PROCESSES FOOD PRODUCTS AND METHODS FOR THEIR PREPARATION

TECHNOLOGICAL FIELD

[001] The present invention provides a solid processed food product that is ready to be consumed having a high deformation or melting temperature and processes for its preparation.

BACKGROUND OF THE INVENTION

[002] Chocolate has become one of the most popular food types and flavors in the world, and a vast number of foodstuffs involving chocolate have been created, particularly desserts. Chocolate is compelling to the human palate partly because cocoa butter, the natural fat of the bean, melts at just below body temperature, at around 33 °C to 34°C. This melting property of cocoa butter gives chocolate its distinctive mouth-feel. The cocoa butter does not dissolve by the saliva rather it lingers in the mouth as a paste, covering the taste buds thickly and evenly.

[003] In chocolate, the fat element forms the continuous phase in which all other ingredients are embedded. Therefore, the melting characteristics of the fat used are of importance to the stability of the chocolate, especially in warm climate areas. It is well known that when chocolate is exposed to heat and then cools, the fat crystals break apart. The chocolate "blooms": cocoa butter rises to the surface, creating a yellowish sheen or even a thick layer of fat. Although it is still edible, it is texture and look are not appealing.

[004] The addition of milk fat to make milk chocolate can soften the product and make it less heat resistant. Milk fat has a different crystalline form compared to cocoa butter, and the resulting incompatibility can lead to a destabilization of the product.

[005] In order to improve the heat resistance of solid fatty foodstuffs, like chocolate, manufacturers use processes like tempering and cooling or are trying to replace the amount of cocoa butter (i.e. the natural fat element of chocolate), wholly or in part, with replacements and equivalents (such as for example vegetable fats). Such products are either not heat resistant enough (having a melting point of below 36°C), have a displeasing taste and texture, and are not suitable for use as ingredients in making other foodstuffs.

[006] Therefore, there is still a need to create a heat stable chocolate and other foodstuffs that have high amount of natural fat in them, without changing the taste of the food product or the amount and source of fat therein.

SUMMARY OF THE INVENTION

[007] The present invention provides a processed food product comprising: (i) at least one lipid-based edible component having a melting point lower than 60°C; (ii) at least 0.5% weight of at least one thickening agent and (iii) at most 5% weight of water; wherein the processed food product is a freeze-dried, ready to consume product that melts or deforms above the melting point of said lipid-based component.

[008] The term "processed food product" as used herein should be understood to encompass any type of solid product that is intended to be consumed by an individual either as is or in combination with other food products that has been processed, i.e. it has been subjected to a process of manufacture involving modifications of its components so that it will be ready to consume. Such processes according to the present invention include but are not limited to the process of freeze-drying.

[009] The term "lipid-based edible component" should be understood to encompass a component that is suitable for consumption that comprises at least one lipid (fat or triglycerides) that is selected from saturated fats, non- saturated fats and any combinations thereof. Due to its lipid content said lipid-based edible component has a melting point (i.e. the component is liquefied, becomes liquid from its solid state) at a temperature of is lower than about 60°C. When referring to the melting point of the lipid-based edible component it should be understood that this melting point refers to the property of the component prior to its processing into the final processed food product of the invention.

[0010] In some embodiments, the melting point of said at least one lipid based edible component is lower than about 50°C. In some embodiments, the melting point of said at least one lipid based edible component is between about 30°C to 40°C. In some embodiments, the melting point of said at least one lipid based edible component is between about 25°C to 60°C.

[0011] In some embodiments, said at least one lipid-based edible component is selected from chocolate based component (for example chocolate liquor, cocoa butter and so forth), coconut based component, peanut based component, cocoa butter based component, hazelnut based component, sesame based component and any combinations thereof.

[0012] In some embodiments said lipid content is at least 25% of the edible component. In some other embodiments said lipid content is between about 30% to 70% of the edible component. In some other embodiments said lipid content is between about 50% to 100% of the edible component. In some further embodiments said lipid content is about 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100% of the edible component.

[0013] The term "thickening agent" should be understood to encompass any type of food grade thickening agent. Typically, such food grade thickening agents are based on either saccharides (including monosaccharides, Glucose (dextrose), Fructose (levulose or fruit sugar), Galactose, disaccharides, Sucrose, Lactose, Maltose, polysaccharides, starches, vegetable gums, and pectin), and/or proteins and any combinations thereof. Such agents include but are not limited to: (starched) arrowroot, cornstarch, katakuri starch, potato starch, sago, tapioca and their starch derivatives, (vegetable gums) alginin, guar gum, locust bean gum, and xanthan gum, (proteins) collagen, egg whites, and gelatin, (sugars) agar and carrageenan and any combinations thereof. Different thickeners may be suitable in each application, due to differences in taste, clarity, and their responses to chemical and physical conditions.

