Friday, May 16, 2014 9:47:48 AM
**********CRRA: BOOOOOOOOOM UPDATE 5/16 DD*************
"Capital Resource Alliance, Inc. Announces LOI to Acquire Nate’s Pancakes"
Nate’s Pancakes make ready-to-use, pre-mixed pancake and waffle batter delivered in a pressurized can. Our pre-made batter makes light and airy pancakes or waffles that are fun for the entire family to make together, and are a great way to start your day. Nate’s Pancakes was created by Nate Steck who also created Batter Blaster which sold nearly 2 million cans and exceed $15-20 Million dollars a year in revenue
http://www.natespancakes.com
61M Shares Outstanding
Holladay Stock Transfer
Transfer Agent
2939 N. 67th Place
Scottsdale, AZ 85251
480-481-3940
IR response 1: LINK FROM IR
Articles:
CNNMONEY: "It's pancakes. In a can. It's made $15 million."
COMPANY'S STORY
WALMART ARTICLE:
AWARDS:
The CPG Awards for Innovation and Creativity were presented to General Mills and Batter Blaster by the Grocery Manufacturers Association and its Associate Member Council at GMA’s Executive Conference Monday. “Both winners demonstrated a unique execution of originality and resourcefulness that benefits not only the demand of the consumers, but the industry as a whole,” said AMC Chairman Gregory Smith, global lead partner of KPMG, in a statement.
Read More: http://supermarketnews.com/latest-news/general-mills-batter-blaster-win-gma-awards#ixzz31ocqdu2L
CBS NEWS:
REGIS & KELLY:
FOOD NETWORK:
PBS SPECIAL ON THE COMPANY
THE TODAY SHOW KATHY LEE STARTS 4:50
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http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PALL&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.htm&r=1&f=G&l=50&s1=8,147,893.PN.&OS=PN/8,147,893&RS=PN/8,147,893
Parent Case Text
PRIORITY CLAIM
The present application claims the benefit of priority under 35 U.S.C. .sctn.119(e) to U.S. Provisional Patent Application No. 60/812,674, entitled "REFRIGERATOR STABLE PRESSURIZED BAKING BATTER", inventors: Sean Francis O'Connor and Nathan Steck, filed Jun. 9, 2006, which application is incorporated herein by reference.
Claims
What is claimed is:
1. A method of preparing a batter for a bakable food product comprising; (a) selecting a plurality of dry ingredients wherein the dry ingredients include flour, sugar, and egg powder and blending said plurality of dry ingredients at a temperature at or below 4.degree. C.; (b) adding water at a temperature between approximately 1.degree. C. and 3.degree. C. to the dry ingredients to form a batter wherein the water is no less than 40.5% by weight and no greater than 52.5% by weight of the batter; (c) loading the batter into a dispenser at a temperature at or below 4.degree. C.; (d) sealing the batter into the dispenser; (e) using carbon dioxide gas to pressurize the dispenser such that the batter has a viscosity between approximately 12000 cP and approximately 14000 cP.
2. The method of claim 1, wherein the batter has a pH of approximately 6.
3. The method of claim 1, wherein the batter has a water activity of approximately 0.96.
Description
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.RTM., a thick sauce product made by Kraft Foods.RTM..
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 INVENTION
Although a number of inventors have proposed bakable 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.
In 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 to 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 preservation 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 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. 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 application contains at least one drawing or photograph executed in color. Copies of this patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
This invention is described with respect to specific embodiments thereof. Additional aspects can be appreciated from the Figures in which:
FIG. 1 shows a flow chart outlining the steps involved in preparing the batter for dispensing;
FIG. 2 shows the change in pressure in un-pressurized cans (Dots--0.15% sorbates, no N.sub.2 cap; Vertical Lines--0.15% sorbates, N.sub.2 cap; Horizontal Lines--0.15% sorbates, 1.0% lactic acid, no N.sub.2 cap; Black--0.15% sorbates, 1.0% lactic acid, N.sub.2 cap);
FIG. 3 shows the change in pressure in CO.sub.2 pressurized cans (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% 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--1.0% sorbates, 0.5% lactic acid; White--1.0% sorbates, 1.0% lactic acid);
FIG. 4 shows the change in pressure in N.sub.2 pressurized cans (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% 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--1.0% sorbates, 0.5 lactic acid; White--1.0% sorbates, 1.0% lactic acid); and
FIG. 5 shows a comparison between waffles (10 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).
FIG. 6 is a color photograph which shows a comparison between waffles (10 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. In 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. In an embodiment of the present invention, the pressurized gasses are a mixture of N.sub.2 and CO.sub.2. In an alternative embodiment of the invention, the pressurized gas is 100% CO.sub.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, FIG. 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 sealable 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 carried out in an inert atmosphere. In an embodiment of the present invention, steps 10-14 are carried out at between 32-48.degree. F. In an alternative embodiment of the present invention, steps 12-14 are carried out at between 38-44.degree. 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, dicalcium phosphate dihydrate, xanthan gum, cultured dextrose and water. This recipe is mixed by blending all the dry ingredients, adding water at approximately 1.degree. C. (34.degree. F.) to the cultured dextrose 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.degree. C. (40.degree. 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 alternative embodiment of the invention, the ingredients are 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 1.degree. C. (34.degree. 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.degree. C. (41.degree. 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% CO.sub.2) 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 (100% CO.sub.2) 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-US-00001 TABLE 1.0 Nutritional Analysis per 100 g Calories 130 cal Fat Calories 10 cal Sat Fat Calories 0 cal Total Fat 1 g Saturated Fat 0 g Stearic Acid 0 g Trans Fatty Acids 0 g Polyunsaturated Fat 0 g Omega 6 0 g Omega 3 0 g Monounsaturated Fat 0 g Cholesterol 15 mg Sodium 160 mg Potassium 0 g Total Carbohydrate 28 g Dietary Fiber 4 g Soluble Fiber 0 g Insoluble Fiber 0 g Sugars 4 g Sugar Alcohol 0 g Other Carbohydrate 20 g Protein 4 g Vitamin A 0% DV Vitamin A (RE) RE Vitamin C 0% DV Calcium 2% DV Iron 10% DV Vitamin D 0% DV Vitamin E 0% DV Vitamin K 0% DV Thiamin 0% DV Riboflavin 0% DV Niacin 0% DV Vitamin B6 0% DV Folate 0% DV Vitamin B12 0% DV Biotin 0% DV Pantothenic Acid 0% DV Phosphorous 0% DV Iodine 0% DV Magnesium 0% DV Selenium 0% DV Copper 0% DV Manganese 0% DV Chromium 0% DV Molybdenum 0% DV Chloride 0% DV
Processing Procedure
In 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.degree. C. (34.degree. F.) 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.degree. C. (40.degree. 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. In 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.degree. C. (136-142.degree. 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.
