WO2006063690A1

Why Did Bjs Stop Selling Beef Bouillon Cubes

Info

Publication number: WO2006063690A1
Application number: PCT/EP2005/012837
Authority: WO
Inventors: Vivyan Yan Ying
Original assignee: Unilever N.V.; Unilever Plc; Hindustan Lever Limited
Priority date: 2004-12-14
Filing date: 2005-11-24
Publication date: 2006-06-22
Also published as: AU2005315984B2; AU2005315984A1; AR051718A1

Abstract

Process for making bouillon cubes or seasoning cubes free of trans unsaturated fatty acids. The process comprises mixing powdered fat with the particulate ingredients followed by pressing.

Description

PROCESS FOR MAKING BOUILLON OR SEASONING CUBES

Field of the invention

The present invention relates to a process for making bouillon or seasoning cubes, wherein at least part of the fat is powdered fat.

Background of the invention

Bouillon cubes are well known articles in the western and non-western cooking. Conventionally, bouillon cubes comprise solid, more or less dry ingredients such as one or more of salt, sugar, flavour enhancers (like e.g. monosodium glutamate MSG), herbs, spices, vegetable particulates, colourants and flavourants, next to e.g. 1-30% fat or oil.

The industry distinguishes between so-called hard bouillon cubes and soft (or pasty) bouillon cubes. Soft or pasty bouillon cubes can usually be deformed by squeezing between two fingers before they break up into lumpy crumbles, and usually leave a_ pasty/oily feel on the fingers. Hard cubes tend to crumble into powder, lumps or small particulates upon squeezing between fingers. Crumbling between fingers is relevant for seasoning cubes, or for bouillon cubes used as seasoning cubes, as such cubes are usually crumbled between two fingers above food (e.g. in a cooking pot) or a dish. Even though some processed cubes crumble fairly well, a lot of cubes are still too hard to be easy to crumble, or, if they can be crumbled reasonably well they crumble to lumpy matter, rather than fine particulates or powders, as may be desired for good dispersion of flavouring ingredients. Also, the hardness of most (pressed) bouillon cubes tends to increase over time, but it is desired that over time, the cubes stay easy to crumble.

Hence, there is a need for bouillon and seasoning cubes, tablets and the like (including all geometric forms, including ball shape, ecetera) that are easy to crumble, and preferable stay easy to crumble over time. It is also preferred that the cubes crumble to powdery matter, and not to lumpy matter (as lumpy matter still hinders good dispersion of flavouring ingredients).

Seasoning cubes can be prepared in a similar way as bouillon cubes and often contain similar ingredients, but can contain (depending upon use) more fat, e.g. 10-98%. As the fats used in bouillon cubes or seasoning cubes should not stain the packaging and/or melt upon storage, partially or fully hardened vegetable oils are frequently used as fat in such cubes, optionally together with liquid oil.

Conventional manufacturing of pressed bouillon cubes involves melting fat, mixing with dry solid ingredients (salt, MSG, herbs, spices, etc), leaving the mixture to mature for e.g. 24 hours, followed by pressing into cubes. Seasoning cubes can be prepared in much the same way. EP 1419699 discloses bouillon cubes using a specific fat blend. The fat used is solid at room temperature, and processing is reported to be in the conventional way for bouillon cubes, which is along the lines as disclosed above.

EP 594152 discloses a process for manufacturing granules comprising fat and particulate matter (e.g. flour), in which the fat is first melted and then mixed with the particulates matter and processed further.

EP 780058 relates to processes for producing flowable powdered foodproducts. To this end, fat is melted, when melted mixed with particulate ingredients, thus coating the particulate ingredients with melted fat. The so-obtained mixture is reported to be flowable. The introduction of this patent application refers to a process for producing stock cubes via a process which is referred to as the "hard" process. Such "hard" process is reported to comprise the steps of melting and mixing solid fats, cool such melted fats on a roller to produce fat flakes. Such fat flakes are then mixed with the other ingredients of the stock products and the mixture pressed to cubes.

US 2002/0168450 discloses melting bodies comprising a filling and an outer wall. The filling is reported to be pulverulent, liquid or semi-liquid.