[0014] In some embodiments, said at least one thickening component is selected from a monosaccharide, oligosaccharide (for example disaccharides, like sugar), polysaccharide (for example starch, which can be either native, none-native, modified or processed starch and any combinations thereof) or any combinations thereof. In other embodiments, said at least one thickening component is starch. In yet further embodiments, said at least one thickening component is a mixture of starch and sugar. In some embodiments, said at least one thickening component is starch selected from potato starch, tapioca starch, rice starch, corn starch, wheat starch, maze starch, cassava starch, sweet potato starch or any combinations thereof.

[0015] In some embodiments, said at least one thickening agent is selected from a monosaccharide, an oligosaccharide, a polysaccharide, agar, gelatin, albumin and any combinations thereof. In other embodiments, said at least one thickening agent is starch. In further embodiments, said product of the invention comprises at least two thickening agents being a mixture of starch and sugar.

[0016] In some embodiments, said at least one thickening agent is at least about 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% of said processed product. In some embodiments, said at least one thickening agent is at least about 20% of said processed product. In some other embodiments, said at least one thickening agent is at least about 50% weight of said processed product. In some embodiments, said at least one thickening agent is between about 20% to about 70% weight of said processed product.

[0017] Said processed food product comprises, at most, 5% weight of water of the total weight % of the processed food product of the invention. Thus, said processed food product of the invention includes no more that 5% weight of water or alternatively, less than about 5% weight of water. In some embodiments, said processed food product comprises 2% of water. In other embodiments, said processed food product of the invention comprises 1% of water. In some further embodiments, said processed food product of the invention comprises between about 1% to about 5% weight of water. It is noted that the when referring to the property of water content of the processed food product, it relates to the property of the final processed food product of the invention.

[0018] In some embodiments, prior to the processing of said processed food product, the water content is between about 10% to about 80% weight of water. Upon processing (among other processes, freeze-drying of the components) of the components to achieve the processed food product of the invention, said water content decreases to the water content indicated herein above.

[0019] It is further defined that the processed food product of the present invention is "freeze - dried", therefore it is achieved by the process of freeze drying resulting in a solid form (see also "Lyophilization: Introduction and Basic Principles" Thomas A. Jennings, http://www.spscientific.com/freeze-drying-lyophilization-bas ics/,

http://www.foodnavigator.conVScience/Freeze-dryin^

nutrients-Study, https://www. foodnavigator.com/ Article/2016/11/14/Freeze-drying-fruit- is-top-technique-for-retaining-nutrients-Study, http://www.watershedfoods.com/our- products/freeze-driedsnacks.html. wherein the processed food product is a freeze-dried, ready to consume product that melts or deforms above the melting point of said lipid-based component.

[0020] Additionally, a processed food product of the present invention is defined to be a "ready to be consumed product", thus a product of the present invention does not have to be further prepared in any manner. It does not have to be cooked, rehydrated, steamed, mixed with a liquid (hot or cold), fried, microwaved or any other form of preparation. A product of the present invention is ready to be consumed by a subject as is, without any other additions or preparations. Thus, in some embodiments a processed food product of the invention is a chewable processed food product, consumed by eating it by said subject.

[0021] Furthermore, a processed food product of the present invention has a melting point or a deformation temperature (a temperature by which the form of the processed food product of the present invention is altered or loses its cohesiveness. Such alteration may include melting, incinerating, blooming, phase separating, changing its solid structure and firmness, losing its luster/shine/color, developing a crust, discoloring, and so forth including any combinations thereof) that is higher than the melting point of said lipid-based component.

[0022] In some embodiments, a processed food product of the invention melts or deforms at a temperature of at least above 60°C. In other embodiments, a processed food product of the invention melts or deforms at a temperature of at least above 80°C. In further embodiments, a processed food product of the invention melts or deforms at a temperature of at least above 100°C.

[0023] In some embodiments, a processed food product of the invention further comprises at least one edible oil component. In other embodiments, a processed food product of the invention further comprises at least one further edible lipid component. In some embodiments said at least one edible oil component is at least one vegetable oil (for example canola, sunflower oil, or olive oil). In other embodiments, said at least one edible oil component is at least one saturated or unsaturated fatty acid (for example from a vegetable origin or from animal fat origin) and any combinations thereof.

[0024] In yet other embodiments, a processed food product of the invention further comprises at least one flavoring agent. It should be noted that said flavoring agent relates to any type of edible substance added to a product of the invention (at any step of product preparation) that adds and/or alters and/or intensifies the flavor of a product of the invention through the sense of taste and/or smell. In some embodiments said at least one flavoring agent is a natural flavoring substance (i.e. flavoring substances obtained from plant or animal raw materials, by physical, microbiological or enzymatic processes), a nature- identical flavoring substance (i.e. flavoring substances that are obtained by synthesis or isolated through chemical processes, which are chemically and organoleptically identical to flavoring substances naturally present in products intended for human consumption) or an artificial flavoring substance (i.e. chemically produced flavoring substances that are typically chemically different from the corresponding natural flavoring substance however, in sensory characteristics are the same as natural ones), and any combination thereof.

