Abstract:
The present invention is comprised of an increased dietary fiber method and treatment for processed foods to add dietary fiber to processed foods, control water activity (aw) and increase the pliability of the high fiber ingredients during mixing, blending and forming operations. The method adds soluble fiber ingredients to the processed food mixtures to provide consumers with a high fiber source to meet recommended daily Adequate Intake of fiber. The method additionally reduces non-fiber carbohydrate sources and sugar alcohols providing other beneficial physiological effects and helps to control water activity by using liquid soluble fiber to bind water adding to the shelf life of the processed food products. The treatment increases the pliability of the ingredient mixtures to more thoroughly combine, mix and blend the ingredients. The treatment continues to provide increased pliability of the completed product mixture during a product forming process.

Description:
BACKGROUND 
       [0001]    The USDA states that dietary fiber and the macronutrients they contain have beneficial physiological effects in humans. USDA reports that data shows Median intakes of Dietary Fiber for young men and women are half of the Adequate Intake (AI) for Total Fiber in foods. Currently many processed foods use non-fiber carbohydrates sources in order to increase pliability in forming or shaping processes such as bar making techniques. The reduced fiber content deprives the consumer of an opportunity to increase their dietary intake of fiber. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0002]      FIG. 1  shows a block diagram of an overview of an increased dietary fiber method and treatment for processed foods of one embodiment of the present invention. 
           [0003]      FIG. 2A  shows a flow chart of an increased dietary fiber method and treatment for processed foods high fiber flavored sweetener mixture process of one embodiment of the present invention. 
           [0004]      FIG. 2B  shows a flow chart of an increased dietary fiber method and treatment for processed foods dry ingredients coating process of one embodiment of the present invention. 
           [0005]      FIG. 2C  shows a flow chart of an increased dietary fiber method and treatment for processed foods forming process of one embodiment of the present invention. 
           [0006]      FIG. 3A  shows for illustrative purposes only shows an example of the increased dietary fiber method and treatment for processed foods for processing nutrition/protein bars of one embodiment of the present invention. 
           [0007]      FIG. 3B  shows for illustrative purposes only shows an example of the increased dietary fiber method and treatment for processed foods nutrition/protein bars forming process of one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0008]    In a following description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration a specific example in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. 
       General Overview: 
       [0009]    It should be noted that the descriptions that follow, for example, in terms of nutrition/protein bars are described for illustrative purposes and the underlying process can apply to any food components in an increased dietary fiber method and treatment for processed foods. In one embodiment of the present invention, the increased dietary fiber method and treatment for processed foods is used for the ingredients of nutrition/protein bars through the controlled treatment with natural additives that control the dietary fiber content. The increased dietary fiber method and treatment for processed foods is adjustable and the amounts and types of flavorings, additives and processes can be adjusted to result in an increased dietary fiber content of any processed food using the present invention. In one embodiment of the present invention, the preservation process is used for the ingredients of nutrition/protein bars through the controlled treatment with natural additives that control the water activity (aw). The preservation process is adjustable and the amounts of additives and processes can be adjusted to result in the extension of shelf life of any processed food using the present invention. 
       Dietary Fiber: 
       [0010]    According to the USDA Dietary Fiber consists of non-digestible carbohydrates and lignin that are intrinsic and intact in plants. The USDA says that daily Adequate Intake of fiber has beneficial physiological effects in humans such as improved laxation, reduced risk of coronary heart disease, assisted maintenance of normal blood glucose levels, reduces the risk of diabetes, weight maintenance and increased prevention of various types of cancer. There is strong link between the use of fiber and reduced risk of colon cancer as well as beneficial effect of calcium on osteoporosis. 
         [0011]    The collected data indicates that the consumption of fiber is well below, approximately one-half of the Adequate Intake of fiber recommended for all sexes and Life Stage Group. The present invention is a food treatment process that increases the quantity of dietary fiber in processed foods. USDA data shows the deficit in total fiber daily intake is 12 to 20 grams per day. High fiber ingredients are less pliable and this characteristic makes forming and shaping of finished processed food products a major consideration in reducing the selection of fiber containing ingredients. 
