ULTRASONICALLY-TREATED NUTRITIONAL PRODUCTS HAVING
EXTENDED SHELF LIFE
FIELD OF THE DISCLOSURE
[000 11 The present disclosure relates to ultrasonically-treated nutritional
products, such as nutritional bars that have extended shelf life. The present disclosure also
relates to methods of manufacturing nutritional products using high power ultrasound.
BACKGROUND OF THE DISCLOSURE
[0002] Many nutritional products, and specifically nutritional bars, food bars,
snack bars, energy bars and the like, contain significant amounts of protein materials.
Typical protein-containing ingredients may include soy and whey isolates, which can
differ in functional properties, such as emulsification, water-binding, and gel strength.
Protein ingredients such as soy protein isolate, whey protein isolate, sodium or calcium
caseinate, whole milk protein and others that exhibit significant viscosity, gel strength, and
water-binding properties, significantly influence the initial textural properties of the
nutritional bar.
[0003] Nutritional bars that include protein-containing ingredients, and
specifically high levels of protein-containing ingredients, typically harden over their shelf
life, thus reducing commercial acceptability over their shelf life. Proteins that exhibit high
water-binding properties are thought to positively influence the initial texture of the bar,
but are believed to have the effect of firming the bar's texture over its shelf life. It is
generally believed that the firming is not caused by water loss per se, but rather, by
migration of the water from some ingredients to others, such as from the carbohydrate
fraction to the protein fraction. This hardening or firming of the nutritional bar over time
is generally thought to be the result of the dual cause of protein aggregation and the
formation of crystalline-like structures by the carbohydrate fractions.
[0004] A variety of different carbohydrates, such as gums, maltodextrin, and
cellulose derivatives, are added to nutritional bar formulations to hold moisture and to
modify texture. While those ingredients may be somewhat effective in preventing
moisture loss to the environment, their effectiveness in preventing moisture transfer to
protein ingredients is minimal. Increasing the amount of carbohydrates, such as
maltodextrin, that take on a crystalline-like form upon moisture loss, is believed to
enhance the firming effect during shelf life, thus reducing commercial acceptability.
[0005] There is therefore a need for nutritional bars and related nutritional
formulations that provide the intended nutrition, energy, and the like, that maintain a soft
texture over time leading to an improved shelf life.
SUMMARY OF THE DISCLOSURE
[0006] The present disclosure is directed to a composition comprising an
ultrasonically-treated nutritional formulation and a sealed package, the nutritional
formulation comprising a carbohydrate in an amount of from about 5% to about 95% by
weight of the nutritional formulation a protein in an amount of from about 5% to about
95% by weight of the nutritional formulation, and a lipid in an amount of from about 1%
to about 30% by weight of the nutritional formulation, wherein the nutritional formulation
has a shelf life of at least three months.
[0007] The present disclosure is further directed to a process of manufacturing an
ultrasonically-treated nutritional formulation having improved shelf life. The process
comprises combining a protein, a carbohydrate, a lipid, a binder, and water to form a
slurry, subjecting the slurry to high power ultrasound, and extruding the slurry to produce
the ultrasonically-treated nutritional composition.
[0008] The present disclosure is further directed to a process of manufacturing an
ultrasonically-treated nutritional formulation having improved shelf life. The process
comprises combining a protein, a carbohydrate, a lipid, a binder and water to form a slurry,
subjecting the slurry to high power ultrasound, and slabbing the ultrasonically-treated
slurry to produce the ultrasonically-treated composition
[0009] It has been found that high power ultrasound can be utilized to
manufacture a nutritional bar having an extended shelf life. By subjecting a nutritional
slurry utilized to prepare the nutritional bar to high power ultrasound at the appropriate
time during the manufacturing process, the resulting nutritional bar maintains a softer
texture over an extended time and its shelf life is increased as the high power ultrasound
appears to inhibit and/or delay water migration to the surface of the manufactured bar, thus
increasing shelf life by maintaining softness. Additionally, the improved shelf life may be
linked to conformational changes of the polymers present in the bars due to the application
of high power ultrasound. It has been found that by applying high power ultrasound to a
nutritional bar slurry prior to andlor during extrusion, or prior to slabbing, an extended
shelf life nutritional bar may be produced.
[0010] The nutritional formulations and nutritional bars of the present disclosure
that are prepared utilizing high power ultrasound have the advantage of having an
increased shelf life, relative to nutritional bars not made utilizing high power ultrasound in
the manufacturing process. Prior to the present disclosure, hardening of the texture of
nutritional bars over time was a problem, even when the bars were wrapped in moisture
and oxygen tight packaging, resulting in shortened shelf life. The texture of the nutritional
bars of the present disclosure at any given point in time during the shelf life of the product
may be substantially similar to the texture of the nutritional bars when first manufactured.
A nutritional bar with an increased shelf life according to the present disclosure is
therefore a nutritional bar that exhibits reduced hardening over time.
[001 I] In addition to the advantages outlined with respect to texture, softness,
and shelf life, it has been unexpectedly found that the ultrasonically-treated nutritional
formulations and nutritional bars of the present disclosure also advantageously are
prepared from slurries that are more visually pleasing; that is, the slurries that are
subjected to the high power ultrasound process prior to being formed into a bar or similar
product present a creamier, darker, more consistent and homogeneous look, which
translates into a more desirable, commercially acceptable product. This results in an
overall improved appearance of the nutritional bar product, and may actually conceal some
components, such as the protein component, better than current nutritional bars, which also
results in a more visually pleasing product such that a consumer would not expect the
resulting product to be a "high protein" product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 is a schematic diagram of an ultrasonically-assisted extrusion
apparatus suitable for use in the extrusion processes of the present disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[OO 131 The nutritional formulations and corresponding manufacturing methods of
the present disclosure are directed to nutritional bars or other solid product forms,
optionally containing a solid crisp matrix, as defined herein, that have been manufactured
utilizing high power ultrasound at one or more specific times during the manufacturing
process. These and other essential or optional elements or limitations of the nutritional
formulations and methods of the present disclosure are described in detail hereinafter.
[0014] The term "solid crisp matrix" as use herein, unless otherwise specified, is
a term of art within the nutrition formulation art which refers to light, crispy food products
having a low bulk density character similar to rice crisps, corn crisps, or similar other well
known carbohydrate-containing or protein-containing materials and which have a bulk
density of less than about 0.4 g/cm3, preferably less than about 0.35 g/cm3, even more
preferably from about 0.10 &m3 to about 0.30 &m3, and even more preferably from
about 0.22 g/cm3 to about 0.28 &m3, including from about 0.24 g/cm3 to about 0.27
&m3. The term "solid crisp matrix" includes free flowing crisp particulates, bound
aggregates of such particulates, and/or solid bar-like matrices, provided that all such
particulates, aggregates, or matrices also have the requisite bulk density character as
described herein.
[0015] The term "sealed package" as used herein refers to a suitable plastic or
foil food grade package that encloses and seals in an air tight manner a nutritional
formulation, such as a nutritional bar, from air.
[0016] The term "shelf life" as used herein refers to a product's commercially
viable life-span, after which the product is unfit or undesirable for sale andlor
consumption.
[0017] All percentages, parts and ratios as used herein, are by weight of the total
formulation, unless otherwise specified. All such weights as they pertain to listed
ingredients are based on the active level and, therefore, do not include solvents or byproducts
that may be included in commercially available materials, unless otherwise
specified.