Cold 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.degree. C. (50.degree. F.). In an alternative embodiment of the present invention, the batter temperature can be controlled to not exceed approximately 4.degree. C. (40.degree. F.). In an embodiment of the present invention, in a jacketed mixing tank the water coolant can be introduced at approximately 1.+-.2.degree. C. (34.+-.2.degree. 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 can 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.degree. C. (40.degree. 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 invention, sodium lactate (below approximately 1%) can be added to the water prior to agitation with the dry mix to minimize `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 ensure 120 day refrigerated `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 ensure 120 day refrigerated `shelf life`.
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 60% 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.
In 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 higher levels of gluten and as a result requires more water. In contrast, pastry flour has lower levels of gluten, which requires less 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. In an embodiment of the invention, there are 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. In 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.degree. C. (40.+-.2.degree. F.). In an embodiment of the present invention, the water to be added to the dry mix can be provided with approximately 0.1% potassium sorbate and approximately 0.05% sorbic acid (by weight).
In an embodiment of the present invention, an amount of potassium sorbate controls the growth of yeast and mold to keep the product stable. In an embodiment of the present invention, sodium lactate controls the growth of yeast, mold, lactic acid bacteria and L. monocytogenes to keep the product stable. In an embodiment of the present invention, an amount of cultured dextrose controls the growth of yeast 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.degree. C. (40.+-.2.degree. F.).
In an embodiment of the present invention, batter can be pumped to a jacketed holding vessel, where the batter temperature is not allowed to exceed 4.+-.2.degree. C. (40.+-.2.degree. 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, sanitized 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 valved with tilt valve 2.times.0.0022 or vertical action valve 2.times.0.033.times.0.090 valves and the cans can be crimped and gassed to approximately 150.+-.3 psi. Cans can be tipped, capped, packed and stored in cold storage at 4.+-.2.degree. C. (40.+-.2.degree. F.).
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 provides 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.sub.2) and carbon dioxide (C0.sub.2) mixed in a ratio of approximately 10% N.sub.2 and approximately 90% C0.sub.2 by weight, pressurized at 150 pounds per square inch (psi). For a pancake mix, the gas can be N.sub.2 and C0.sub.2 mixed in a ratio of approximately 50% each gas by weight. For a cup cake mix, the gas can be N.sub.2 and C0.sub.2 mixed in a ratio of approximately 55% N.sub.2 and approximately 45% C0.sub.2 by weight. For a brownie mix, the gas can be N.sub.2 and C0.sub.2 mixed in a ratio of approximately 85% N.sub.2 and approximately 15% C0.sub.2 by weight.
In an alternative embodiment of the invention, if the batter is to be used as a waffle mix, the gas can be 100% carbon dioxide (CO.sub.2), pressurized at 150 pounds per square inch (psi).
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 (C0.sub.2). C0.sub.2 is a water miscible or soluble gas. After sealing the can, the pressure drops considerably (up to approximately 40%) after canning because the CO.sub.2 dissolves into the mixed batter in the can. For a waffle mix where the gas is 90% C0.sub.2 this can have a significant impact on the final pressure. For a pancake mix, the gas composition can include both nitrogen (N.sub.2) and C0.sub.2. In contrast, to C0.sub.2, N.sub.2 is largely a non water-soluble gas. When N.sub.2 and C0.sub.2 are mixed in a ratio range of approximately 90% nitrogen and approximately 10% carbon dioxide to approximately 80% nitrogen and approximately 20% carbon dioxide, the N.sub.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 C0.sub.2, this combination gives sufficient gas emulsification 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 bakable 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, heating in a gas convection oven, heating in a microwave oven and heating in a toaster.
Example 1
Aim: to determine an acceptable pancake powder mix to water ratio; and determine suitable propellant(s) to make an aerosol packaged pancake batter.
Mix: 50/50 Elite Spice Pancake Mix/DI Water (.about.50.degree. C.; .about.120.degree. F.); Preservatives (0.05% potassium sorbate and 0.05% sorbic acid); Fill: 16 oz; can: 214.times.804, 3-piece, lined; Propellants Tested: (i) 5 g Carbon Dioxide (CO.sub.2), (ii) 2.8 g Nitrogen (N.sub.2).
TABLE-US-00002 TABLE 1.1 Cook Test Results on the Aerosol Packaged Batter Amount Dispensed, g Appearance of Pancakes Samples gassed with 5.0 g CO.sub.2 32 thinner pancakes Samples gassed with 2.8 g N.sub.2 58 thicker, "sponge-like" pancakes
Although different amounts of batter were dispensed with the different propellants (see Tables 1.1 and 1.2), the samples made similar diameter pancakes. This is due to the CO.sub.2 dissolved (in water) in the CO.sub.2 sample that gave the batter more volume.
TABLE-US-00003 TABLE 1.2 Spray Rates of Aerosol Packaged Batter Pressure after 17 days, psi Spray Rate, g/s Samples gassed with 5.0 g CO.sub.2 45 psi 10.8 Samples gassed with 2.8 g N.sub.2 95 psi 12.0
Initial tests showed that the ratio of 50/50 Elite Spice powder mix-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 CO.sub.2 was more suitable to make waffles. The waffles produced were light and crispy. Because CO.sub.2 is more soluble in water than N.sub.2, the batter dispensed from the CO.sub.2-gassed sample had dissolved CO.sub.2 in it. When cooked in the waffle iron, the CO.sub.2 escaped making the waffle light, thin and crispy. When this sample was used to make pancakes, the dissolved CO.sub.2 escaped the batter during the cooking process making the pancakes flat and thin. The sample gassed with N.sub.2 made better pancakes than the one gassed with CO.sub.2. The N.sub.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 flat ones. Summary of trial: samples gassed with CO.sub.2 made good waffles; samples gassed with N.sub.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 214.times.804 can; filled at 16 oz; gassed with 3.9 g N.sub.2 at 130 psi; (ii) 45 powder mix/55 water; in 205.times.604 can; filled at 4 oz; gassed with 2.7 g N.sub.2 at 130 psi; and (iii) 40 powder mix/60 water; in 214.times.804 can; filled at 12 oz; gassed with 4.6 N.sub.2 at 130 psi. Additionally, the following samples were prepared for test candidate testing: (iv) 50 powder mix/50 water; gassed with CO.sub.2; (v) 47.5 powder mix/52.5 water; gassed with N.sub.2.