       Preservation of Food: 
       [0012]    The preservation of food for storage is a part of the history of the human race. Drying foods and packing foods in sugars and salts are processes thousands of years old. Even prehistoric humans knew that untreated foods would spoil in a very short time. Modern humans discovered that the growth of bacteria, yeasts and fungi or molds were the cause of this spoilage and potential food poisoning. During more recent decades nutritional studies have shown that while preservation is the goal the processes and ingredients used may add unwanted higher levels of carbohydrates and lack addition of desirable dietary fiber. Preservation can be accomplished by reducing the water activity (aw), shown by the abbreviation (aw), in foods being processed for storage and packaging. 
       Water Activity in Food: 
       [0013]    The water activity (aw) of a food is not the same thing as its moisture content or water content. Water content is the total amount of water in a product. Water in food which is not bound to food molecules can support the growth of bacteria, yeasts and fungi or molds. The term water activity (aw) refers to this unbound water. The water activity (aw) represents the ratio of the water vapor pressure of the unbound water of the food to the water vapor pressure of pure water under the same conditions, such as temperature, and it is expressed as a fraction. 
         [0014]    The water activity (aw) scale extends from 0 aw (bone dry) to 1.0 aw (pure water) while most foods have a water activity (aw) level in the range of 0.2 aw for very dry foods to 0.99 aw for moist fresh foods. Water activity (aw) can also be expressed as equilibrium relative humidity (ERH). When the water activity (aw) fraction is multiplied by 100 the result obtained is the equilibrium relative humidity (ERH). The equilibrium relative humidity (ERH) is that which the foodstuff would produce if enclosed with air in a sealed container at constant temperature. Thus a food with a water activity (aw) of 0.7 aw would produce an ERH of 70%. Water activity (aw) affects the shelf life, safety, texture, flavor, and smell of foods. 
       Predicting Food Spoilage: 
       [0015]    Water activity (aw) is a useful application in predicting the growth of bacteria, yeasts and moulds. For a food to have a useful shelf life without relying on refrigerated storage, controlling either its acidity level (pH) or the level of water activity (aw) or a suitable combination of the two may be used. This can effectively increase the product&#39;s stability and make it possible to predict its shelf life under known ambient storage conditions. 
         [0016]    Food can be made safe to store by lowering the water activity (aw) to a point that will not allow bacteria, yeasts, fungi or molds and dangerous pathogens such as  Clostridium botulinum  and  Staphylococcus aureus  to grow in it. For example a food with a water activity (aw) below 0.6 aw will not support the growth of osmophilic yeasts.  Clostridium botulinum,  the most dangerous food poisoning bacterium, is unable to grow at an (aw) of 0.93 aw and below. Low acid foods (pH&gt;4.5) with a water activity (aw) greater than 0.86 aw allow the risk of food poisoning. 
       Soluble Fiber—Isomalto-Oligosaccharide (IMO): 
       [0017]    The present invention includes the use of isomalto-oligosaccharide (IMO) which contains dietary fiber. IMO is a natural nutrient sweetener refined from the starch of the corn, rice and other grains. The sweetness of IMO is about 70% of sugar. It is produced into both powder and liquid. IMO is a non-digestible, low calorie health sweetener that supports the proliferation of the beneficial bacteria residing in the large intestine (colon), therefore acts as a prebiotic. IMO improves overall gastrointestinal and bowel functions in humans in addition to having low calories. A diet with IMO was also shown to reduce the abdominal fat tissue in mammals. The effect of IMO on blood glucose level was predicted and expected to be effective therapeutically for diabetes or pre-diabetes. According to the FDA it has been reported in clinical trials that IMO do not cause any GI upset when consumed up to 10-20 g/day. Generally, IMO has been reported to be safe up to 30 g/day per adult individual. IMO is a soluble fiber which binds water to food. The binding of water to food extends shelf life by effectively controlling the water activity (aw) as part of a preservative treatment. 