[0018] Numerical ranges as used herein are intended to include every number
and subset of numbers within that range, whether specifically disclosed or not. Further,
these numerical ranges should be construed as providing support for a claim directed to
any number or subset of numbers in that range. For example, a disclosure of from 1 to 10
should be construed as supporting a range of from 2 to 8, from 3 to 7, from 5 to 6, from 1
to 9, from 3.6 to 4.6, from 3.5 to 9.9, and so forth.
[0019] All references to singular characteristics or limitations of the present
disclosure shall include the corresponding plural characteristic or limitation, and vice
versa, unless otherwise specified or clearly implied to the contrary by the context in which
the reference is made.
[0020] All combinations of method or process steps as used herein can be
performed in any order, unless otherwise specified or clearly implied to the contrary by the
context in which the referenced combination is made.
[002 11 The various embodiments of the present disclosure may also be
substantially free of any optional or selected essential ingredient or feature described
herein, provided that the product still contains all of the required ingredients or features as
described herein. In this context, and unless otherwise specified, the term "substantially
free" means that the selected product contains less than a functional amount of the optional
ingredient, typically less than 0.1% by weight, and also including zero percent by weight
of such optional or selected essential ingredient.
[0022] The nutritional formulations, nutritional bars and corresponding
manufacturing methods of the present disclosure can comprise, consist of, or consist
essentially of the essential elements and limitations of the disclosure as described herein,
as well as any additional or optional ingredients, components, or limitations described
herein or otherwise useful in nutritional formulation formula applications.
Product Form
[0023] The nutritional formulations of the present disclosure are ultrasonically
treated nutritional formulations generally including at least lipid, protein, carbohydrate,
and binder. The nutritional formulations are typically nutritional bars, such as snack bars,
meal replacement bars, energy bars, blunted glycemic response bars (diabetic bars), weight
loss bars, and the like that are formed by extrusion or slabbing.
[0024] The nutritional bars of the present disclosure generally have a moisture
content of from about 5% to about 20% (by weight), or even from about 3% to about 15%
(by weight), or even from about 5% to about 10% (by weight), or even from about 7% to
about 9% (by weight).
[0025] The ultrasonically treated nutritional formulations have increased shelf
life as compared to conventionally prepared nutritional formulations. The shelf life for the
nutritional bars of the present disclosure is at least about 3 months, or even at least about 4
months, or even at least about 5 months or even 12 months, or even 18 months, including
from 6 to 18 months.
[0026] The nutritional formulations may be formulated with sufficient kinds and
amounts of nutrients so as to provide a sole, primary, or supplemental source of nutrition,
or to provide a specialized nutritional formulation for use in individuals afflicted with
specific diseases or conditions.
Macronutrients
[0027] The nutritional formulations and nutritional bars generally comprise at
least lipid, protein, and carbohydrate. Generally, any source of lipid, protein, and
carbohydrate that is known or otherwise suitable for use in nutritional formulations may
also be suitable for use herein, provided that such macronutrients are also compatible with
the essential elements of the nutritional formulations as defined herein.
[0028] Although total concentrations or amounts of the lipid, protein, and
carbohydrates may vary depending upon the nutritional needs of the intended user, such
concentrations or amounts most typically fall within one of the following embodied
ranges, inclusive of any other essential lipid, protein, and or carbohydrate ingredients as
described herein.
Carbohvdrate
[0029] The nutritional formulations of the present disclosure comprise a
carbohydrate source. The carbohydrate concentration most typically ranges from about
5% to about 95%, including from about 1% to about 50%, including from about 10% to
about 30% by weight of the nutritional formulation. The carbohydrate source may be any
known or otherwise suitable source that is safe and effective for oral administration and is
compatible with the essential and other ingredients in the selected product form.
[0030] Suitable carbohydrates or carbohydrate sources for use in the nutritional
formulations may be simple, complex, or variations or combinations. Non-limiting
examples of suitable carbohydrates include hydrolyzed or modified starch or cornstarch,
maltodextrin, glucose polymers, oligosaccharides (e.g., fructooligosaccharides,
glucooligosaccharides), sucrose, corn syrup, corn syrup solids, rice-derived carbohydrate,
glucose, fructose, lactose, high fructose corn syrup, honey, sugar alcohols (e.g., maltitol,
erythritol, sorbitol), and combinations thereof.
[003 11 Other suitable carbohydrates include any dietary fiber or fiber source,
non-limiting examples of which include insoluble dietary fiber sources such as oat hull
fiber, pea hull fiber, soy hull fiber, soy cotyledon fiber, sugar beet fiber, cellulose, corn
bran, and combinations thereof.
[0032] The carbohydrate for use in the nutritional formulation may therefore
include soluble and/or insoluble fiber, or other complex carbohydrate, preferably having a
DE (dextrose equivalent) value of less than about 40, including less than 20, and also
including from 1 to 10.
[0033] The nutritional formulations of the present disclosure may comprise a
lipid or lipid source. The lipid concentration most typically ranges from about 0% to about
90%, including from about 1% to about 30%, including from about 3% to about 15% by
weight of the nutritional formulation. The lipid or lipid source may be any known or
otherwise suitable source that is safe and effective for oral administration and is
compatible with the essential and other ingredients in the selected product form.
[0034] Lipids or lipid sources suitable for use in the nutritional formulations
include coconut oil, fractionated coconut oil, soy oil, corn oil, olive oil, safflower oil, high
oleic safflower oil, MCT oil (medium chain triglycerides), sunflower oil, high oleic
sunflower oil, palm and palm kernel oils, palm olein, canola oil, marine oils, flaxseed oil,
borage oil, cottonseed oils, evening primrose oil blackcurrant seed oil, transgenic oil
sources, fungal oils, marine oils (e.g., tuna, sardine) and so forth. Other suitable lipids
include both essential and non-essential fatty acids, including omega-3 fatty acids, omega-
6 fatty acids, and combinations there.
[0035] The nutritional formulations of the present disclosure also comprise a
protein or protein source. The protein concentration most typically ranges from about 5%
to about 95%, including from about 1% to about 20%, including from about 2% to about
10% by weight of the nutritional formulation. The protein or protein source may be any
known or otherwise suitable source that is safe and effective for oral administration and is
compatible with the essential and other ingredients in the selected product form.
[0036] Protein or protein sources suitable for use in the nutritional formulations
include hydrolyzed, partially hydrolyzed or non-hydrolyzed proteins or protein sources,
and can be derived from any known or otherwise suitable source such as milk (e.g., casein,
whey), animal (e.g., meat, fish, egg albumen), cereal (e.g., rice, corn), vegetable (e.g., soy,
pea, potato), or combinations thereof. The proteins for use herein can also include, or
may be entirely or partially replaced by, free amino acids known for use in nutritional
formulations, non-limiting examples of which include tryptophan, glutamine, tyrosine, Lmethionine,
cysteine, taurine, L-arginine, carnitine, and combinations thereof.
[0037] In one embodiment, the nutritional formulations of the present disclosure
comprise a soy protein component, sources of which include, but are not limited to, soy
flakes, soy protein isolates, soy protein concentrate, hydrolyzed soy protein, soy flour, soy
protein fiber, or any other protein or protein source derived from soy. Commercial sources
of soy protein are well known in the nutrition art, some non-limiting examples of which
include soy protein isolates distributed by The Solae Company under the trade designation
"Soy Protein Isolate EXP-HO118," "EXP-E-0101, and "Supro Plus 675.