Results
As in Example 1, sample (iv) that was 50/50 and gassed with CO.sub.2 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.sub.2 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 N.sub.2. Test candidate test result: sample (iv) 50/50 with CO.sub.2--good for waffles; sample (v) 47.5/52.5 with N.sub.2--good for pancakes.
TABLE-US-00004 TABLE 2.1 Cook Test Results on N.sub.2-Pressured Pancake Batter with Varying Powder Mix-to-Water Ratio. Powder Mix-to- Fill, Water ratio Can oz Propellant Results 50/50 214 .times. 804 16 3.9 g N.sub.2 gassed batter was dense; the at 130 psi pancakes were sponge- like as typical pancakes 45/55 205 .times. 604 4 2.7 g N.sub.2 gassed batter was less dense; at 130 psi cooked pancakes looked like typical pancakes (sponge-like with bigger air pockets) 40/60 214 .times. 804 12 4.6 g N.sub.2 gassed batter was thin and at 130 psi runny
Example 3
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 acid and 0.10% potassium sorbate; (ii) 0.10% sorbic acid and 0.20% potassium sorbate. Additional preservatives: EDTA, sodium benzoate, methyl paraben, propyl paraben and lactic acid. All the samples were aseptically prepared. One set of vials were was capped with N.sub.2 and one set was not. All the vials were stored in the dark at room temperature for 1 week.
Results
The evaluation of the samples was limited to visual and olfactory testing. Based on these results, no preservative was suitable for the required batter 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 batter mixture can require an emulsifier or a suspending agent. The pressure build-up can have been due to: generation of CO.sub.2 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-US-00005 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 Additional Preservatives Air Headspace N.sub.2 Headspace None no phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk odor 200 ppm EDTA beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 500 ppm EDTA no phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk odor 0.10% Na Benzoate beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 0.025% Methyl beginning of phase beginning of phase Paraben separation separation 0.075% Propyl pressure build-up pressure build-up Paraben sour milk odor sour milk odor masked by paraben odor 0.50% Lactic Acid phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk, rancid, off odor 1.00% Lactic Acid phase beginning of phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor
TABLE-US-00006 TABLE 3.2 Preservative Test Results on Pancake Batter in Glass Vials with 0.10% Sorbic Acid and 0.20% Potassium Sorbate After 170 Hrs. Additional Preservatives Air Headspace N.sub.2 Headspace None beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 200 ppm EDTA beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 500 ppm EDTA no phase beginning of phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 0.10% Na Benzoate beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 0.025% Methyl phase separation no phase separation Paraben pressure build-up pressure build-up 0.075% Propyl sour milk odor sour milk odor Paraben masked by masked by paraben odor paraben odor 0.50% Lactic Acid phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk odor 1.00% Lactic Acid phase beginning of phase separation separation pressure build-up pressure build-up no off odor sour milk 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.
Propellants: (i) None; (ii) CO.sub.2; (iii) N.sub.2. Fill: 8 oz. Hot process, 50.degree. C. (120.degree. F.) DI water+Elite Spice pancake mix. Preservative trials:
1. Un-pressurized crimped 205.times.604 3-pc steel, EP coated cans with
a. 0.05% sorbic acid and 0.10% potassium sorbate combo b. 0.05% sorbic acid and 0.10% potassium sorbate combo with N.sub.2 cap c. 0.05% sorbic acid and 0.10% potassium sorbate combo+1.00% lactic acid (88%) d. 0.05% sorbic acid and 0.10% potassium sorbate combo+1.00% lactic acid (88%) with N.sub.2 cap 2. Pressurized crimped 205.times.604 3-pc steel, EP coated cans with a. 1.0% sorbates (combination of 0.40% sorbic acid and 0.60% potassium sorbate) b. a+200 ppm EDTA c. a+500 ppm EDTA d. a+0.1% sodium benzoate e. a+0.075% propyl paraben+0.025% methyl paraben f. a+0.5% lactic acid (88%) g. 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.sub.2 Cap; Horizontal Lines--0.15% sorbates, 1.0% lactic, no N.sub.2 Cap) and N.sub.2-pressurized samples (Vertical Lines--0.15% sorbates, N.sub.2 Cap; Black--0.15% sorbates, 1.0% lactic acid, N.sub.2 Cap) after 60 days. On the contrary, CO.sub.2-pressurized samples dropped in pressure in the same time frame (Tables 4.1 and 4.2 and FIG. 3). The pressure build-up was more pronounced in the un-pressurized samples (FIG. 2; .about.40 psi average after 60 days) than in the N.sub.2-pressurized samples (.about.13 psi average after 60 days) (FIG. 4). And for the un-pressurized set, the samples with sorbates only (Dots--0.15% sorbates, no N.sub.2 Cap) result in more than double the final pressure compared to the sample with sorbates+lactic acid preservative system (Horizontal Lines--0.15% sorbates, 1.0% lactic, no N.sub.2 Cap) (FIG. 2).
For the samples pressurized with CO.sub.2 (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% 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--1.0% sorbates, 0.5% lactic acid; White--1.0% sorbates, 1.0% lactic acid), the average pressure drop after 60 days was about 29 psi (FIG. 3).
As discussed in Example 3, the probable causes for the build up of pressure in the un-pressurized and N.sub.2 pressurized cans can have been (i) evolution of CO.sub.2 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 ethanol and CO.sub.2. Some of the CO.sub.2 is released to the headspace of the can. However, a portion of the CO.sub.2 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 cause the sodium bicarbonate to release further CO.sub.2.
The CO.sub.2 due to microbial activity or bicarbonate decomposition in the un-pressurized cans produced the headspace pressure (FIG. 2). But when the headspace of the can already had a positive pressure as in the N.sub.2 pressurized samples (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% Sorbates 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--1.0% sorbates, 0.5% lactic acid; White--1.0% sorbates, 1.0% lactic acid) (FIG. 4), the production of CO.sub.2 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.sub.2-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 (FIGS. 2 and 4). Although the lactic acid efficacy cannot completely offset the bicarbonate decomposition due to acidity, it was significantly better as a preservative, in combination with sorbates, than the other preservative systems used.
The CO.sub.2-pressurized cans exhibited reversed results and the pressure decreased after 60 days (FIG. 3). One explanation is that some of the CO.sub.2 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.sub.2 generation in these samples cannot have been enough to overcome the amount of CO.sub.2 dissolved in the sample. Therefore, the pressure effects of CO.sub.2 dissolution were more evident than the effects of CO.sub.2 generation. Alternatively, the CO.sub.2 can have natural anti-microbial action which impeded or slowed down microorganism growth. For fermentation, the CO.sub.2 injected can have saturated the system retarding further CO.sub.2 production from yeast. For aerobic microorganisms, CO.sub.2 made the environment undesirable for microbial growth.
