Food bar and method for the production thereof
The present invention concerns a sterile food bar according to the preamble of claim 1.
The present invention also concerns a method for producing a food bar of this kind according to claim 10.
It is commonly known that different confectioneries and combinations of meats and vegetables are eaten as snacks and substitutes for meals. Various food preserves and convenience food preserves as well as energy bars are also known.
Easily consumed pastries and meat pies can be kept for only a few days as refrigerated, since they cannot be sterilized without completely destroying the structure of the product. Food preserves and convenience food preserves are sterilized by heat treatment at overpressure, but they can only be consumed by removing them from the package and by using cutlery; they are not meant to be eaten by hand.
Ordinary energy bars, on the other hand, are produced from dry ingredients, such as grain, nuts and chocolate, and from nutritional supplements added therein. They do not contain meat or vegetables, nor food-like moisture and essence. Their preservability is based on dryness and preservatives. They are rich in energy or proteins as well as in additives, but their nutritional value is limited and they are tasteless.
The purpose of the present invention is to remove the problems of the prior art and present a completely new convenience food preserve to be eaten by hand as well as a method for its production.
The invention is based on the idea that the convenience food preserve is produced in layers of bread and minced foodstuff. The invention is being characterized by providing two layers of bread, between which there is a mass of minced foodstuff. Furthermore, the product is packed sterilely in a stretch package that is impermeable to air, light and water, causing it to be preservable for months in room temperature. Its preservability is based on the package being oxygen-free and the contents being sterilized during production of the package.
In a product according to the invention the bread and the minced foodstuff are not substantially mixed with each other and their structure is firm. It is shaped as a rectangular bar.
The product is produced using a method in which - the bread is cut into predetermined dimensions and a mass of minced foodstuff is rationed onto it, - another loaf of bread having predetermined dimensions is placed upon the mass, - the entity formed by the loafs of bread and the mass of minced foodstuff is compressed in order to attach the layers to each other, without, however, mixing the bread and the minced foodstuff, - the compressed products are cut into pieces that correspond to bars having a desired size, - the bars are placed into stretch packages inside which are evacuated for creating a vacuum, after which the packages are seamed and the products sterilized.
More specifically, the food bar according to the invention is mainly characterized by what is stated in the preamble of claim 1.
The method according to the invention is, again, characterized by what is stated in the preamble of claim 10.
Considerable advantages are achieved by the invention. The present food bar can be kept in room temperature for more than six months; it does not need to be heated nor set out and it is eaten straight from its package by hand. Since a food bar according to the invention is sterilely and compactly packed, the invention provides for many microbiologically risk- free opportunities in problematic storage situations, like camping, outdoor sports and mass events. Further, the food bar can be stored even for long times as reserve nutrition for unexpected situations. Consuming it is very easy while doing something else, for example travelling, exercising or working.
Different tastes and themes can be added into the minced foodstuff according to the desires of the consumers. The food bars can be produced for different uses, like breakfast, dieting, nutritional supplements or functional uses.
Compared to other snacks, the invention is nutritionally very diverse and low-fat. This is due to e.g. diverse foodstuffs, as grain-products and the fibre within them, being added to the meal together with the bread. The homogenous, relatively dry layer of bread, forming the upper and lower surfaces, respectively, on both sides of the mass of minced foodstuff in the food bar, assists in opening the package, since too large friction would otherwise be formed between the minced foodstuff and the inside of the package wrapping. For this reason it is also advantageous that the bread and the minced foodstuff are essentially not mixed with each other.
The invention will now be studied more extensively with reference to the attached figures, whereby
In Figure 1 the profile of the food bar of the invention is presented,
In Figure 2 the perspective of the cross section of the split food bar, as well as the profile of the second piece, are presented, and In Figure 3 the perspective of the product packed in stretch packaging impermeable to air, light and microbes is presented.
The food bar of the invention (Figure 1) is shaped to be easily eaten using one hand. The top layer (Figure 2) is a special oat bread 1 covered with wheat bran. A mass of minced foodstuff 2, that has been developed for this invention, has been fitted as an intermediate layer. At the bottom is again a special oat bread 1'. The layers are attached to each other by pressing the raw mass of minced foodstuff between two well done loafs of bread inside a mould. Despite the compact structure, the separate parts of the invention are not substantially mixed. The bars cut into their shape are packed (Figure 3) into stretch packages 3, impermeable to air, light and microbes. Vacuum is created inside the packages, they are seamed and the products are sterilized. The products are also sold and consumed from the same packages.