Macronutrient Profile
[003 81 The total amount or concentration of lipid, carbohydrate, and protein, in
the nutritional formulations of the present invention can vary considerably depending upon
the selected formulation and dietary or medical needs of the intended user. Additional
suitable examples of macronutrient concentrations are set forth below. In this context, the
total amount or concentration refers to all lipid, carbohydrate, and protein sources in the
nutritional formulation. Such total amounts or concentrations are most typically and
preferably formulated within any of the embodied ranges described in the following table.
Macronutrients*
Each numerical value is preceded by the term "about"
[0039] The nutritional formulations of the present disclosure also comprise a
binder or binding agent that acts as a "glue" for combining and providing structure to
various relatively dry ingredients. The binder concentration most typically ranges from
about 1% to about 25%, including from about 1% to about 20%, including from about 2%
to about 15% by weight of the nutritional formulation. The binder or binding agent source
may be any known or otherwise suitable source that is safe and effective for oral
administration and is compatible with the essential and other ingredients in the selected
product form.
[0040] Binders suitable for use in the nutritional formulations of the present
disclosure include sugar containing and sugar free binders, such as syrups, such as corn
syrup, sugar free syrups, shortening, alcohols, and the like. One specific example of a
suitable binder is a sugar free marshmallow binder.
Solid Crisp Matrix
[004 11 The ultrasonically-treated nutritional formulations of the present
disclosure are generally directed to solid dietary product forms, preferably nutritional
snack or nutritional meal replacement bars, as noted above. In some embodiments, the
nutritional formulations include a solid crisp matrix, as defined herein. Any solid dietary
product form, known or otherwise, is suitable for use herein. It is generally preferred that
the solid crisps that make up the solid crisp matrix, if utilized in the nutritional
formulation, such as a nutritional bar, be added to the slurry for forming the nutritional
formulation after the slurry has been subjected to the high power ultrasound to minimize
deterioration of the crisps in the end product.
[0042] Because of the nature of the interaction of the components conventionally
utilized to manufacture nutritional bars and other nutritional formulations (i.e., protein,
carbohydrate, lipid, binder, etc.), and the amounts of these components, nutritional bars
prepared by conventional processes (i.e., processes not utilizing high power ultrasound as
described herein) have the ability to hold shape and resist deformation after extrusion or
slabbing, as described herein. When a solid crisp matrix is added to a conventionally
prepared nutritional bar, additional density and structure is provided by the solid crisp
matrix, and the slurries prepared and containing the solid crisp matrix can easily be
conventionally extruded or slabbed into the desired nutritional bar without the problem of
deformation; that is, they generally hold their shape very well after extrusion or slabbing
and can easily be cut without deformation, as compared to some extruded or slabbed
slurries containing different starting materials that tend to deform or collapse after
extrusion or slabbing (such as pretzel dough, shortbread dough, cracker dough, bread, etc,
which include different components as compared to nutritional bars).
[0043] When present, the solid crisp matrix of the nutritional formulations of the
present disclosure generally comprises: 1) from about 10% to about 89% by weight of a
carbohydrate other than, and in addition to, an optional soluble viscous fiber; 2) from
about 1% to about 49% by weight of protein; and 3) optionally from about 10% to about
50% by weight of a soluble viscous fiber. Each of these components of the solid crisp
matrix is described hereinafter in greater detail.
[0044] The nutritional formulations of the present disclosure may include a
combination of the solid crisp matrix along with one or more other solid crisp materials,
wherein the other solid crisp material does not contain a soluble viscous fiber or does not
otherwise contain more than about 9% by weight of a soluble viscous fiber. The other
solid crisp material may represent within the nutritional formulation from zero percent to
about 99%, including from about 5% to about 90%, also including from about 20% to
about 80%, and also including from about 30% to about 50%, by weight of the
combination of the solid crisp matrix and the solid crisp material in the formulation. Such
other solid crisp material includes any conventional or otherwise known grain-based crisp,
preferably having a bulk density within the ranges described herein for the essential solid
crisp matrix component of the nutritional formulation. Non-limiting examples of such
other solid crisp materials include soy crisps, rice crisps, corn crisps, tapioca starch in crisp
form, various multi-grain crisps, and combinations thereof.
[0045] The optional solid crisp matrix component of the nutritional formulation
or nutritional bar of the present disclosure, alone or in combination with an additional crisp
material as described above, preferably represents from about 5% to 100% by weight of
the nutritional formulation, including from about 50% to about 98%, and also including
from about 75% to about 95%, and also including from about 80% to about 90%, by
weight of the nutritional formulation. The nutritional formulation may also comprise from
zero to 95% by weight of optional materials such nuts or seeds, fruit or other flavored
materials, processing aids (e.g., binders), antioxidants, vitamins and minerals, and so forth.
[0046] The solid crisp matrix as formulated into the nutritional formulation may
be an aggregate of low bulk density materials or food particles bound together, or a
continuous or substantially continuous low bulk density matrix, wherein the solid crisp
matrix has a bulk density of less than about 0.4 g'cm3, preferably less than about 0.35
&m3, even more preferably from about 0.10 &m3 to about 0.30 &m3, and even more
preferably from about 0.22 &m3 to about 0.28 &m3, including from about 0.24 &m3 to
about 0.27 g'cm3.
[0047] The bulk density of the solid crisp matrix can be measured or otherwise
determined by most any conventional method, wherein the bulk density is the mass or
weight (gm) per unit volume (cm3) of the matrix, whether the matrix is a solid porous bar
or a formed or free flowing aggregate of smaller solid crisp matrices, with air or gaseous
voids dispersed throughout and between the matrices.
[0048] The solid crisp matrix may be prepared by any method suitable for
making a low bulk density material as described herein. In one embodiment, the solid
crisp matrix may be prepared by an extrusion process, such as a high temperature short
time (HTST) extrusion as a continuous cooking process. The crisp ingredients are
combined (e.g., rice flour, guar gum, tricalcium phosphate, maltodextrin, soy protein
isolate, water), and the combination metered into a feed line with additional moisture
(steam) to an extrusion barrel and conveyed forward by a screw or a series of screws.
Within the screw, there is a groove that becomes progressively shallower towards the
exiting end of the barrel. The mechanical energy, imparted to the feed, is transformed into
heat to cook the feed. To further facilitate this cooking, the barrel can be heated. This
combination of moisture and heat transforms the feed powder into a dough. When the
temperature of the dough exceeds 100" C, the water becomes super-heated. And as the
dough exits the die, the super-heated water explodes and causes expansion of the dough.
This expanded dough can be cut into small pieces and dried or toasted which results in a
solid crisp matrix for use in the nutritional formulations of the present invention. The
process is controlled by conventional means to deliver the requisite bulk density. Some
suitable methods of making such low bulk density food particles or materials in forming a
solid crisp matrix are described, for example, in U.S. Patent 6,676,982 (Mody), which
description was previously incorporated herein by reference.
[0049] The solid crisp matrix, regardless of the method used in preparing it, is
most typically in the form of individual, free flowing, crispy particles, which can then be
combined to form a continuous or discontinuous solid matrix within the nutritional
formulation, all of which may be prepared by conventional bar manufacturing methods
using such food particle crisps as an ingredient.