TABLE-US-00007 TABLE 4.1 Pressure Build-up in Un-Pressurized Cans Can Pressure, psi Preservative System N.sub.2 Cap 12 Hrs 48 Hrs 1440 Hrs 0.15% sorbates no 0.5-1.0 ~1.0 37 0.15% sorbates yes ~1.0 ~1.0 42 0.15% sorbates + no ~1.0 ~2.0 16 1.00% lactic acid 0.15% sorbates + yes ~1.0 ~2.0 16 1.00% lactic acid
TABLE-US-00008 TABLE 4.2 Pressure Changes in Pressurized Cans Pressure, psi 0 Hrs 72 Hrs 1440 Hrs CO.sub.2- N.sub.2- CO.sub.2- N.sub.2- CO.sub.2- N.sub.2- Preservative pressur- pressur- pressur- pressur- pressur- pressur- System ized* ized* ized ized ized ized 1.0% sorbates** 126 107 115 109 100 121 1.0% sorbates + 120 105 111 106 96 120 200 ppm EDTA 1.0% sorbates + 118 112 109 112 87 126 500 ppm EDTA 1.0% sorbates + 122 107 112 107 93 122 0.10% sodium benzoate 1.0% sorbates + 122 107 112 107 89 120 0.075% propyl paraben + 0.025% methyl paraben 1.0% sorbates + 121 107 112 107 92 117 0.5% lactic acid 1.0% sorbates + 122 105 114 106 91** 111 1.0% lactic acid *Amount of propellant used: ~3.30 g CO.sub.2 and ~1.70 g N.sub.2 **1.0% sorbates is a combination of 0.4% sorbic acid and 0.6% potassium sorbate
Example 5
Aim: to study the pressure changes in the can pressurized with 50/50 CO.sub.2/N.sub.2 as a follow-up to Example 4.
TABLE-US-00009 TABLE 5.1 Sample* Description for the Pressure Build-Up test on Cans Pressurized with 50/50 CO.sub.2/N.sub.2 Combo. Sample Fill, Code Formula Propellant oz 06-023 Waffle formula (50/50 CO.sub.2/N.sub.2) 18 50.0% Water 2 g CO.sub.2 followed 49.5% Elite Spice with powder mix (lot 2- 2 g N.sub.2 @ ~120 psi 27601) Total 4 g 0.5% Guardian CS1-50 (cultured dextrose) 06-024 Pancake formula (50/50 CO.sub.2/N.sub.2) 18 52.5% Water 2 g CO.sub.2 followed 47.0% Elite Spice with powder mix (lot 2- 2 g N.sub.2 @ ~120 psi 27601) Total 4 g 0.5% Guardian CS1-50 *Samples were stored at room temp for the duration of the study.
TABLE-US-00010 TABLE 5.2 Pressure Changes in Cans Pressurized with 50/50 CO.sub.2/N.sub.2 Combo Pressure, psi .DELTA. Sample Code 2 Hrs 72 Hrs 264 Hrs 400 Hrs 1700 Hrs Pressure 06-023 110 109 109 109 121 +11 06-024 109 108 107 107 118 +9 *For Time 0, the pressure reading was taken ~2 to 3 hours after the samples were made
Results
The pressure build up was similar to the N.sub.2-pressurized samples in Example 4 (see FIG. 4 (1.0% sorbates, 0.5% lactic acid), but the amount of product in the cans was increased in this trial. Some of the injected CO.sub.2 dissolved in the water but more CO.sub.2 (or other gaseous microorganism byproducts) can be generated, causing the pressure increase.
Example 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/DI Water. Screw cap glass vials. Primary Preservatives used: MG510 gassed with CO.sub.2 CS1-50 gassed with CO.sub.2 MG510 gassed with N.sub.2 CS1-50 gassed with N.sub.2
TABLE-US-00011 TABLE 6.1 Parameters of the micro-study Batch 1 Batch 2 (Pancake) 50/50 (Pancake) 47.5/52.5 Elite Spice powder Elite Spice powder mix/Water mix/Water Preservative (Cultured Microgard 510 Guardian CS1-50 Dextrose Maltodextrin) (MG510) (lot# FS-102) (lot# 510-425301) Preservative Dosage 0.75% 0.50% Fill 18.3 oz 18.3 oz Can 214 .times. 804 214 .times. 804 Temp of finished batch 65.degree. F. 55.degree. F. Nitrogen cap No yes Codes V1, V3 V2, V4
Inoculants: Y--yeast LAB--lactic acid bacteria SA--Staphylococcus aureus LM--Listeria monocytogenes BC--Bacillus cereus 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 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 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 the facility. Listeria innocua will be used instead.
Product Variables
The product variables to be studied include: 1) MicroGard 510 with CO.sub.2 (waffle) 2) MicroGard CS150 with CO.sub.2 (waffle) 3) MicroGard 510 with N.sub.2 (pancake) 4) MicroGard CS150 with N.sub.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 4.0.degree. C. (40.degree. F.). Finished cans were stored for 1.5 days and transported in a refrigerated truck.
Organisms
The organisms for challenge represented those of potential safety and spoilage concern. The only pathogen of potential concern that was not represented was C. botulinum. The test organism categories included: Bacillus cereus (gram positive spore former, thermo labile toxin) Staphylococcus aureus (gram positive non-spore former, thermo stable toxin) Listeria monocytogenes (gram positive non-spore former, psychrotroph) Zygosaccharomyces rouxii (yeast) Lactobacillus formentum, Lactobacillus plantarum (combined inoculum of gram positive non-spore formers). Culture Preparation
Lactic acid bacteria was grown in sterile MRS broth. Other bacteria were grown in sterile trypticase soy broth. Yeast extract was added for the L. monocytogenes culture. Bacteria were cultured for 24 hours at 35.degree. C., then streaked on trypticase soy agar and incubated for 48 hours at 35.degree. C. Yeast were cultured for 5 days at 24.degree. 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 10.sup.3-10.sup.4 cfu/g (minimum 590,000 cfu/can in each 20 fl. oz. can). Inoculation was delivered with a 1 mL inoculum volume. The 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 representative conducted the inoculation.
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 sanitization was complete to determine adequacy of cleaning. The unit was not used before results were available.
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 Interval
Test intervals were spaced appropriately to represent the 105 day storage period. Testing was conducted on inoculated variables 1, 2, and 4 at day 2, 15, 30, 45, 60, 75, 90, and 105. Testing for inoculated variable 3 was conducted at day 2, 15, 30, and 45. Later test intervals for variable 3 were discontinued because inoculum loads significantly increased. Uninoculated controls were analyzed after 2 and 105 for variables 1 and 2. An additional 45 day test interval was added for variables 3 and 4 to determine midpoint shifts in background flora levels.