EP 888723 discloses a process for preparing solid savoury seasoning articles which are prepared by melting fat at e.g. 50-60⁰C, followed by mixing the melted fat with the other ingredients, conditioning this mixture at 5-25°C, shaping, covering with a sticking agent followed by covering with visual elements.

Summary of the invention

A process for preparing bouillon or seasoning cubes has now been developed, the process c coommpprriissiinngg t thhee s stteeppss o off:: (a) mixing 2-99% of particulate ingredients comprising one or more of salt, flavour enhancers, spices, herbs, flavourants, sugar, yeast extract, or hydrolysed vegetable protein with 1- 98% of fat solid at 20⁰C in the form of a powdered fat,

(b) pressing to cubes, wherein the powdered fat has such a particle size that in a sieve analysis at least 80% by weight of the individual powdered fat particles passes a sieve with a mesh size of 2 mm, and wherein the powdered fat is prepared by one or more of spray-cooling, spray-chilling, spray- freezing, prilling, grinding, cryo-grinding, or milling.

In the process as given above wide ranges of the amount of ingredients are given. The actual amount depends e.g. on the intended use. For bouillon (incl. broth and stock and the like) cubes the amount of fat is preferably 1-30%, more preferably 2-25%. For seasonings (incl. melting) cubes the amount of fat is preferably 10-99%, more preferably 20-70%. Cubes e.g. for soups and sauces can have fat contents of 5-60%, preferably 10-50%. All percentages are percentages by weight of the total cube. For very low amounts of fat (e.g. 1-5%) it may be needed to include ingredients of which it is known that they aid compressing into a tablet, like maltodextrin and/or moist ingredients.

In the above, the powdered fat has preferably such a particle size that in a sieve analysis: at least 80% by weight of the individual fat powder-particles passes a sieve with a mesh size of 2 mm, and more preferably at least 80% by weight of the individual fat powder-particles passes a sieve with a mesh size of 1.5 mm, and even more preferably at least 80% by weight of the individual fat powder-particles passes a sieve with a mesh size of 1 mm, and most preferably at least 80% by weight of the individual fat powder-particles passes a sieve with a mesh size of 0.5 mm. Preferably, the powdered fat is not micronised fat or granulated micronised fat.

Detailed description of the invention

It was surprisingly found that cubes prepared in this way are, under otherwise identical processing conditions (e.g. compression pressure, moisture, temperature) can be easier to crumble between fingers, can stay easier to crumble over time, and can yield non-lumpy matter upon crumbling. In this case, crumbling was easier and more complete than cubes prepared in a process in which the solid fat is in a different physical format. Herein, the powdered fat (or fat in pwodered form) which is prepared by spray-cooling, spray- chilling, spray freezing, prilling, grinding, cryo-g rind ing, or milling, as in use in the present invention, is for brevity referred to as "powdered fat".

It was furthermore found that (when working at temperatures less than 2O⁰C) in the process according to the invention the fat (when in such small particulates as indicated) could be mixed with the other particulate ingredients in a fairly easy way using equipment as known in the art, e.g. using a ribbon, paddle or Nauta mixer. It can be prefeσed, e.g. when working at higher temperatures than 20⁰C) that the fat in the process according to this invention is solid at 30⁰C, in powdered form. More preferred can be wherein the fat in the process according to this invention is solid at 40⁰C, in powdered form. Powdered form is herein to be understood as each individual particulate is solid, and (due to e.g. size of the particulates) the whole mass of fat is preferably free-flowing.

At reasonable environmental and processing conditions, the fat as specified above is free flowing at temperatures below 20°C (prior to mixing with the other ingredients). To take into account slightly higher processing or environmental temperatures, it can be preferred to use powdered fat of which the particulates are free flowing at temperatures below 30⁰C, more preferably free flowing at temperatures below 40°C.

Such fat (in particular specified by the small particles and the temperature at which they are solid: 20°C, preferably 30⁰C, more preferably 40⁰C) can be free flowing. The bulk density (as a bed) of the powdered fat as used in the process according to the invention is preferably 400- 700 g/l, more preferably 500-600 g/l. The free-flowing nature of the fat can enhance efficiency, which is an additional benefit of the process according to this invention.