[0050] The nutritional formulations of the present invention may be prepared in
most any dietary product forms of any size or configuration, e.g., rounded or cylindrical,
circular or wafer-like, rectangular or in a conventional bar form, or random or other
defined shapes. These product forms also include small bite size solids, including those
that are packaged as a plurality of bites within a single container or package. The solid
crisp matrix may also be packaged as free flowing food particles, e.g., breakfast cereal, in
an appropriate box or other package.
[005 11 The nutritional formulations of the present invention may contain one or
more layers of the solid crisp matrix, or may otherwise contain one or more discrete
regions of the solid crisp matrix in a random, arranged, or patterned configuration. The
nutritional formulation, as well as the solid crisp matrix therein, may be partially or
completely coated with any suitable coating material, some common examples of which
include yogurt, chocolate, or other confectionary or otherwise flavored material.
Soluble Viscous Fiber
[0052] The optional solid crisp matrix of the nutritional formulations of the
present disclosure may optionally comprise from about 1% to about 50%, preferably from
about 15% to about 40%, including from about 19% to about 46%, and also including
from about 21% to about 32%, of a soluble viscous fiber by weight of the solid crisp
matrix. The soluble viscous fiber is preferably guar.
[0053] The term "soluble viscous fiber" as used herein, unless otherwise
specified, may include any fiber or fiber containing material that is both viscous and
soluble as defined herein. A soluble fiber for purposes of the present invention is defined
by the American Association of Cereal Chemists (AACC) Method 32-07, wherein a
soluble fiber or fiber source is one in which at least 60% of the dietary fiber is soluble
dietary fiber as determined by AACC Method 32-07.
[0054] The term "viscous fiber" as used herein, unless otherwise specified, refers
to a soluble fiber that when formulated into a solid crisp matrix may provide the matrix
with an in vivo viscosity greater than about 300 centipoise (cps), including at least about
1,000 cps, also including from about 1,000 cps to about 10,000 cps, and also including
from about 3000 cps to about 10,000 cps.
[0055] The in vivo viscosity for purposes of characterizing soluble viscous fibers
is measured by the following method: (I) prepare an aqueous mixture containing 3% by
weight of the solid crisp matrix (10.4 g solid crisp matrix and 349.34 g water); (2) blend
the just-formed mixture for 1 minute; (3) raise the blend temperature to about 37°C by
placement in a 37°C water bath; (4) add 300 microliters of sigma alpha amylase to the
warmed and blended mixture; (5) allow the mixture to set for one hour, and then rapidly
agitate it over about 0.5 minutes to more fully disperse the incubating mixture; and (6)
allow the mixture then to set for a second hour, and then immediately transfer
approximately 250 cm3 of the mixture to a 250 cm3 beaker, and then measure the viscosity
(e.g. of the transferred mixture using a Brookfield viscometer, #62 spindle, at 3 rpm).
[0056] Soluble viscous fibers for use in the solid crisp matrix include any fiber or
fiber system satisfying the above described criteria for fiber in vivo viscosity and fiber
solubility. The soluble viscous fibers may also be defined in the alternative as being a
fiber source comprising one or more of guar gum, gum arabic, sodium carboxymethyl
cellulose, locust bean gum, tapioca starch, alginates, tapioca dextrins, citrus pectin, low
and high methoxy pectin, carrageenan, barley glucans, carrageenan, psyllium, oat Pglucan,
and combinations thereof. Guar gum is preferred.
[0057] As the preferred soluble viscous fiber herein, guar gum (galactomannan
polymer) is a complex carbohydrate derived from the seed of specially grown bean plants.
This carbohydrate is a long chain linear molecule with a molecular weight of
approximately 1 million. The long polymer chains attract and weakly capture water; as
well as physically tangle with one another in solution thus producing viscosity when
mixed with water.
[0058] Non-limiting examples of suitable sources of the soluble viscous fibers,
including sources of guar gum, are available from Tic Gums, 4609 Richlynn Drive,
Belcamp, Maryland, U.S.A 21017 (Guar 8/24, fine mesh, very high viscosity product).
[0059] The soluble viscous fiber may also include two or more soluble viscous
fibers, including the dual fiber systems described in U.S. Patent Application
20030125301Al (Wolf et al.), which description is incorporated by reference herein.
[0060] It has been found that the viscous soluble fiber is formulated into the solid
crisp matrix to provide palatability benefits (e.g., reduced slimy mouth feel, reduced tooth
packing) described herein. And although minor amounts of the fiber may be found
elsewhere in the nutritional formulation, the nutrition formulation outside the solid crisp
matrix may be substantially free of such fibers, including guar. In this context, the term
"substantially free means that the composition may contain less than about 3%, including
less than about 2%, and also including less than about 0. I%, and also including zero
percent, of such fiber within the nutritional formulation but outside the solid crisp matrix
component, all by weight of the nutritional formulation."
Acidulant And Sour Flavorant
[0061] The nutritional formulations and nutritional bars of the present disclosure
may optionally comprise an acidulant, a sour flavorant, or both. Any material that
provides a sour andlor acidic flavor that is known or otherwise suitable for use in a solid
nutritional product may be used in the formulations of the present disclosure, provided that
such materials are safe and effective for oral administration and are compatible with the
essential and other ingredients in the selected product form.
[0062] It has been found that the acidulant and sour flavorants, especially when
used in combination, and even more so when used in combination with pectin pieces as
described hereinafter, improves overall mouthfeel and reduces the extent or frequency of
tooth packing while chewing and consuming the nutritional formulations. Without being
limited by theory, it is believed that the selected acidulants andlor sour flavorants stimulate
more salivation than many other flavors (or no flavor at all) and that the increased
salivation then acts as a lubricant during chewing to further reduce adhesion of the guarcontaining
formulation onto the surfaces of the teeth, especially on the crevaced chewing
surfaces where undesirable tooth packing most often occurs.
[0063] Acidulants suitable for use in the formulations of the present invention
include any organic or inorganic edible acid in undissociated form or, alternatively, as
their respective salts, for example, potassium or sodium hydrogen phosphate, potassium or
sodium dihydrogen phosphate salts, and so forth. Non-limiting examples of suitable
acidulants include citric acid, phosphoric acid, malic acid, fumaric acid, adipic acid,
gluconic acid, tartaric acid, ascorbic acid, acetic acid, phosphoric acid, and combinations
thereof. Acidulant concentrations in the formulation most typically exceed about 0.01% by
weight of the formulation, more typically from about 0.05% to about 3%, including from
about 0.1% to about 1.0%, by weight of the formulation.
[0064] Sour flavorants suitable for use in the formulation of the present
disclosure include any natural or artificial favor or combination of flavors, which provides
the formulation with sufficient sour notes to be detected during consumption. Nonlimiting
examples of such sour flavorants include pieces or extracts of, or natural or
artificial flavors based upon, natural materials such as strawberry, apple, blueberry,
raspberry, blackberry, cherry, orange, lime, lemon, grapefixit, tangerine, bergamot,
calamondin, chironja, citron, clementine, dancy, kumquat, limequat, mandarin orange,
mandarin lime, minneola, orangelo, orangequat, pummelo, rangpur, satsuma, shaddock,
shekwasha, sweety, tangelo, tangor, ugli, or other plant materials containing one or more
of the organic acidulants as described herein. Especially useful are dried strawberry pieces
(flakes) and/or apple pieces.