       Soluble Fiber—Inulin: 
       [0018]    The present invention can include the use of inulin which contains dietary fiber. Inulin is a soluble fiber and can be used to replace sugar, fat, and flour in the control of water activity (aw). The soluble fiber inulin binds water to food. The binding of water to food extends shelf life by effectively controlling the water activity (aw) as part of a preservative treatment. Inulin is generally recognized as safe by the U.S. Food and Drug Administration (FDA). Inulin is a group of naturally occurring polysaccharides; several simple sugars linked together, and are produced by many types of plants. Some natural plants that contain high concentrations of inulin include for example chicory root, dandelion, wild yam, Jerusalem artichokes, jicama, onion, garlic and agave. 
         [0019]    Inulin belongs to a class of fibers known as fructans. Most plants that synthesize and store inulin do not store other materials such as starch which contain high levels of glucose sugars. The sweetness of inulin can range from 10% to 50% of the sweetness of a sucrose solution of the same concentration equaling 100%. Inulin comes in both a dry powder and as syrup. 
         [0020]    Normal digestion does not break inulin down into a monosaccharide. Inulin resists digestion because of the bonds holding its sugar molecules together. Inulin has a minimal impact on blood sugar and does not raise triglycerides, making it generally considered suitable for diabetics and potentially helpful in managing blood sugar-related illnesses. Inulin also has other health benefits such as increasing calcium absorption and possibly magnesium absorption. Inulin passes through the stomach and duodenum undigested and is highly available to the gut bacterial flora. 
         [0021]      FIG. 1  shows a block diagram of an overview of an increased dietary fiber method and treatment for processed foods of one embodiment of the present invention.  FIG. 1  shows foods selected for processing  100  that will go through processes to reduce carbohydrates as a preservative treatment and add dietary fiber. The foods selected for processing  100  have water activity (aw) measured  104  to formulate specific treatment ingredient combinations  108  to provide effective water activity (aw) control to extend shelf life. The specific proportions of the additive ingredients to be combined are formulated based on the water activity (aw) measured  104  ratio, taste and texture. The additive ingredients include liquid soluble fiber  140  that add dietary fiber, reduce carbohydrates and bind the water to the foods selected for processing  100  to control water activity (aw) as part of the preservative treatment. A pliability heat process  110  exposes the various high fiber ingredients to adjustable levels of heat to make the ingredients or combination of ingredients pliable. 
         [0022]    A liquid soluble fiber  140  such as IMO is heated using the pliability heat process  110 . The heated liquid soluble fiber  140  is added to a combine and mix process  145 . A sweetener is heated using the pliability heat process  110  and mixed while at temperature with flavorings in a flavorings process  130 . The heated flavorings-sweetener mixture is added to the combine and mix process  145 . The combine and mix process  145  produces a high fiber flavorings-sweetener mixture of one embodiment of the present invention. 
         [0023]    A dry ingredients coating process  120  uses the pliability heat process  110  to heat a binding agent such as fats that is used to coat dry ingredients. The coated dry ingredients and high fiber flavorings-sweetener mixture and combined in a blending process  150 . The blending process is controlled being careful not to over mix, which will make the matrix clumpy and difficult to put through for example a slabber or extruder used to form the processed food. Other additives  160  are combined after the blending process to reach a desired level of water activity (aw)  165 . The other additives  160  and blended ingredients are combined in a mixing process  170 . The mixing process  170  is regulated to maintain the heat of the mixture of ingredients. The heated mixture of ingredients is pliable and easily worked in a forming process  180  of one embodiment of the present invention. 