Preferred fats for the application as set out herein are fully hardened vegetable fats. It is preferred to use powdered fat which comprises 10-100% fully hardened palm oil.

Although the mixing stage can last almost infinitively long, it is preferred for that mixing is sufficiently long to obtain a homogeneous mixture for all particulate ingredients. Actual mixing times needed will depend e.g. on the type of mixer chosen, and the mixing times needed can be determined by the skilled person in the art, taking into account a minimum time of mixing needed. From a practical point of view preferred that the first mixing stage takes 10 seconds to 60 minutes, preferably 1 - 20 minutes (as long as a homogeneous mixture is obtained by the mixing operation). The mixing itself can be performed with any mixer as known in the art of making bouillon cubes, such as a ribbon, paddle mixer or Nauta mixer.

It is preferred that the powdered fat according to the present invention comprises less than 3% (wt % based on total fat) of triglycerides of trans-fatty acids.

Contrary to the prior art, the presently claimed process does not require the bulk ingredients (apart from the fat) to be milled. Hence, preferably they are not milled. Also, it is preferred that the cubes according to the invention do not comprise a filler (e.g. material of the carbohydrate group like (com)starch, flour, cassava powder, and/or maltodextrin) and/or sticking agent.

In the process and product according to the invention the flavour enhancers preferably comprise monosodium glutamate or other particulate flavour enhancers.

At least part of the fat solid at 20°C should be powdered fat. Preferably all of the fat solid at 20⁰C used in the present formulation is powdered fat (particles sizes as indicated before). The powdered fat can be a fat already solid at 20⁰C as it is, or by fully hardening a vegetable oil. Although fats that become liquid at e.g. 25°C may work under processing temperatures which are lower, it may be preferred to use fats (for fraction (a) above) that are still solid at 30⁰C, or more preferably still solid at temperatures above 40⁰C. This will widen the margin for operating conditions. The fat fraction (a) should be solid at processing (mixing) temperature, and preferably still contain enough solid matter under storage conditions. Preferably, no liquid oil is included in the formulations and processes according to the invention.

Depending upon the recipe, the mixing stage may include one or more of herbs, spices, nucleotide flavour enhancers, vegetable particulates, meat powder, flavourants, colourants in the mixture.

The pressing preferably comprises pressing in a mould. The cubes may be pressed by conventional pressing equipment for (hard) bouillon or seasoning cubes, such as Fette presses.

Although it is referred to herein as "bouillon cubes or seasoning cubes", the present invention of course does not just encompass cube-shaped objects, but also other solid particulates of 1- 25 gram weight (preferably 2-2Og, more preferably 3-2Og), preferably of regular shape, and of other geometric form, such as tablets, triangles, balls, cones, and also briquettes, pellets etcetera. Likewise, the invention does not just relate to cubes for making bouillon, but also to cubes for preparing a broth or stock, use as seasoning, as or for use in soup, sauce, etcetera. The apparent bulk density of the pressed cubes according to the invention is preferably above 650 g/l, more preferably above 700 g/l.

Depending upon the exact compositions and auxiliary components, either hard or soft cubes can be obtained.

EXAMPLES

Example 1

Hard bouillon cubes were made according to the following composition:

Figure imgf000007_0001

In the above, Sett P55 is a powdered fat having a bulk density range of 500-600g/L. The sieve analysis is as follows.

- approx. 50%, with mesh size 0.2 mm

- approx. 100%, mesh size 0.5 mm - 100%, mesh size 1.0 mm.

The processing involved mixing all dry ingredients including the solid fat (Sett P55) in a paddle mixer for 5 minutes. Then the mixture was fed to a cubing machine (W. Fette, Rotary Tabletting Machine Hanseate Perfecta 4B). No maturation time was needed between mixing and pressing. The resulting cubes were dry, still fairly hard, but upon pressure by hand crumbled apart. Example 2

Bouillon cubes were made according to the following composition:

Figure imgf000008_0001

With the above base recipe three different trials were made, differing in the physical format of the fat employed. The physical formats were: melted, liquid fat

- fat flakes

- spray-cooled fat powder

The spray cooled powdered fat was obtained from the firm Juchem. The fat flakes were produced between rollers and breaking it up. Particle sizes as estimated by microscopy: Fat flakes: at least 70% by weight has a diameter of 350-500 microns, and a thickness of 200- 400 microns. Powdered fat: at least 70% by weight has a diameter of 2-6 microns.