Uninoculated control samples were analyzed for B. cereus, S. aureus, L. monocytogenes, lactic acid bacteria, yeast, mesophilic aerobic plate count, and mesophilic anaerobic spore former counts.
Storage Conditions
Products stored at 4.degree. C. (40.degree. F.).
The pathogenic organisms detected in the product after 2-105 days are shown in Tables 6.2-6.9.
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Nate’s Pancakes make ready-to-use, pre-mixed pancake and waffle batter delivered in a pressurized can. Our pre-made batter makes light and airy pancakes or waffles that are fun for the entire family to make together, and are a great way to start your day. Nate’s Pancakes was created by Nate Steck who also created Batter Blaster which sold nearly 2 million cans and exceed $15-20 Million dollars a year in revenue
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Parent Case Text
PRIORITY CLAIM
The present application claims the benefit of priority under 35 U.S.C. .sctn.119(e) to U.S. Provisional Patent Application No. 60/812,674, entitled "REFRIGERATOR STABLE PRESSURIZED BAKING BATTER", inventors: Sean Francis O'Connor and Nathan Steck, filed Jun. 9, 2006, which application is incorporated herein by reference.
Claims
What is claimed is:
1. A method of preparing a batter for a bakable food product comprising; (a) selecting a plurality of dry ingredients wherein the dry ingredients include flour, sugar, and egg powder and blending said plurality of dry ingredients at a temperature at or below 4.degree. C.; (b) adding water at a temperature between approximately 1.degree. C. and 3.degree. C. to the dry ingredients to form a batter wherein the water is no less than 40.5% by weight and no greater than 52.5% by weight of the batter; (c) loading the batter into a dispenser at a temperature at or below 4.degree. C.; (d) sealing the batter into the dispenser; (e) using carbon dioxide gas to pressurize the dispenser such that the batter has a viscosity between approximately 12000 cP and approximately 14000 cP.
2. The method of claim 1, wherein the batter has a pH of approximately 6.
3. The method of claim 1, wherein the batter has a water activity of approximately 0.96.
Description
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.RTM., a thick sauce product made by Kraft Foods.RTM..
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 INVENTION
Although a number of inventors have proposed bakable 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.
In 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 to 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 preservation 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 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. 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 application contains at least one drawing or photograph executed in color. Copies of this patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
This invention is described with respect to specific embodiments thereof. Additional aspects can be appreciated from the Figures in which:
FIG. 1 shows a flow chart outlining the steps involved in preparing the batter for dispensing;
FIG. 2 shows the change in pressure in un-pressurized cans (Dots--0.15% sorbates, no N.sub.2 cap; Vertical Lines--0.15% sorbates, N.sub.2 cap; Horizontal Lines--0.15% sorbates, 1.0% lactic acid, no N.sub.2 cap; Black--0.15% sorbates, 1.0% lactic acid, N.sub.2 cap);
FIG. 3 shows the change in pressure in CO.sub.2 pressurized cans (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% 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--1.0% sorbates, 0.5% lactic acid; White--1.0% sorbates, 1.0% lactic acid);
FIG. 4 shows the change in pressure in N.sub.2 pressurized cans (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% 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--1.0% sorbates, 0.5 lactic acid; White--1.0% sorbates, 1.0% lactic acid); and
FIG. 5 shows a comparison between waffles (10 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).
FIG. 6 is a color photograph which shows a comparison between waffles (10 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. In 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. In an embodiment of the present invention, the pressurized gasses are a mixture of N.sub.2 and CO.sub.2. In an alternative embodiment of the invention, the pressurized gas is 100% CO.sub.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, FIG. 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 sealable 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 carried out in an inert atmosphere. In an embodiment of the present invention, steps 10-14 are carried out at between 32-48.degree. F. In an alternative embodiment of the present invention, steps 12-14 are carried out at between 38-44.degree. 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, dicalcium phosphate dihydrate, xanthan gum, cultured dextrose and water. This recipe is mixed by blending all the dry ingredients, adding water at approximately 1.degree. C. (34.degree. F.) to the cultured dextrose 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.degree. C. (40.degree. 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 alternative embodiment of the invention, the ingredients are 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 1.degree. C. (34.degree. 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.degree. C. (41.degree. 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% CO.sub.2) 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 (100% CO.sub.2) 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-US-00001 TABLE 1.0 Nutritional Analysis per 100 g Calories 130 cal Fat Calories 10 cal Sat Fat Calories 0 cal Total Fat 1 g Saturated Fat 0 g Stearic Acid 0 g Trans Fatty Acids 0 g Polyunsaturated Fat 0 g Omega 6 0 g Omega 3 0 g Monounsaturated Fat 0 g Cholesterol 15 mg Sodium 160 mg Potassium 0 g Total Carbohydrate 28 g Dietary Fiber 4 g Soluble Fiber 0 g Insoluble Fiber 0 g Sugars 4 g Sugar Alcohol 0 g Other Carbohydrate 20 g Protein 4 g Vitamin A 0% DV Vitamin A (RE) RE Vitamin C 0% DV Calcium 2% DV Iron 10% DV Vitamin D 0% DV Vitamin E 0% DV Vitamin K 0% DV Thiamin 0% DV Riboflavin 0% DV Niacin 0% DV Vitamin B6 0% DV Folate 0% DV Vitamin B12 0% DV Biotin 0% DV Pantothenic Acid 0% DV Phosphorous 0% DV Iodine 0% DV Magnesium 0% DV Selenium 0% DV Copper 0% DV Manganese 0% DV Chromium 0% DV Molybdenum 0% DV Chloride 0% DV
Processing Procedure
In 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.degree. C. (34.degree. F.) 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.degree. C. (40.degree. 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. In 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.degree. C. (136-142.degree. 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.
Cold 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.degree. C. (50.degree. F.). In an alternative embodiment of the present invention, the batter temperature can be controlled to not exceed approximately 4.degree. C. (40.degree. F.). In an embodiment of the present invention, in a jacketed mixing tank the water coolant can be introduced at approximately 1.+-.2.degree. C. (34.+-.2.degree. 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 can 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.degree. C. (40.degree. 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 invention, sodium lactate (below approximately 1%) can be added to the water prior to agitation with the dry mix to minimize `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 ensure 120 day refrigerated `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 ensure 120 day refrigerated `shelf life`.
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 60% 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.