It is emphasized that the product of the invention can have various layers of the mass of minced foodstuff separated from each other by layers of bread. Therefore, a product can have 3 layers of bread and 2 layers of the mass of minced foodstuff. It can also have 4 layers of bread and 3 layers of the mass of minced foodstuff etc. It is, however, essential that the layers of bread form the top and bottom layers.
In the present invention "bread" generally stands for a firm product produced by baking or otherwise solidification by removing liquid/water, said product containing mainly material, in form of e.g. flour or groats, derived from grain products. Grain products include e.g. rice, corn, tapioca and buckwheat, in addition to the traditional grains - wheat, oat, rye and barley. The ability of the gluten or similar protein in the grain product to act as a binder is generally exploited to form a firm material. The portion of dry matter in the bread formed by the grain products is generally at least 50% by weight.
In one embodiment, the bread 1, 1' stays the same in all versions. Its characteristics ai'e constancy during sterilization and maintaining its own fluids inside while pressure is applied, as well as rejection of the fluids from the mass of minced foodstuff. These characteristics are achieved using oat abundantly and other ingredients in optimal proportions.
The characteristics of the bread have been more closely examined below, in context with the description of the method for production.
Carboxy-methyl cellulose, shortened CMC, acts as a precipitant for the bread. The packing of the invention into a stretchy package is achieved by using bags made of a membrane impermeable to air, light and microbes. In this case, a membrane having 12 microns of polyethene, 9 microns of aluminium and 70 microns of polypropene is used. Other possible precipitants are potato flour, arrowroot flour, different modified cornstarches.
"Mass of minced foodstuff stands for a protein-containing, relatively rough mass of foodstuff that is made of meat (including fish or chicken) or vegetables and that usually contains diversely both proteins (at least about 10% by weight, preferably at least 15% by weight) and carbohydrates and fats. The mass of minced foodstuff usually lacks the firmness, toughness and coherence that are typical for bread. It consists of foodstuff that usually is grain-like, whereby the particle-size of the groats usually is about 0.5-20mm, preferably about 1-15mm, particularly about 3-10mm.
The mass of minced foodstuff 2 of the invention can be made from various ingredients. The right structure is assured using a mixture of additives. According to the first application of the invention, this mixture of additives contains a cold-precipitant, which is
modified corn flour, and a hot-precipitant, which is soy protein. Using these, the mass can be made firm enough for production and they prevent mixing of fluids and fats during sterilization.
The basic composition of the mass of minced foodstuff comprises the following ingredients: water, sugar, salt, soy isolate and wax-corn flour (see Table 2). The portion of solids is altogether about 20 % by weight of the mass of minced foodstuff. In addition to these, the mass of minced foodstuff can contain about 5 to 40 % by weight protein- containing foodstuff, about 15 to 50 % by weight carbohydrates. Typical components include the following:
Vegetable products: kuro-guwai, zucchini, carrot, potato, miniature corn, Swedish turnip, broccoli, tofu, rice, mushroom (champignon), sesame seed; Chicken products: chicken, rice, paprika, pineapple, potato, corn; Beef products: beef, rice, paprika, pineapple, potato, corn.
In addition to these, mixtures of spices and additives are added into the masses of minced foodstuff. Preservatives; nitrite, ascorbic acid, alpha-tocopherol or rosemary extract can also be added to the product. Using these, the development of anaerobic microbes and the oxidation of the product can be prevented.
It can be stated that the above mentioned water is water that is separately added during production. It is clear that all foodstuffs also contain some water. Reducing and constricting the water of the product and the foodstuffs is preferable for the production method, as becomes evident by the following.
A method according to the invention, for production of a food bar from bread and a mass of minced foodstuff, comprises, in the first phase, the separate production of a bread and a mass of minced foodstuff. After this, a first layer of bread is cut into its fixed size and the mass of minced foodstuff is rationed onto it. Onto the mass, another fixed size loaf of bread is placed, and then the entity formed by the loafs of bread and the mass of minced foodstuff is compressed to attach the layers to each other, without, however, mixing the bread and the minced foodstuff. The compressed products are cut into pieces that
correspond to the wanted bars in size. The bars are put into stretch packages into which a vacuum is sucked, after which the packages are seamed and the products sterilized.