The processing involved mixing all non-fat ingredients in a small, lab-bench Kenwood mixer for 2 minutes. The fat was added and mixed for another 5 minutes (melted liquid fat was added whilst in melted state, at 60⁰C). Thereafter, the mixture was fed to a lab-bench, simple cubing equipment. The powder was compressed by applying 5 kN pressure. The resulting cubes were tested for hardness / ease of crumbling, as well as the type of crumbles formed, by crumbling by hand, on two moments: immediately after pressing and 5 days later. The resulting cubes were tested on easy of crumbling, and it was monitored how it crumbled. The results are set out in the table below:

Figure imgf000009_0001

(1): directly after pressing. (2): 5 days after pressing

It shows that cubes prepared with fat flakes and spray cooled fat are immediately after pressing far easier to crumble than processes in which melted fat is included (using otherwise the same recipe and processing, e.g. compression force), with the cubes with powdered fat being easiest to crumble. The resulting crumbled product was similar for flakes and powdered fat (immediately after pressing).

After 5 days there is a difference between cubes which contain (spray-cooled) powdered fat vs. flakes: the cubes that contain powdered fat still break down to powder, whereas the cubes that contain fat flakes now break down in more lumpy material. This breaking down in powder is a desired result. It is expected that the difference between recipes in which (spray-cooled) powdered fat is used when compared with recipes with fat flakes become bigger when there is more time between testing and pressing. Such is relevant as such cubes are usually stored by the consumer for a long to very long time.

Claims

1. Process for preparing bouillon or seasoning cubes, the process comprising the steps of: (a) mixing 2-99% of particulate ingredients comprising one or more of salt, flavour enhancers, spices, herbs, flavourants, sugar, yeast extract, or hydrolysed vegetable protein with 1-98% of fat solid at 20⁰C in the form of a powdered fat, (b) pressing to cubes, wherein the powdered fat has such a particle size that in a sieve analysis at least 80% by weight of the individual powdered fat particles passes a sieve with a mesh size of 2 mm, and wherein the powdered fat is prepared by one or more of spray-cooling, spray- chilling, spray-freezing, prilling, grinding, cryo-grinding, or milling.

2. Process according to claim 1, wherein the powdered fat has such a particle size that in a sieve analysis at least 80% by weight of the individual powdered fat particles passes a sieve with a mesh size of 1.5 mm.

3. Process according to claim 1-2, wherein the powdered fat has such a particle size that in a sieve analysis at least 80% by weight of the individual powdered fat particles passes a sieve with a mesh size of 1 mm.

4. Process according to claim 1-3, wherein the formulation comprises 1-30% of fat solid at 30⁰C in particulate form.

5. Process according to claim 1-4, wherein the formulation comprises 1-30% of fat solid at 40⁰C in particulate form.

6. Process according to claim 1-5, wherein the fat prior to mixing is free flowing at temperatures below 20⁰C, preferably below 30°C, more preferably below 40⁰C.

7. Process according to claim 1-6, wherein the bulk density of the powdered fat used in the process is 400-700 g/l, preferably 500-600 g/l.

8. Process according to claim 1-7, wherein the fat solid at 2O⁰C in particulate form comprises 10-100% fully hardened palm oil.

9. Process according to claim 1-8, wherein the mixing stage takes 10 seconds to 120 minutes, preferably 30 seconds to 60 minutes.

10. Process according to claim 1-9, wherein pressing comprises pressing in a mould.

11. Process according to claim 1-10, wherein the amount of fat solid at 2O⁰C in particulate form is 5-20%.

12. Process according to claim 1-11 , wherein fat solid at 20⁰C contains less than 3% (wt % based on total fat) of triglycerides of trans-fatty acids.

13. Process according to claim 1-12, wherein one or more of herbs, spices, nucleotide flavour enhancers, vegetable particulates, meat powder, flavourants, colourants are included in the mixing step.