[0065] Flavorant concentrations can vary considerably depending upon the
flavorant, other ingredients in the formulation, the desired overall flavor profile of the
formulation, whether the flavor comprises whole fruit or only an extract therefrom, and so
forth. Such concentrations, however, most typically and collectively range from at least
about 0.01%, more typically from about 0.05% to about lo%, also including from about
0.1% to about 5%, and also including from about 0.5% to about 4%, by weight of the
nutritional formulation.
Gelled Inclusion
[0066] The nutritional formulations of the present invention may further
comprise one or more gelled inclusions, wherein the inclusions comprise water and not
more than about 9%, including from about 0.5% to about 7%, and also including from
about 1.5% to about 5%, of a primary gellant by weight of the inclusions, and preferably
an acidulant, sour flavorant, or both.
[0067] The term "gelled inclusion" as used herein refers to separate gelled
structures that are prepared prior to final formulation, and then added to the nutritional
formulation as a component of the solid crisp matrix, or as a component separate from the
solid crisp matrix. The gelled inclusions can take the form of many gelled particulates or
pieces collectively dispersed throughout the solid crisp matrix or other areas of the
nutritional formulation, or it can take the form of one or a few larger discrete regions or
layers which represent a large, continuous gelled inclusion(s), e.g., a gelled layer(s) on top
of or within a nutritional bar embodiment.
[0068] Once added to and formulated into the formulation, especially when
dispersed as individual particulates throughout the solid crisp matrix or other component
of the formulation, the gelled inclusions may lose much if not all of their gelled structure,
but still form discreet areas or regions within the nutritional formulation defined by the
presence of the selected gellant and any other ingredients specifically formulated into the
gelled particulates prior to formulating into the nutritional formulation. Such other
ingredients preferably include acidulants, sour-flavorants, or combinations thereof, but
may also comprise any of a variety of other optional ingredients such as other flavorants,
flavor enhancers, artificial or natural sweeteners, sugar alcohols, etc.
[0069] The gelled inclusions preferably represent at least about 1.0% by weight
of the nutritional formulation, more preferably from about 1.2% to about 15%, including
from about 2% to about 1 I%, and also including from about 5% to about 9%, by weight of
the formulation.
[0070] The gellant for use in the gelled inclusions may be any gellant material
safe and effective for use in a nutritional formulation, and which is otherwise compatible
with the other selected ingredients as formulated within the nutritional formulation.
Preferred gellants include the viscous soluble fibers as described herein, to the extent such
fibers can form an aqueous gel at the requisite gellant concentration described above.
Among the viscous soluble fibers described herein, pectin is most preferred.
[007 11 The gelled inclusions are preferably formulated into the nutritional
formulation in combination with the optional but preferred acidulant, sour flavorant, or
both, all as described hereinbefore. The gelled inclusions as particulates are preferably
prepared so that the various particulates contain an acidulant andor sour flavorant,
although it is understood that all or some of such acidulants and sour flavorants can also be
formulated into the nutritional formulations separate from the gelled inclusion, although
the formulation with the gelled inclusion is preferred. When used in combination with a
sour flavorant andor acidulant, the preferred pectin gellant is also preferably a highly
methoxylated pectin, most typically those having a degree of esterification of less than
about 65%, including less than about 50%.
[0072] It has been found that the gelled inclusions such as those containing pectin
pieces or other similar particulates, especially when used in combination with an acidulant
and sour flavorant, provides for even better performance in reduced tooth packing during
consumption, and improved mouthfeel. For purposes of defining the formulations of the
present disclosure, therefore, the concentration of the viscous soluble fiber in the crisp
solid matrix is considered separate from the concentration of the viscous soluble fiber or
gellant concentration provided by the gelled inclusion.
[0073] Non-limiting examples of some gelled inclusions suitable for use in the
formulations of the present invention, including those containing sourlacid flavored pectin
pieces suitable for use herein, include Fantasy 8 Strawberry NSA Fruit Pieces, Artificial;
Natural and Artificial Chocolate Peanut Pieces, NSA; Natural and Artificial Butter-Pecan
Pectin Pieces, NSA; Natural and Artificial Espresso Pectin Pieces, NSA; Natural Apple
Cinnamon Pectin Pieces, NSA; all of which are available from Sensient, Indianapolis,
Indiana, U.S.A. Other non-limiting examples of suitable flavored pectin pieces include
Realfruitchips, Raspberry No Sugars added- Low Net Carbs, available from Brookside
Foods, Ltd., Abbotsford, British Columbia, Canada.
Optional Ingredients
[0074] The nutritional formulations of the present disclosure may further
comprise other optional components that may modify the physical, chemical, aesthetic or
processing characteristics of the products or serve as pharmaceutical or additional
nutritional components when used in the targeted population. Many such optional
ingredients are known or otherwise suitable for use in medical food or other nutritional
products or pharmaceutical dosage forms and may also be used in the formulations herein,
provided that such optional ingredients are safe and effective for oral administration and
are compatible with the essential and other ingredients in the selected product form.
[0075] Non-limiting examples of such optional ingredients include preservatives,
anti-oxidants, buffers, pharmaceutical actives, additional nutrients as described herein,
sweeteners including artificial sweeteners (e.g., saccharine, aspartame, acesulfame K,
sucralose) colorants, flavorants in addition to those described herein, thickening agents and
stabilizers, lubricants, and so forth.
[0076] The nutritional formulations of the present disclosure may further
comprise in addition to and separate from the materials in the solid crisp matrix, various
combinations of the different lipid, carbohydrate, and protein materials described herein,
as well as additional vitamins, minerals, or other nutrients.
[0077] Non-limiting examples of suitable minerals for use herein include
phosphorus, sodium, chloride, magnesium, manganese, iron, copper, zinc, iodine, calcium,
potassium, chromium, molybdenum, selenium, and combinations thereof.
[0078] Non-limiting examples of suitable vitamins for use herein include
carotenoids (e.g., beta-carotene, zeaxanthin, lutein, lycopene), biotin, choline, inositol,
folic acid, pantothenic acid, choline, vitamin A, thiamine (vitamin Bl), riboflavin (vitamin
B2), niacin (vitamin B3), pyridoxine (vitamin B6), cyanocobalamine (vitamin B12), ascorbic
acid (vitamin C), vitamin D, vitamin E, vitamin K, and various salts, esters or other
derivatives thereof, and combinations thereof.
Food Particulates
[0079] The formulations of the present disclosure include embodiments
formulated as free flowing crisp particulates, which may be a final product form or an
intermediate material from which other products may be formulated, such as various solid
bar embodiments of the present disclosure. These free flowing crisp particulates comprise
any of the solid crisp formulations of the present disclosure, which may further comprise
any of the optional ingredients also described herein.
[0080] The free flowing crisp particulates may be coated using any material
suitable for application to such particulates while also maintaining the free flowing
character of such particulates. Such coating materials may be film-forming or non-filmforming
materials, most of which are either biopolymers (proteins and polysaccharides) or
lipids. Non limiting examples of such coating materials include gluten (e.g., wheat
gluten), milk proteins, soy proteins, gelatin, starch (e.g., hydroxypropylated starch),
pectinates, cellulose-ethers, hydrophobic fats or waxes, and combinations thereof.
