Food or edible material: processes – compositions – and products – Products per se – or processes of preparing or treating... – Foam or foamable type
Reexamination Certificate
2000-04-13
2001-02-13
Bhat, Nina (Department: 1761)
Food or edible material: processes, compositions, and products
Products per se, or processes of preparing or treating...
Foam or foamable type
C426S566000, C426S587000, C426S588000, C426S515000, C426S519000, C426S524000
Reexamination Certificate
active
06187365
ABSTRACT:
FIELD OF THE INVENTION
The present invention is directed to a method for preparing a molded aerated frozen bar and to a molded aerated frozen bar obtainable from the method.
BACKGROUND OF THE INVENTION
Traditionally, molded aerated frozen bars are manufactured by partially freezing an ice cream mix, water ice mix, or fruit juice mix in conventional batch or continuous freezers followed by pumping and filling the mix into molds of different shapes and sizes. During the last decade, a new generation of freezers has been developed which are equipped with pre-whippers that enable the mix to be pre-aerated before being partially frozen in the freezer. The molded products are usually quiescently frozen using a cold brine system at −30° to −40° C. If desired, after demolding, the molded products may be coated with chocolate or compound coating. Finally, the products are usually packaged and stored at about −30° C. until transport and distribution.
This traditional process for manufacturing molded aerated frozen bars has limitations. For example, the partial freezing of the mix in the freezer, followed by quiescent freezing in the molds, leads to the formation of an icy texture, loss of air, and formation of large air cells in the product having a size range of about 110-185 microns (Arbuckle, W. S. Ice Cream, Fourth Edition, 1986, Van Nostrand Reinhold, N.Y. p 234). Additionally, shrinkage of the products is often a problem. Moreover, when eating the product, a very cold feeling in the mouth is experienced. Furthermore, it is difficult to achieve more than 20% overrun in water ice products and a typical overrun is from 0 to 20% and usually is about 5%. It is very difficult to achieve more than 80% overrun and almost impossible to achieve an overrun of 120% or higher in finished ice cream products using conventional manufacturing.
Currently, there is no process that can produce very finely aerated molded frozen bars (e.g., those having an average air cell size of less than 50 microns) that are smooth in texture, do not suffer from shrinkage, do not give a very cold feeling in the mouth, and have a uniform appearance without large air pockets on the surface. Moreover, no process can produce an overrun of more than 20% for water ice products and an overrun between about 80 to about 250% for ice cream products. The present invention provides a process and product which overcomes these disadvantages.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a process for the production of a molded aerated frozen bar comprising the steps of preparing a mix of ingredients suitable for preparing a frozen aerated bar, whipping the mix to obtain an aerated mix having an overrun of between about 20% to about 250%, molding the aerated mix to give a molded aerated mix, and freezing the molded aerated mix to form the molded aerated frozen bar. In this process, the mix can be an ice cream mix, a water ice mix, a fruit juice mix, a frozen yogurt mix, a sherbet mix, or a mixture thereof.
The mix of ingredients is typically prepared by combining the ingredients with shear mixing to disperse and solubilize them into a homogeneous mass, followed by homogenizing the mass and pasteurizing the homogenized mass. Also, the mix can be aged after pasteurization by storing at a temperature of from between about 0° C. to about 6° C. for between about 1 hour to about 24 hours. If desired, the mix can be colored and flavored before being aerating in a mixer at a temperature of between about 0° C. to about 12° C. to obtain the desired overrun. Preferably, the molding of the aerated mix is accomplished by directly feeding the aerated mix to a mold and freezing the aerated mix therein to produce the frozen molded bar, with the freezing being allowed to take place quiescently at a temperature between about −25° C. to about −45° C.
The invention also relates to a molded aerated frozen bar having an overrun of from between about 20% to about 250% and containing air cells having an average size of less than about 50 microns which cells are uniformly distributed throughout the bar and which are substantially invisible to the naked eye, the bar having a smooth texture similar to an extruded bar, warm eating quality and quick melt with substantially no lingering of product in the mouth.
The molded aerated frozen bar can be a water ice product having an overrun of from between about 25% to about 150% or a an ice cream product having an overrun of from between about 40% to about 200%. If desired, the product can contain inclusions or have a coating that optionally contains inclusions. Further, the molded aerated bar can be a shell and core products with ice cream as a core and ice water, fruit juice, fruit ice, real fruit, or a mixture thereof as a shell. The latter having an overrun of between about 0% to about 20%. Optionally, the molded aerated bar can have a coating or a compound coating.
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Sharkasi Tawfik Yousef
Vaghela Madansinh
Bhat Nina
Nestec S.A.
Pennie & Edmonds LLP
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