Edible laminated dough and edible lamination dispersion...

Food or edible material: processes – compositions – and products – Products per se – or processes of preparing or treating... – Basic ingredient is starch based batter – dough product – etc.

Reexamination Certificate

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C426S576000, C426S578000, C426S603000

Reexamination Certificate

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06248388

ABSTRACT:

The invention relates to an edible laminated dough and to an edible lamination dispersion therefor. Lamination dispersions are dispersions used 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 (pré-) 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 suitable 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 glycero 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 composition 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.
EP 284026 describes an oil-in-water emulsified fat composition which contains cheese and that is suitable for incorporation and folding into foods. The composition contains 20-85% fat. To obtain a good product the composition must contain 0.1-5% based on the fat of mono acyl glycerol phospholipid and 0.5-5% based on the cheese of “molten salts” (melting salts). The phospholipid emulsifier system is the same as that of EP 327120 described above. The use of melting salts is required to solubilize the protein contained in the cheese. Similar as for the products described in EP 327120 the incorporation of ingredients such as starch materials, gums and preservatives is dispreferred. The resulting product can be flowable and can e.g. be incorporated in cake. The use of more firm products of this type with higher fat content and lower water content for preparing puff pastry is described as well.
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 laminate doughs. The publication teaches that the fat-replacer should not be a protein-based fat-replacer because they do not have good rolling-out properties. The use of protein-based materials is also rejected because they fail to give the “fatty impression” expected of laminated baked goods and often have an off-taste.
EP 529891 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% Ca2+ 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. It is stated that the creme filling can also be used in preparing puff pastry in which a layer of filling is placed on a layer of rolled dough, the dough is folded over several times, rolled out and this process is repeated until numerous alternating dough filling layers are produced.
WO 94/28741 describes 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 dispersion do not have a sufficiently good performance in lamination and/or that the resulting baked laminated pr

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