[008 11 The free flowing crisp particulates may be used as food additives
sprinkled onto or mixed within various foods, consumed alone or in combination with
other food or beverages as a snack or satiety agent, especially prior to meals. The free
flowing crisps may be used as a formulation intermediate in the preparation of other food
products such as snack or meal replacement bars or other consumer food products. As a
food additive for sprinkling onto or mixing with foods, the free flowing crisp particulates
may be formulated with conventional seasoning or other flavors to provide a seasoned or
other flavored food additive in particulate form.
[0082] When formulated for use as a snack or satiety agent, for use prior to or
with a meal, the free flowing crisp particulates include those embodiments comprising in a
single dose of up to about 100 kcals, including from 25 to 100 kcals, also including from
40 to 75 kcal, from at least about 6 grams per dose, including from about 7 to about 16
grams, and also including from about 8 to about 12 grams per dose.
[0083] Optional ingredients especially useful in these free flowing particulates
include sugar alcohols (e.g., maltitol, erythritol, sorbitol, xylitol, mannitol, glycerol,
isolmalt, lactitol) or other low glycemic index ingredients, seasoning, phytosterols,
glycomacropeptide, and so forth, all of which may be formulated within or on (i.e.,
coating) the crisp particulates.
[0084] For coated particulates, the coating may represent up to 25% by weight of
the finished product, including from about 5 to about 20%, and including from about 8 to
about 14%, by weight of the finished product.
[0085] The methods of the present disclosure are directed to the nutritional
formulations of the present disclosure. These methods include the following: (I) the oral
administration of the nutritional formulations to individuals to provide a balanced or
complete source of nutrition; (2) the oral administration of the nutritional formulations to
diabetics or other individuals to provide a blunting of the glycemic response following
administration of a snack or meal; (3) the oral administration of the nutritional
formulations s to diabetics or other individuals to help reduce appetite; and (4) the oral
administration of the nutritional formulations to diabetics or other individuals to help
reduce total body weight or total fat content of the individual.
[0086] The methods of the present invention may comprise the daily
administration of at least one serving of the nutritional formulation, in single or divided
doses, to an individual to whom the benefits of such administration would be useful. In
this context, a serving is defined as the total daily amount of the nutritional formulation to
be administered to the individual, which is most typically in the form of from about 1 to
about 6 bars per day, for a total daily caloric intake from the formulation of at least about
50 kcallday, more typically from about 50 kcallday to about 3,000 kcallday, and even
more typically from about 120 kcallday to about 600 kcallday.
[0087] The nutritional formulations of the present disclosure for use in the
various methods is preferably a bar formulation comprising a combination of lipid, protein,
carbohydrate, vitamins, and minerals, and more preferably comprises from about 99 kcal
to about 350 kcal, more preferably from about 120 kcal to about 280 kcal, per individual
bar.
Manufacture
[0088] The nutritional formulations of the present disclosure may be prepared by
any known or otherwise effective manufacturing technique for preparing the selected solid
product form (including nutritional bars) such as, for example, extrusion or slabbing, so
long as the slurry utilized to form the nutritional formulation is subjected to high power
ultrasound at some point prior to or during the manufacturing process. The high power
ultrasound energy may be applied to the nutritional formulation at any time, so long as the
nutritional formulation is in a flowable state (a slurry for example). Many such
manufacturing techniques are known for any given product form, such as coated or
uncoated, layered or un-layered, nutritional bars, and can be applied by one of ordinary
skill in the art to the nutritional formulations described based on the disclosure herein.
[0089] The methods of the present disclosure utilizing high power ultrasound
provide for improved rheology performance of the flowable material during the
manufacturing of the nutritional product (i.e., nutritional bar) in the form of a less elastic
material. The flowable material subjected to the high power ultrasound and extruded has
flowable properties similar to that of honey; that is, the flowable material subjected to the
high power ultrasound has more Newtonian-type properties such that it can be pumped and
fed into the extruder easier.
[0090] In general, the nutritional bars and other solid formulations of the present
disclosure are most typically manufactured by conventional methods commonly used for
non-baked nutrition bars, so long as the methods include the use of high power ultrasound
as described herein. In one specific embodiment, an extrusion process including a high
power ultrasound step or steps is utilized to make a nutritional bar. One suitable extrusion
process is a conventional high temperature short time (HTST) extrusion as a continuous
cooking process including at least one high power ultrasound step wherein the slurry is
exposed to high power ultrasound.
[009 11 Referring now to Figure 1, there is shown an extrusion apparatus 1
suitable for use in the high power ultrasound extrusions processes of the present
disclosure. The extrusion apparatus 1 includes feeder 3 (which may optionally include one
or more stirrers within, not shown) for dry ingredients, feeding screw 4, and liquid additive
opening 5 for liquid ingredients. Feeder 3 and liquid additive opening 5 both feed into
preconditioner 7, which includes mixing arms 9, 1 1, 13, and 15. Preconditioner 7 provides
a mixture of dry and liquid ingredients for extrusion into extruder 17 including screw 19
(multiple screws may also be used, not shown) and through shaping die 21. Connected to
the extruder 17 is horn 23, which provides the high power ultrasound to the extruder 17.
Horn 23 is connected to booster 25, which is connected to converter 27 for originating the
high power ultrasound. High power ultrasound power supply 29 and wattmeter 3 1 are also
shown.
[0092] When an extrusion process is utilized to prepare a nutritional bar, the
desired components are first combined (e.g., protein, carbohydrate, lipid, binder, water,
flavorings, vitamins, minerals, etc.), to form a slurry, or multiple slurries, that are
ultimately combined together at a point prior to extrusion to form a final slurry including
all desired components. This resulting slurry is then subjected to high power ultrasound
either before extrusion, during extrusion, or both before and during extrusion of the slurry
to form the nutritional bar. In some embodiments, if multiple slurries are formed, each of
the multiple slurries may be subjected to high power ultrasound individually and then
combined into the final slurry, which may or many not be subjected to further high power
ultrasound prior to extrusion. If solid crisps are to be added to the extruded nutritional bar
such that the resulting nutritional bar includes a solid crisp matrix, they are preferably
added to the slurry or slurries after high power ultrasound has been applied to the slurry or
slurries and before extrusion. Because the high power ultrasound may, in some
embodiments, reduce the structural integrity of the formed crisps in the nutritional bar, it is
generally preferred to add the crisps to the slurry or slurries after high power ultrasound
has been applied to the slurry or slurries, but prior to the extrusion process. It is within the
scope of the present disclosure, however, to add crisps into one or more of the slurries
prior to the treatment of the one or more slurries with high power ultrasound such that the
crisps are subjected to the high power ultrasound.
[0093] High power ultrasound is generally applied to the slurry for a time period
of less than about 60 minutes total, including about 50 minutes total, or even about 40
minutes total, or even 30 minutes total, or even 25 minutes total, or 20 minutes total, or 15
minutes total, or 10 minutes total, or 5 minutes total, or even 3 minutes total. In some
processes, the slurry ultimately introduced into the extruder may be subjected to multiple
rounds of high power ultrasound during formation; that is, a slurry including a first two
ingredients may be subjected to high power ultrasound for a few minutes before one or
more additional components is added to the ultrasonically treated slurry and then the new
slurry, including the additional components may be subjected to high power ultrasound.
The slurry ultimately introduced into the extruded may have been subjected to high power
ultrasound 1, 2, 3, 4, or even 5 or more times during the preparation process of the ultimate
slurry extruded into the final product.