In 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 higher levels of gluten and as a result requires more water. In contrast, pastry flour has lower levels of gluten, which requires less 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. In an embodiment of the invention, there are 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. In 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.degree. C. (40.+-.2.degree. F.). In an embodiment of the present invention, the water to be added to the dry mix can be provided with approximately 0.1% potassium sorbate and approximately 0.05% sorbic acid (by weight).
In an embodiment of the present invention, an amount of potassium sorbate controls the growth of yeast and mold to keep the product stable. In an embodiment of the present invention, sodium lactate controls the growth of yeast, mold, lactic acid bacteria and L. monocytogenes to keep the product stable. In an embodiment of the present invention, an amount of cultured dextrose controls the growth of yeast 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.degree. C. (40.+-.2.degree. F.).
In an embodiment of the present invention, batter can be pumped to a jacketed holding vessel, where the batter temperature is not allowed to exceed 4.+-.2.degree. C. (40.+-.2.degree. 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, sanitized 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 valved with tilt valve 2.times.0.0022 or vertical action valve 2.times.0.033.times.0.090 valves and the cans can be crimped and gassed to approximately 150.+-.3 psi. Cans can be tipped, capped, packed and stored in cold storage at 4.+-.2.degree. C. (40.+-.2.degree. F.).
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 provides 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.sub.2) and carbon dioxide (C0.sub.2) mixed in a ratio of approximately 10% N.sub.2 and approximately 90% C0.sub.2 by weight, pressurized at 150 pounds per square inch (psi). For a pancake mix, the gas can be N.sub.2 and C0.sub.2 mixed in a ratio of approximately 50% each gas by weight. For a cup cake mix, the gas can be N.sub.2 and C0.sub.2 mixed in a ratio of approximately 55% N.sub.2 and approximately 45% C0.sub.2 by weight. For a brownie mix, the gas can be N.sub.2 and C0.sub.2 mixed in a ratio of approximately 85% N.sub.2 and approximately 15% C0.sub.2 by weight.
In an alternative embodiment of the invention, if the batter is to be used as a waffle mix, the gas can be 100% carbon dioxide (CO.sub.2), pressurized at 150 pounds per square inch (psi).
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 (C0.sub.2). C0.sub.2 is a water miscible or soluble gas. After sealing the can, the pressure drops considerably (up to approximately 40%) after canning because the CO.sub.2 dissolves into the mixed batter in the can. For a waffle mix where the gas is 90% C0.sub.2 this can have a significant impact on the final pressure. For a pancake mix, the gas composition can include both nitrogen (N.sub.2) and C0.sub.2. In contrast, to C0.sub.2, N.sub.2 is largely a non water-soluble gas. When N.sub.2 and C0.sub.2 are mixed in a ratio range of approximately 90% nitrogen and approximately 10% carbon dioxide to approximately 80% nitrogen and approximately 20% carbon dioxide, the N.sub.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 C0.sub.2, this combination gives sufficient gas emulsification 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 bakable 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, heating in a gas convection oven, heating in a microwave oven and heating in a toaster.
Example 1
Aim: to determine an acceptable pancake powder mix to water ratio; and determine suitable propellant(s) to make an aerosol packaged pancake batter.
Mix: 50/50 Elite Spice Pancake Mix/DI Water (.about.50.degree. C.; .about.120.degree. F.); Preservatives (0.05% potassium sorbate and 0.05% sorbic acid); Fill: 16 oz; can: 214.times.804, 3-piece, lined; Propellants Tested: (i) 5 g Carbon Dioxide (CO.sub.2), (ii) 2.8 g Nitrogen (N.sub.2).
TABLE-US-00002 TABLE 1.1 Cook Test Results on the Aerosol Packaged Batter Amount Dispensed, g Appearance of Pancakes Samples gassed with 5.0 g CO.sub.2 32 thinner pancakes Samples gassed with 2.8 g N.sub.2 58 thicker, "sponge-like" pancakes
Although different amounts of batter were dispensed with the different propellants (see Tables 1.1 and 1.2), the samples made similar diameter pancakes. This is due to the CO.sub.2 dissolved (in water) in the CO.sub.2 sample that gave the batter more volume.
TABLE-US-00003 TABLE 1.2 Spray Rates of Aerosol Packaged Batter Pressure after 17 days, psi Spray Rate, g/s Samples gassed with 5.0 g CO.sub.2 45 psi 10.8 Samples gassed with 2.8 g N.sub.2 95 psi 12.0
Initial tests showed that the ratio of 50/50 Elite Spice powder mix-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 CO.sub.2 was more suitable to make waffles. The waffles produced were light and crispy. Because CO.sub.2 is more soluble in water than N.sub.2, the batter dispensed from the CO.sub.2-gassed sample had dissolved CO.sub.2 in it. When cooked in the waffle iron, the CO.sub.2 escaped making the waffle light, thin and crispy. When this sample was used to make pancakes, the dissolved CO.sub.2 escaped the batter during the cooking process making the pancakes flat and thin. The sample gassed with N.sub.2 made better pancakes than the one gassed with CO.sub.2. The N.sub.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 flat ones. Summary of trial: samples gassed with CO.sub.2 made good waffles; samples gassed with N.sub.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 214.times.804 can; filled at 16 oz; gassed with 3.9 g N.sub.2 at 130 psi; (ii) 45 powder mix/55 water; in 205.times.604 can; filled at 4 oz; gassed with 2.7 g N.sub.2 at 130 psi; and (iii) 40 powder mix/60 water; in 214.times.804 can; filled at 12 oz; gassed with 4.6 N.sub.2 at 130 psi. Additionally, the following samples were prepared for test candidate testing: (iv) 50 powder mix/50 water; gassed with CO.sub.2; (v) 47.5 powder mix/52.5 water; gassed with N.sub.2.
Results
As in Example 1, sample (iv) that was 50/50 and gassed with CO.sub.2 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.sub.2 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 N.sub.2. Test candidate test result: sample (iv) 50/50 with CO.sub.2--good for waffles; sample (v) 47.5/52.5 with N.sub.2--good for pancakes.
TABLE-US-00004 TABLE 2.1 Cook Test Results on N.sub.2-Pressured Pancake Batter with Varying Powder Mix-to-Water Ratio. Powder Mix-to- Fill, Water ratio Can oz Propellant Results 50/50 214 .times. 804 16 3.9 g N.sub.2 gassed batter was dense; the at 130 psi pancakes were sponge- like as typical pancakes 45/55 205 .times. 604 4 2.7 g N.sub.2 gassed batter was less dense; at 130 psi cooked pancakes looked like typical pancakes (sponge-like with bigger air pockets) 40/60 214 .times. 804 12 4.6 g N.sub.2 gassed batter was thin and at 130 psi runny
Example 3
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 acid and 0.10% potassium sorbate; (ii) 0.10% sorbic acid and 0.20% potassium sorbate. Additional preservatives: EDTA, sodium benzoate, methyl paraben, propyl paraben and lactic acid. All the samples were aseptically prepared. One set of vials were was capped with N.sub.2 and one set was not. All the vials were stored in the dark at room temperature for 1 week.