[0025] In some embodiments, said at least one flavoring agent is selected from the group consisting of sugar, sugar substitutes, fructose, galactose, flavoring extracts, natural or artificial flavoring agents and any combinations thereof. In some embodiments, said at least one flavoring agent is selected from the group consisting of a sweetening agent (such as a sweetening saccharide, sugar, sugar substitutes), fructose, galactose, flavoring extracts (such as spices and herb flavors, including vanilla, cinnamon, nutmeg, cardamom and so forth; fruit flavors including banana, strawberry, berry, grape, orange, pineapple and so forth) and any combinations thereof.

[0026] In some embodiments, a processed food product of the invention further comprises at least one dairy component. In some embodiments, said at least one dairy component is at least 0.5% weight of said product.

[0027] In some embodiments, a processed food product of the invention, further comprising at least one further edible component. In some embodiments, a processed food product of the invention further comprises at least one food supplement or food additive, such as for example at least one nutritional supplement (minerals such as Mg, taurine and so forth), training beneficial supplements (such as for example creatine) and so forth.

[0028] In some embodiments, a processed food product of the invention is a non-dairy food product, thus it does not contain any dairy component.

[0029] In some other embodiments, a processed food product of the invention further comprises at least one solid edible component such as rice puffs, popcorn, ground coffee beans, and a like. Under these embodiments, said at least one solid component is between 5% to 25% weight of said product.

[0030] In some embodiments, said processed food product of the invention is a chewable food product.

[0031] In other embodiments, said processed food product of the invention is a non-dairy food product. In other embodiments, said processed food product of the invention is a dairy food product.

[0032] The invention further provides a foodstuff product comprising at least one processed food product as defined herein above and below. In further embodiments, said at least one processed food product of the invention forms the outer layer of a foodstuff product. In other embodiments, said at least one processed food product forms the inner part of a foodstuff product.

[0033] In yet another aspect, the invention provides a foodstuff product comprising at least two processed food products as defined herein above and below, which can be the same or different (said at least two processed food products, may be different by any element selected from said edible component, consistency of food product, flavoring agent, dairy component and so forth). In some embodiments, said at least two processed food products are layered. In some embodiments, said at least two processed food products are layered one on top of the other. In some embodiments, said at least two processed food products are mixed to form a single layer.

[0034] In another aspect the invention provides a method for the preparation of a processed food product as defined hereinabove, said method comprising the steps of: (a) providing at least one lipid based edible component comprising: (i) at least about 5% weight of fat and (ii) at least about 10% weight of water; (b) preparing a mixture of said at least one lipid based edible food component and at least one thickening agent; (c) freeze dry said mixture until water content is less than about 5% weight of the product; thereby producing a processed food product as defined in the preceding claims.

[0035] In some embodiments, a method of the invention further comprises adding at least one edible oil component to said mixture at step (b). In other embodiments, a method of the invention further comprises adding at least one further edible component to said mixture step (b). In other embodiments, a method of the invention further comprises adding at least one further solid edible component to said mixture step (b).

[0036] In another embodiment, said mixture formed in step (b) is casted into a mold prior to said freeze dry step (c). [0037] In other embodiments, said mixture of step (b) is frozen into droplets prior to said step (c).

[0038] In further embodiments, said mixture of step (b) is frozen prior to freeze dry step (c). In other embodiments, said freezing prior to step (c) is performed in an individual quick freeze process. In yet other embodiments, said freezing prior to step (c) is performed by directional freezing of said mixture. In yet further embodiments, said freezing prior to step (c) is performed by freezing while steering (like the processes used in ice-cream making).

[0039] In some embodiments, a method of the invention further comprises adding at least one emulsifier (such as for example lecithin or any other type of food grade emulsifier) or emulsifying agent to said mixture in step (b).

[0040] In some of embodiments, a method of the invention further comprises adding at least one antioxidative agent component (food grade) to said mixture in step (b).

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0041] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.

[0042] Example 1

[0043] The following ingredients were used in the preparation of a product of the present invention:

Water 400 gr

100% Chocolate 90 gr

Sugar 66 gr Palm oil 15 gr

Corn starch 10 gr

Ultratex 8 5 gr

Vanilla extract 4 gr

Salt 0.4 gr

Lecithin 1.3 gr

[0044] All ingredients were mixed and heated to a temperature of 80°C (176F) to melt the solids, activate the starch, and create a uniform thick blend. The warm mixture was poured into molds of desired shape/size, and frozen to -29°C (-20F). The frozen samples were transferred to a freeze dryer. The samples are freeze dried in the molds or demolded into a tray. The freeze-drying process was performed for a period of between 16 to 24 hours with temperature starting at -29°C (-20F), and slowly ramping up to 36°C (96F), under vacuum. The product produced included 32% fat content. The product did not show signs of deformity or melting when exposed to 90°C for 30 minutes.

[0045] While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those of ordinary skill in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.