[0094] The high power ultrasound applied to the slurry generally has a frequency
of less than about 40 Kilohertz, including less than about 30 Kilohertz, or even less than
about 20 Kilohertz, or even less than about 15 Kilohertz.
[0095] After the slurry is formed and high power ultrasound has been applied to
the slurry (as noted above, high power ultrasound may optionally be applied during the
extrusion), the slurry is metered into a conventional feed line with additional moisture
(steam) to an extrusion barrel and conveyed forward by a screw or a series of screws.
Within the screw, there is a groove that becomes progressively shallower towards the
exiting end of the barrel. The mechanical energy, imparted to the slurry feed, is
transformed into heat to cook the slurry feed. To further facilitate this cooking, the barrel
can optionally be heated. This combination of moisture and heat transforms the slurry
feed into a dough. When the temperature of the dough exceeds 100" C, the water becomes
super-heated. And as the dough exits the die, the super-heated water explodes and causes
expansion of the dough. This expanded dough can be cut into desired shapes and sizes and
packaged in a sealed package to form ultrasonically treated nutritional bars of the present
disclosure having increased shelf life. The process is generally controlled by conventional
means to deliver the desired bulk density.
[0096] In another suitable embodiment for making nutritional bars of the present
disclosure, which does not include an extrusion process, the various components (e.g.,
protein, carbohydrate, lipid, binder, water, etc.) are combined together with agitation and
heated to about 140°F to form a substantially homogeneous slurry. The slurry is then
subjected to high power ultrasound as described above, and then fed into a mixer and
optionally combined with solid crisp particles and other ingredients. The resulting slurry
is then slabbed (e.g., 0.5-1.0 inch sheets), cut into the desired shapes, optionally coated,
cooled, and then packaged in a sealed package to produce an ultrasonically treated
nutritional bar having extended shelf life.
[0097] In another embodiment of the present disclosure nutritional bars may be
produced in any conventional manner, such as by conventional extrusion, and be subjected
to high power ultrasound as described herein after extrusion; that is, the nutritional bar
may be extruded using conventional means (i.e., means without high power ultrasound)
and the formed nutritional bar (not still in a substantially flowable state) subjected to high
power ultrasound to impart one or more of the benefits described herein. In this
embodiment, the formed bar may be subjected to high power ultrasound immediately after
extrusion, or within about 1 minute, or about 2 minutes, or about 3 minutes, or even about
5 minutes, or 10 minutes or even up to about 30 minutes after extrusion.
[0098] The formulations of the present disclosure may, of course, be
manufactured by other known or otherwise suitable techniques not specifically described
herein without departing from the spirit and scope of the present invention. The present
embodiments are, therefore, to be considered in all respects as illustrative and not
restrictive and that all changes and equivalents also come within the description of the
present invention. The following non-limiting examples will further illustrate the
formulations and methods of the present invention.
EXAMPLES
[0099] The following examples illustrate specific embodiments and/or features of
the nutritional formulations and nutritional bars of the present disclosure. The examples
are given solely for the purpose of illustration and are not to be construed as limitations of
the present disclosure, as many variations thereof are possible without departing from the
spirit and scope of the disclosure. All exemplified amounts are weight percentages based
upon the total weight of the formulation, unless otherwise specified.
Example 1
[0100] Example 1 illustrates hardness reduction and toughness reduction in three
nutritional samples prepared utilizing high power ultrasound in the preparation process
(Samples 1-3) as compared to two control nutritional samples prepared without high power
ultrasound (Controls 1-2). The frequency of the high power ultrasound was fixed at 20
KHz and 100% and the power was set at 1,000 W. Each bar dough formed was shaped
into a bar and measured for hardness (force measurement) and toughness (area under the
force curve) within the same day as being manufactured.
[0101] The components of the five nutritional samples prepared and evaluated
are set forth in the table below.
juice concentrates and natural grain
[0102] Control #I is prepared by mixing together all of the liquid ingredients and
heating the resulting mixture to 120°C. Once the temperature is achieved, all of the
powdered ingredients are added to the liquid ingredients and the resulting slurry mixed
together to form a bar dough.
[0103] Control #2 is prepared by first mixing together all of the liquid ingredients
and heating the resulting mixture to 120°C, and then adding the soy protein isolate,
fi-uctose, maltodextrin 180 and fi-uctooligosaccharides thereto to form a slurry. The slurry
is then heated to 170°C in a microwave oven. Once the temperature is achieved, the
remaining powdered ingredients are added to the slurry and mixed together to form a bar
dough.
[0104] Sample #I is prepared by first microwaving the chocolate liquor for about
90 seconds and then introducing the remaining liquid ingredients into the chocolate liquor
with mixing. The resulting liquid mixture is subjected to high power ultrasound for about
5 minutes. The soy protein isolate is then added to the mixture and the resulting mixture is
subjected to high power ultrasound for about 15 minutes. The fi-uctose is then added to the
mixture and the resulting mixture is subjected to high power ultrasound for about 10
minutes. The maltodextrin 180 is then added to the mixture and the resulting mixture is
then subjected to high power ultrasound for about 10 minutes. One half of the total
amount of Fibersol 2 is then added to the mixture and the resulting mixture is subjected to
high power ultrasound for about 10 minutes. The remaining powdered ingredients are then
mixed into the mixture to form a bar dough.
[0105] Sample #2 is prepared by first microwaving the chocolate liquor for about
90 seconds and then introducing the remaining liquid ingredients into the chocolate liquor
with mixing. The resulting liquid mixture is subjected to high power ultrasound for about
5 minutes. The soy protein isolate is then added to the mixture and the resulting mixture is
subjected to high power ultrasound for about 15 minutes. The fi-uctose is then added to the
mixture and the resulting mixture is subjected to high power ultrasound for about 10
minutes. The fi-uctooligosaccharides are then added to the mixture and the resulting
mixture is then subjected to high power ultrasound for about 10 minutes. The
maltodextrin 180 is then added to the mixture and the resulting mixture is subjected to
high power ultrasound for about 10 minutes. The remaining powdered ingredients are then
mixed into the mixture to form a bar dough.
[0106] Sample #3 is prepared by first microwaving the chocolate liquor for about
90 seconds and then introducing the remaining liquid ingredients into the chocolate liquor
with mixing. The resulting liquid mixture is subjected to high power ultrasound for about
30 seconds. The soy protein isolate is then added to the mixture and the resulting mixture
is subjected to high power ultrasound for about 1 minute. The fi-uctose is then added to the
mixture and the resulting mixture is subjected to high power ultrasound for about 1
minute. The fi-uctooligosaccharides and maltodextrin 180 are then mixed together, and
this mixture of fi-uctooligosaccharides and maltodextrin 180 is then added to the mixture
and the resulting mixture is then subjected to high power ultrasound for about 1 minute.
The remaining powdered ingredients are then mixed into the mixture to form a bar dough.
[0107] The hardness and toughness of the control and samples bars were
measured using a TA.XTplus Texture Analyzer (Texture Technologies, Scarsdale, N.Y.)
wherein hardness was determined as the maximum point on the curve generated and
toughness was determined as the area under the same curve. The test used the 45 degree
angle Chisel Blade, and the following settings (two distance settings were utilized as each
sample was tested at both distances): (I) Test Mode: compression; (2) Pre-Test Speed: 1
millimeter per second; (3) Test Speed: 2 millimeters per second; (4) Post-Test Speed: 10
millimeters per second; (5) Target Mode: Distance; (6) Distance: 5 millimeters and 10
millimeters per second; (7) Trigger Type: Auto (Force); (8) Trigger Force: 5.0 grams; (9)
Break Mode: Off; (10) Stop Plot At: Start Position; (1 1) Tare Mode: auto; (12) Advanced
Options: On; (13) Control Oven: disabled; and (14) Frame Deflection Correction: off.