Results
The evaluation of the samples was limited to visual and olfactory testing. Based on these results, no preservative was suitable for the required batter 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 batter mixture can require an emulsifier or a suspending agent. The pressure build-up can have been due to: generation of CO.sub.2 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-US-00005 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 Additional Preservatives Air Headspace N.sub.2 Headspace None no phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk odor 200 ppm EDTA beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 500 ppm EDTA no phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk odor 0.10% Na Benzoate beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 0.025% Methyl beginning of phase beginning of phase Paraben separation separation 0.075% Propyl pressure build-up pressure build-up Paraben sour milk odor sour milk odor masked by paraben odor 0.50% Lactic Acid phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk, rancid, off odor 1.00% Lactic Acid phase beginning of phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor
TABLE-US-00006 TABLE 3.2 Preservative Test Results on Pancake Batter in Glass Vials with 0.10% Sorbic Acid and 0.20% Potassium Sorbate After 170 Hrs. Additional Preservatives Air Headspace N.sub.2 Headspace None beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 200 ppm EDTA beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 500 ppm EDTA no phase beginning of phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 0.10% Na Benzoate beginning of phase phase separation separation pressure build-up pressure build-up sour milk odor sour milk odor 0.025% Methyl phase separation no phase separation Paraben pressure build-up pressure build-up 0.075% Propyl sour milk odor sour milk odor Paraben masked by masked by paraben odor paraben odor 0.50% Lactic Acid phase separation phase separation pressure build-up pressure build-up sour milk odor sour milk odor 1.00% Lactic Acid phase beginning of phase separation separation pressure build-up pressure build-up no off odor sour milk 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.
Propellants: (i) None; (ii) CO.sub.2; (iii) N.sub.2. Fill: 8 oz. Hot process, 50.degree. C. (120.degree. F.) DI water+Elite Spice pancake mix. Preservative trials:
1. Un-pressurized crimped 205.times.604 3-pc steel, EP coated cans with
a. 0.05% sorbic acid and 0.10% potassium sorbate combo b. 0.05% sorbic acid and 0.10% potassium sorbate combo with N.sub.2 cap c. 0.05% sorbic acid and 0.10% potassium sorbate combo+1.00% lactic acid (88%) d. 0.05% sorbic acid and 0.10% potassium sorbate combo+1.00% lactic acid (88%) with N.sub.2 cap 2. Pressurized crimped 205.times.604 3-pc steel, EP coated cans with a. 1.0% sorbates (combination of 0.40% sorbic acid and 0.60% potassium sorbate) b. a+200 ppm EDTA c. a+500 ppm EDTA d. a+0.1% sodium benzoate e. a+0.075% propyl paraben+0.025% methyl paraben f. a+0.5% lactic acid (88%) g. 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.sub.2 Cap; Horizontal Lines--0.15% sorbates, 1.0% lactic, no N.sub.2 Cap) and N.sub.2-pressurized samples (Vertical Lines--0.15% sorbates, N.sub.2 Cap; Black--0.15% sorbates, 1.0% lactic acid, N.sub.2 Cap) after 60 days. On the contrary, CO.sub.2-pressurized samples dropped in pressure in the same time frame (Tables 4.1 and 4.2 and FIG. 3). The pressure build-up was more pronounced in the un-pressurized samples (FIG. 2; .about.40 psi average after 60 days) than in the N.sub.2-pressurized samples (.about.13 psi average after 60 days) (FIG. 4). And for the un-pressurized set, the samples with sorbates only (Dots--0.15% sorbates, no N.sub.2 Cap) result in more than double the final pressure compared to the sample with sorbates+lactic acid preservative system (Horizontal Lines--0.15% sorbates, 1.0% lactic, no N.sub.2 Cap) (FIG. 2).
For the samples pressurized with CO.sub.2 (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% 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--1.0% sorbates, 0.5% lactic acid; White--1.0% sorbates, 1.0% lactic acid), the average pressure drop after 60 days was about 29 psi (FIG. 3).
As discussed in Example 3, the probable causes for the build up of pressure in the un-pressurized and N.sub.2 pressurized cans can have been (i) evolution of CO.sub.2 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 ethanol and CO.sub.2. Some of the CO.sub.2 is released to the headspace of the can. However, a portion of the CO.sub.2 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 cause the sodium bicarbonate to release further CO.sub.2.
The CO.sub.2 due to microbial activity or bicarbonate decomposition in the un-pressurized cans produced the headspace pressure (FIG. 2). But when the headspace of the can already had a positive pressure as in the N.sub.2 pressurized samples (Dots--1.0% sorbates; Vertical Lines--1.0% sorbates, 200 ppm EDTA; Horizontal Lines--1.0% Sorbates 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--1.0% sorbates, 0.5% lactic acid; White--1.0% sorbates, 1.0% lactic acid) (FIG. 4), the production of CO.sub.2 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.sub.2-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 (FIGS. 2 and 4). Although the lactic acid efficacy cannot completely offset the bicarbonate decomposition due to acidity, it was significantly better as a preservative, in combination with sorbates, than the other preservative systems used.
The CO.sub.2-pressurized cans exhibited reversed results and the pressure decreased after 60 days (FIG. 3). One explanation is that some of the CO.sub.2 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.sub.2 generation in these samples cannot have been enough to overcome the amount of CO.sub.2 dissolved in the sample. Therefore, the pressure effects of CO.sub.2 dissolution were more evident than the effects of CO.sub.2 generation. Alternatively, the CO.sub.2 can have natural anti-microbial action which impeded or slowed down microorganism growth. For fermentation, the CO.sub.2 injected can have saturated the system retarding further CO.sub.2 production from yeast. For aerobic microorganisms, CO.sub.2 made the environment undesirable for microbial growth.