The sterilization takes place by putting the vacuum-packed bags into an autoclave, like a counterpressure-autoclave, where they are kept at an increased temperature, e.g. 121°C, until the product has reached an f-value of 9 to 15, preferably at least 10.
The dry bread-like top and bottom layers prevent the forming of an otherwise too large friction between the product and the package. With the help of the bread, a technical advantage, making the product easily removable from the package, is achieved. Otherwise the wetness/dampness of the filling would prevent that. During production, the bread layers also have the advantage of keeping the product in shape preventing the flattening effect of strong underpressure-packing (vacuum-package about lOmbar/lkPa).
The bread found preferable in the invention can therefore be provided with certain demands:
A) Pressure-tightness. The bread must stay intact at at a pressure of up to more than 3 bar/300 kPa and a temperature of 121 degrees. B) The sugar in the bread must not colourize, in other words the Maylard reaction should not take place distractingly because of the ideal proportions of the sugars and fibres in it. More adequately said, the proportions are (calculated based on weight) about 10: 100...50: 100, preferably about 20: 100...40: 100 and particularly 25: 100...35: 100. C) The bread must not lose its structure when absorbing some fluid from the minced foodstuff between it.
To fulfil the last mentioned requirement, the bread most suitably contains a strong precipitant, carboxy-methyl cellulose in an amount of about 0.1 to 5 % by weight, preferably about 0.5 to 3 % by weight.
The bread, according to the recipe presented below, is also fairly compact, which together with strong pressure prevents intrusion of liquids into the bread. The sui ace of the bread
must not be moist/damp because of friction. Therefore it is covered with brans, also improving the appearance.
In a preferred embodiment of the method of the invention, the production method of the product is associated with the freezing of the product after joining together the mass and the bread. The mass 2 and the bread 1, 1' are joined together, forming either a plate with 20 pieces or straight forming singles using a machine. This embodiment is preferred because it considerably furthers the product staying angular and of good quality of appearance during packing. Otherwise the vacuum and the relatively rigid package together might crush the product making it shapeless.
In a preferred embodiment it has also been possible to reduce the use of precipitants and to improve the taste and edibility. Edibility is improved because the product is no longer so firm, but considerably softer.
In the invention it has preferably been further discovered that, while producing the product, the fresh ingredient, except for the potato, is dried by baking, thereby making them lose moisture at least about 20 %, preferably 30 % or more, generally about 25 to 45 % by weight. Thereby mostly 50 to 60 % by weight, typically at least 30 % by weight, of water stay in the ingredients.
After baking mostly about 40 %, typically at least 20 w-%, of moisture stays in the bread.
In the finished product about 50 w-%, generally about 40 to 60 w-%, of water is left bound to the ingredients as well as to the added soy groats, carboxy-methyl cellulose, soy isolate and wax-corn starch.
The sale of the invention takes place in single packages of about 200 grams. Since the shape and preservability differs from that of regular convenience food, also the distribution channels can be chosen differently than for other convenience foods. It is particularly suited for sale in kiosks, vending machines, camping resorts, service stations and snack sale offices at workplaces.
Preparation Examples
Example 1
The bread was produced having the composition presented in Table 1 :
Table 1. The composition of the bread Percentage of the mass Amount for 10 pieces as grams
Oatmeal 12.2 91.6
Potato loaf flakes 1.2 9.2
Corn flour 4.8 36.3
Wheat flour 5.2 39.4 SSuuggaarr 00..88 6.2
Salt 0.2 1.8
CMC 0.4 2.8
Water 75.0 562.7
Total 100% 750g
Additionally 17 grams/ 2.2 % wheat bran for each plate.
The mass is whisked during three minutes. The mass is spread onto a buttered 50x30 cm GN-plate using a casserole spray. The wheat bran is sprinkled as an even surface onto the mass. The temperature of the convection oven is 175 degrees and the baking time is 25 minutes.
The mass of minced foodstuff was made from chicken roast slices, whereby the mass was spiced according to Thai custom.