[0108] The results of the hardness and toughness experiments are shown in the
following Table.
[0109] As the data in the table above indicate, the application of high power
ultrasound during the manufacturing process generally reduces that hardness and
toughness of the resulting bar. Also as the data show, variable that impact that textural
characteristics of the resulting materials include temperature, time, order of addition of the
ingredients, and length of ultrasound. Notably, Samples 2 and 3 had significantly reduced
hardness and toughness as compared to the control bars.
Sample Evaluated
Control # 1
Control #2
Sample #1
Sample #2
Sample #3
Hardness (Force)
1203.4
566.5
935.4
261.8
443.3
Toughness (ForceJ'Displacement)
2586.4
1249.2
1664
323.1
971.6
Examples 2-6
[O 1 101 Examples 2-6 illustrate ultrasonically treated nutritional bar embodiments
of the present disclosure, the starting ingredients of which are listed in the following Table.
[O 11 11 The nutritional bars are prepared in accordance with the present disclosure
utilizing a high temperature short time (HTST) extrusion as a continuous cooking process.
The liquid ingredients are mixed together and heated to a temperature of about 120°C and
the powder ingredients are added thereto to form a slurry. This resulting slurry is then
subjected to high power ultrasound (at about 20 KHz) before extrusion for a time period of
about 10 minutes.
[0112] After the slurry is formed and high power ultrasound has been applied to
the slurry, the slurry is metered into a feed line with additional moisture (steam) to an
extrusion barrel and conveyed forward by a screw or a series of screws. Within the screw,
there is a groove that becomes progressively shallower towards the exiting end of the
barrel. The mechanical energy, imparted to the slurry feed, is transformed into heat to
cook the slurry feed. This combination of moisture and heat transforms the slurry feed
into a dough. When the temperature of the dough exceeds 100°C, the water becomes
super-heated. And as the dough exits the die, the super-heated water explodes and causes
expansion of the dough. This expanded dough can be cut into desired shapes and sizes and
packaged in a sealed package to form nutritional bars of the present disclosure having
increased shelf life.
Example 7-11
[O 1 131 Examples 7- 1 1 illustrate ultrasonically treated nutritional bar
embodiments of the present disclosure, the starting ingredients of which are listed in the
following Table.
[O 1141 The nutritional bars are prepared in accordance with the present disclosure
utilizing a slabbing process. The liquid components and the powdered components are
combined together with agitation and heated to about 140°F to form a substantially
homogeneous slurry. The slurry is then subjected to high power ultrasound (about 20
KHz) for about 10 minutes, and then fed into a mixer. The resulting mixed slurry is then
slabbed (e.g., 0.5-1.0 inch sheets), cut into the desired shapes cooled, and then packaged in
a sealed package to produce a nutritional bar having extended shelf life.

WHAT IS CLAIMED IS:
1. A composition comprising an ultrasonically-treated nutritional
formulation and a sealed package, the nutritional formulation comprising from about
5% to about 95% (by weight) carbohydrate, from about 5% to about 95% (by weight)
protein, and from about 1% to about 30% (by weight) lipid.
2. The composition of claim 1 wherein the carbohydrate is present in an
amount of from about 10% to about 30% by weight of the nutritional formulation and
the protein is present in an amount of from about 2% to about 10% by weight of the
nutritional formulation.
3. The composition of claim 1 wherein the nutritional formulation further
comprises a lipid in an amount of from about 1% to about 30% by weight of the
nutritional formulation.
4. The composition of claim 1 wherein the nutritional formulation further
comprising a lipid in an amount of from about 3% to about 15% by weight of the
nutritional formulation.
5. The composition of claim 1 wherein the nutritional formulation further
comprises a soluble viscous fiber in an amount of from about 10% to about 50% by
weight of the nutritional formulation.
6. The composition of claim 5 wherein the soluble viscous fiber
comprises guar gum.
7. The composition of claim 1 wherein the nutritional formulation has a
bulk density of less than 0.4 &m3.
8. The composition of claim 1 wherein the nutritional formulation has a
bulk density of from about 0.22 &m3 to about 0.28 gkm3.
9. The composition of claim 1 wherein the nutritional formulation
includes a solid crisp matrix.
10. The composition of claim 1 wherein the nutritional formulation has a
moisture content of from about 5% to about 10% (by weight).
11. The composition of claim 1 wherein the nutritional formulation has a
moisture content of from about 7% to about 9% (by weight).
12. A process of manufacturing an ultrasonically-treated nutritional
formulation, the process comprising:
combining a protein, a carbohydrate, a lipid, a binder, and water to form a
slurry;
subjecting the slurry to high power ultrasound; and
extruding the slurry to produce the ultrasonically-treated nutritional
formulation.
13. The process of claim 12 wherein the slurry is subjected to the high
power ultrasound before the extrusion is performed.
14. The process of claim 12 wherein the slurry is subjected to the high
power ultrasound simultaneously with the extrusion.
15. The process of claim 12 wherein the slurry is subjected to the high
power ultrasound before and simultaneously with the extrusion.
16. The process of claim 12 wherein the high power ultrasound has a
frequency of less than about 30 Kilohertz.
17. The process of claim 12 wherein the high power ultrasound has a
frequency of less than about 20 Kilohertz.
18. The process of claim 12 wherein the high power ultrasound has a
frequency of less than about 15 Kilohertz.
19. The process of claim 13 wherein the slurry is subjected to the high
power ultrasound for a time period of about 15 minutes or less prior to extrusion.
20. The process of claim 13 wherein the slurry is subjected to the high
power ultrasound for a time period of about 10 minutes or less prior to extrusion.
2 1. The process of claim 13 wherein the slurry is subjected to the high
power ultrasound for a time period of about 5 minutes or less prior to extrusion.
22. The process of claim 13 wherein the slurry is subjected to the high
power ultrasound for a timer period of about 3 minutes prior to extrusion.
23. The process of claim 12 wherein the extrusion is a high temperature
short time extrusion.
24. The process of claim 12 where solid crisps are introduced into the
slurry after the application of high power ultrasound and prior to extrusion.
25. A process of manufacturing an ultrasonically-treated nutritional
formulation, the process comprising:
combining a protein, a carbohydrate, a lipid, a binder and water to form a
slurry;
subjecting the slurry to high power ultrasound; and
slabbing the ultrasonically-treated slurry to produce the ultrasonically-treated
formulation.
26. The process of claim 25 wherein solid crisps are added to the slurry
after high power ultrasound is applied and prior to slabbing.
27. The process of claim 26 wherein the solid crisps include guar.
28. The process of claim 25 wherein the nutritional formulation includes
from about 1% to about 50% carbohydrate and from about 1% to about 20% protein.
29. The process of claim 25 wherein the nutritional formulation includes
from about 10% to about 30% carbohydrate and from about 2% to about 10% protein.
30. The process of claim 27 wherein the nutritional formulation includes
from about 3% to about 15% lipid, from about 10% to about 30% carbohydrate, and
from about 2% to about 10 % protein.AS ATTACHED