TABLE-US-00007 TABLE 4.1 Pressure Build-up in Un-Pressurized Cans Can Pressure, psi Preservative System N.sub.2 Cap 12 Hrs 48 Hrs 1440 Hrs 0.15% sorbates no 0.5-1.0 ~1.0 37 0.15% sorbates yes ~1.0 ~1.0 42 0.15% sorbates + no ~1.0 ~2.0 16 1.00% lactic acid 0.15% sorbates + yes ~1.0 ~2.0 16 1.00% lactic acid
TABLE-US-00008 TABLE 4.2 Pressure Changes in Pressurized Cans Pressure, psi 0 Hrs 72 Hrs 1440 Hrs CO.sub.2- N.sub.2- CO.sub.2- N.sub.2- CO.sub.2- N.sub.2- Preservative pressur- pressur- pressur- pressur- pressur- pressur- System ized* ized* ized ized ized ized 1.0% sorbates** 126 107 115 109 100 121 1.0% sorbates + 120 105 111 106 96 120 200 ppm EDTA 1.0% sorbates + 118 112 109 112 87 126 500 ppm EDTA 1.0% sorbates + 122 107 112 107 93 122 0.10% sodium benzoate 1.0% sorbates + 122 107 112 107 89 120 0.075% propyl paraben + 0.025% methyl paraben 1.0% sorbates + 121 107 112 107 92 117 0.5% lactic acid 1.0% sorbates + 122 105 114 106 91** 111 1.0% lactic acid *Amount of propellant used: ~3.30 g CO.sub.2 and ~1.70 g N.sub.2 **1.0% sorbates is a combination of 0.4% sorbic acid and 0.6% potassium sorbate
Example 5
Aim: to study the pressure changes in the can pressurized with 50/50 CO.sub.2/N.sub.2 as a follow-up to Example 4.
TABLE-US-00009 TABLE 5.1 Sample* Description for the Pressure Build-Up test on Cans Pressurized with 50/50 CO.sub.2/N.sub.2 Combo. Sample Fill, Code Formula Propellant oz 06-023 Waffle formula (50/50 CO.sub.2/N.sub.2) 18 50.0% Water 2 g CO.sub.2 followed 49.5% Elite Spice with powder mix (lot 2- 2 g N.sub.2 @ ~120 psi 27601) Total 4 g 0.5% Guardian CS1-50 (cultured dextrose) 06-024 Pancake formula (50/50 CO.sub.2/N.sub.2) 18 52.5% Water 2 g CO.sub.2 followed 47.0% Elite Spice with powder mix (lot 2- 2 g N.sub.2 @ ~120 psi 27601) Total 4 g 0.5% Guardian CS1-50 *Samples were stored at room temp for the duration of the study.
TABLE-US-00010 TABLE 5.2 Pressure Changes in Cans Pressurized with 50/50 CO.sub.2/N.sub.2 Combo Pressure, psi .DELTA. Sample Code 2 Hrs 72 Hrs 264 Hrs 400 Hrs 1700 Hrs Pressure 06-023 110 109 109 109 121 +11 06-024 109 108 107 107 118 +9 *For Time 0, the pressure reading was taken ~2 to 3 hours after the samples were made
Results
The pressure build up was similar to the N.sub.2-pressurized samples in Example 4 (see FIG. 4 (1.0% sorbates, 0.5% lactic acid), but the amount of product in the cans was increased in this trial. Some of the injected CO.sub.2 dissolved in the water but more CO.sub.2 (or other gaseous microorganism byproducts) can be generated, causing the pressure increase.
Example 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/DI Water. Screw cap glass vials. Primary Preservatives used: MG510 gassed with CO.sub.2 CS1-50 gassed with CO.sub.2 MG510 gassed with N.sub.2 CS1-50 gassed with N.sub.2
TABLE-US-00011 TABLE 6.1 Parameters of the micro-study Batch 1 Batch 2 (Pancake) 50/50 (Pancake) 47.5/52.5 Elite Spice powder Elite Spice powder mix/Water mix/Water Preservative (Cultured Microgard 510 Guardian CS1-50 Dextrose Maltodextrin) (MG510) (lot# FS-102) (lot# 510-425301) Preservative Dosage 0.75% 0.50% Fill 18.3 oz 18.3 oz Can 214 .times. 804 214 .times. 804 Temp of finished batch 65.degree. F. 55.degree. F. Nitrogen cap No yes Codes V1, V3 V2, V4
Inoculants: Y--yeast LAB--lactic acid bacteria SA--Staphylococcus aureus LM--Listeria monocytogenes BC--Bacillus cereus 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 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 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 the facility. Listeria innocua will be used instead.
Product Variables
The product variables to be studied include: 1) MicroGard 510 with CO.sub.2 (waffle) 2) MicroGard CS150 with CO.sub.2 (waffle) 3) MicroGard 510 with N.sub.2 (pancake) 4) MicroGard CS150 with N.sub.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 4.0.degree. C. (40.degree. F.). Finished cans were stored for 1.5 days and transported in a refrigerated truck.
Organisms
The organisms for challenge represented those of potential safety and spoilage concern. The only pathogen of potential concern that was not represented was C. botulinum. The test organism categories included: Bacillus cereus (gram positive spore former, thermo labile toxin) Staphylococcus aureus (gram positive non-spore former, thermo stable toxin) Listeria monocytogenes (gram positive non-spore former, psychrotroph) Zygosaccharomyces rouxii (yeast) Lactobacillus formentum, Lactobacillus plantarum (combined inoculum of gram positive non-spore formers). Culture Preparation
Lactic acid bacteria was grown in sterile MRS broth. Other bacteria were grown in sterile trypticase soy broth. Yeast extract was added for the L. monocytogenes culture. Bacteria were cultured for 24 hours at 35.degree. C., then streaked on trypticase soy agar and incubated for 48 hours at 35.degree. C. Yeast were cultured for 5 days at 24.degree. 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 10.sup.3-10.sup.4 cfu/g (minimum 590,000 cfu/can in each 20 fl. oz. can). Inoculation was delivered with a 1 mL inoculum volume. The 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 representative conducted the inoculation.
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 sanitization was complete to determine adequacy of cleaning. The unit was not used before results were available.
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 Interval
Test intervals were spaced appropriately to represent the 105 day storage period. Testing was conducted on inoculated variables 1, 2, and 4 at day 2, 15, 30, 45, 60, 75, 90, and 105. Testing for inoculated variable 3 was conducted at day 2, 15, 30, and 45. Later test intervals for variable 3 were discontinued because inoculum loads significantly increased. Uninoculated controls were analyzed after 2 and 105 for variables 1 and 2. An additional 45 day test interval was added for variables 3 and 4 to determine midpoint shifts in background flora levels.
Uninoculated control samples were analyzed for B. cereus, S. aureus, L. monocytogenes, lactic acid bacteria, yeast, mesophilic aerobic plate count, and mesophilic anaerobic spore former counts.
Storage Conditions
Products stored at 4.degree. C. (40.degree. F.).
The pathogenic organisms detected in the product after 2-105 days are shown in Tables 6.2-6.9.
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