycerol phospholipids else a stable product cannot be obtained. The presence of 30% fat is required to be able to get satisfactory “rolling-in” properties. It is preferred not to include materials such as starches, gums and preservatives. The mono acyl glycero phospholipids preferably comprise substantially lyso phosphatidyl choline and may further contain lysophosphatidylethanolamine and a small amount of lyso phosphatidylinositol, lyso phosphatidic acid and lyso phosphatidylserine. A disadvantage of this lamination dispersion is that the preferred phospholipid compositions are not readily available while more generally phospholipid compositions with a substantial amount of mono acyl glycero phospholipid are very expensive. Furthermore, such compositions are in practice produced with the use of phospholipase obtained from swine pancreatic juice which makes the products unacceptable to people of Islamic or Jewish religion.
WO 94/21128 discloses the use of an aqueous gel containing 20-50% of amylodextrin and 0-30% of &bgr;-glucan and/or pentosans as a fat-replacer for making laminated doughs.
This document does not teach to apply a non-gelling component in combination with a gelling component. According to the example the composition contains amylodextrin (=gelling component) and 1.9% &bgr;-glucøn. However, &bgr;-glucøn applied in this amount is also a gelling component.
EP 529 891 discloses a particular fragmented, granular amylose starch hydrolysate that can be used as a fat-replacer in foods. Amongst many other applications, use of the hydrolysate to replace a portion of the shortening in layered pastry articles is envisaged.
U.S. Pat. No. 4,752,494 describes a creme filling based on an intermediate water activity matrix. The matrix comprises 30-80% corn syrup, 0-25% maltodextrin, 0-10% lactose, 1-15% caseinate, 0.01-0.10% Ca
2+
-ions, 0-15% water and optionally further ingredients like 0-10% polydextrose, 0-3% hydrocolloids and 0-5% modified starch. The matrix is heated to cause gelation of the caseinate under influence of the Ca
++
-ions. The filling is then produced by adding fats and emulsifiers which modify the texture and provide desirable mouthfeel, and flavourings. The filling has a water activity of 0.6 to 0.8. The creme filling has a soft creamy texture and is intended for use particularly in baked products e.g. puffed pastries, pie cookies and other filled baked products. The low water activity is required to prevent moisture migration between the filling and the baked dough and to prevent microbial growth.
WO 94/28741 and WO 95/26641 describe a low fat emulsion that can be substituted in 1 to 1 proportions for butter, margarine, shortening, oil, lard, cream cheese and other fats called for in many foods. Three formulae are given which are applicable for different types of foods. For high fat products e.g. croissants, the formula is 27% butter, 46% corn maltodextrin (DE 1-20), 6% rice maltodextrin (DE 1-20), 8 pregelatinized starch, 10.7% water and a range of minor additives. First the butter is creamed, then the other materials are mixed in. Then the product can be rolled into a croissant dough.
The use of lamination dispersions with a continuous aqueous phase offers many potential advantages, some of which have been described in the above publications. Yet, the proposed dispersions not based on a continuous fat phase have not found acceptance and are to the best of our knowledge, not commercially applied. A reason for this, in addition to disadvantages described above, we suspect is that the disclosed lamination dispersions do not have a sufficiently good performance in lamination and/or that the resulting baked laminated products do not have satisfactory sensoric properties such as structure, volume, appearance, taste and/or mouthfeel.
We have studied these issues and we have found that improved lamination dispersions with a continuous aqueous phase can be obtained. We have found amongst other things, that it is not essential to use mono acylglycero phospholipid to obtain a stable dispersion and that it is not necessary to include at least 30% oil or fat or 27% butter to get good lamination performance.
For other applications than lamination dispersions, the literature includes many suggestions for fat replacers. In most cases the proposals concern non-plastic and/or soft products such as desserts, creams and cremes, ice cream, mayonnaise, dressings, cheese spreads and other products for spreading on bread or toast. Examples of such publications are WO 93/17564, U.S. Pat. No. 5,169,671, EP 605 217, WO 94/2358
van Eendenburg Jacobus
Weisenborn Petronella Clementia Maria
Bhat Nina
Foley & Lardner
Pennant Foods Company
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