Table 2. The composition of the mass of minced foodstuff (Thai-chicken)
Percentage of the mass t amount for 10 pieces in grams
Chicken roast slices* 33.0 495
Cooked rice* 17.0 255
Pineapple* 11.5 172.5
Paprika* 3.0 45
Carrot* 3.0 45
Water 10.0 150
Sugar 5.0 75
Vegetable oil* 1.0 15
Salt 1.2 18 Soy groats 6.5 97.5 Soy isolate 2.0 30 Wax-corn starch 5.8 87
Thai Chilli-spice* 0.7 10.5
Fried Chicken-aroma* 0.3 4.5
Total 100.0 1500g
The cooked chicken, paprika, pineapple and carrot have to be chopped into pieces of about 10mm. All the ingredients are mixed, except for the water, which is added last. After this the mass is ready.
It should be noted that the ingredients marked with a *star can be replaced by another mentioned ingredient or be left out.
Assembling the food bar
The bread is cut into its fixed size and onto it the mass of minced foodstuff is portioned. Onto the mass another fixed size bread is placed. The entity is pressed together strongly on the plate, after which it is cut. The pieces, or bars, formed in this way, are bagged in stretchy packages, one in each. The bags are vacuum packed and placed in a counter- pressure autoclave. The inner temperature of the product must be at 121 degrees during 20 minutes. The autoclave must have counter-pressure until the inner temperature of the product has dropped to 80 degrees Celsius. After this the autoclave may be opened and the food bars are ready.
Example 2
Two slightly different products were prepared, namely chicken filling, chilli, and organic tofu filling.
The specification of the first product is as follows:
Chicken, rice, pineapple, soy grout, paprika, carrot, modified corn starch, sugar, soy protein, salt, oat, corn flour, wheat flour, potato flour, potato flakes, wheat bran, carbυxy-
methyl cellulose, spices and aromas. Nutrition contents / 100 g: Energy 135 kcal, protein 10.6 g, carbohydrates 19.5 g, fat 1.7 g and salt 1.5 g.
The specification of the second product is as follows:
Organic tofu, carrot, potato, mushroom (champignon), crushed tomatoes, broccoli, oil of turnip rape, soy groats, paprika, sesame seed, modified corn starch, sugar, soy protein, salt, oat, corn flour, wheat flour, potato flakes, wheat bran, carboxy-methyl cellulose, paprika extract, spices and aromas. Nutrition contents / 100 g: Energy 131.1 kcal, protein 6.8 g, carbohydrates 18.2 g, fat 3.2 g, salt 1.6 g.
The compositions of the products are presented in Tables 3 and 4. Yet another bread composition is presented in Table 5:
Table 3. Chicken filling, chilli
Fried chicken 990.0 Mixture of additives for the chicken
Potato 560.0 soy groats 42.8
Fried Pineapple 330.0 soy isolate 13.2 Fried paprika 90.0 C-tex 38.2 Fried Carrot 90.0 Thai chilli t155303271 4.6
Mixture of spices and 650.0 chicken-aroma 026013 1.3 additives
Nitrite 10% 3.6 100.1 Ascorbic acid 1.8 Water 300.0 Extra Chilli 4.5 3019.9 The ingredients are fried so that 30% of fluids counted from the raw weight has withdrawn. The potato must not be fried.
Table 4. Vegetable filling, Cajun
Fried zucchini 330
Fried carrot 465 The mixture of additives for the vegetable
Potato 366 Soy groats 51.5
Fried mushroom 336 Soy isaolate 21.25
(champignon)
Sesame seed 96 Wax-corn starch 6.25
Tomato puree 100 mixture of spices t250307268 21
Oil of turnip rape 33 100
Fried tofu 560
Mixture of spices and 570 additives
Cajunspice 30
Nut extract 20
Soy groats 100
Nitrite 10% 3.6
Ascorbic acid 1.8
Table 5. Composition of the bread
Oatmeal 300
Potato loaf flakes 30 On top 17g wheat bran/plate
Corn flour 120
Wheat flour 130
Sugar 20
Salt 6
CMC 9
Wheat bran 34
Water 1000
Caramel, brown 3
Walnut extract 3
Ascorbic acid 2 1657
Above are described the most preferable embodiments of the invention. The invention is, however, not limited to these, but can vary in different ways within the limits of the protective claims. The shape of the invention can be different from a bar, for example it can be shaped into a square, triangle, disc, oval, roll or other shapes.