         [0024]    The forming process  180  can include passing the heated mixture through a slabber to roll sheets of the mixture which can be cut to the desired width and length. The heating of the mixture can be controlled to create pliability for processing the heated mixture through an extruder to for example create ropes of the mixture to cut immediately into desired lengths. The formed mixture is then ready for a packaging process  190 . The packaging process  190  wraps individual product servings and these are packaged for example in boxes for distribution with an extended shelf life  195  created using the increased dietary fiber method and treatment for processed foods. The increased dietary fiber method and treatment for processed foods creates finished processed food products that have increased fiber content, reduced carbohydrates and extended shelf life  195  in a cost effective controlled process of one embodiment of the present invention. 
       Detailed Operation: 
       [0025]    The foregoing has described the principles, embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed. The above described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as defined by the following claims. 
       High Fiber Flavored Sweetener Mixture: 
       [0026]      FIG. 2A  shows a flow chart of an increased dietary fiber method and treatment for processed foods high fiber flavored sweetener mixture process of one embodiment of the present invention.  FIG. 2A  shows the foods selected for processing  100  that have the water activity (aw) measured  104 . The particular foods selected for processing  100  can vary individually in water activity (aw) also in salt content and sweetness. Processed foods can be a single food or a combination of separate foods that have different characteristics such as texture, consistency, water content or levels of dryness, amounts of naturally occurring sugars, salts, and taste and water activity (aw) of one embodiment of the present invention. 
         [0027]    The water activity (aw) measured  104  establishes a value of the level of water activity (aw) to be controlled. The desired characteristics of the finished processed food product are determined. The water activity (aw) measured  104  and finished processed food product values for characteristics such as taste and texture are evaluated to formulate specific treatment ingredient combinations  108 . The specific proportions are formulated based on the measured water activity (aw) ratio, taste and texture. The preservative treatment ingredients include liquid soluble fiber  140  that add dietary fiber, reduce carbohydrates and bind the water to the foods selected for processing  100  to control water activity (aw) as part of the preservative treatment to extend shelf life of one embodiment of the present invention. 
         [0028]    The pliability heat process  110  heats the liquid soluble fiber  140  ingredients. The flavorings process  130  begins with the heating of flavorings  210 . The heated flavorings  210  and sweetener  200  ingredients are combined in a mix  215  process that mixes the ingredients to produce a flavored sweetener mixture  220 . The heated flavored sweetener mixture  220  and liquid soluble fiber  140  ingredients pass through a combine and mix process  145  to create a high fiber flavored sweetener mixture  230 . The high fiber flavored sweetener mixture  230  is further processed as shown in  FIG. 2B  of one embodiment of the present invention. 
       Dry Ingredients Coating: 
       [0029]      FIG. 2B  shows a flow chart of an increased dietary fiber method and treatment for processed foods dry ingredients coating process of one embodiment of the present invention.  FIG. 2B  shows a continuation from  FIG. 2A  of the pliability heat process  110  as it is used in the dry ingredients coating process  120 . Various dry ingredients  250  and for example protein powders  252  are combined in a dry mixing  254  process to allow a thorough combination of ingredients that are dry. The pliability heat process  110  is used to heat one or more binding agent  240  such as fats  244 . The binding agent  240  is used to coat  260  the ingredients from the dry mixing  254  process. The high fiber flavored sweetener mixture  230  of  FIG. 2A  and coated dry ingredients mixture  262  are maintained at temperature by the pliability heat process  110  and combined in the blending process  150  of one embodiment of the present invention. 
         [0030]    The blending process is controlled to provide a thorough mixing of the ingredient mixtures to prevent over mixing. Over mixing can make the combined mixtures clumpy and more difficult to form in the desired shapes. The other additives  160  such as salt  270 , water  272  and other ingredients  274  are added to the heated blended ingredients. The proportions of the other additives  160  are measured to reach the desired finished processed food product characteristics including taste, texture and the desired level of water activity (aw)  165 . The other additives  160  and the heated blended ingredients are combined in a mixing process  170 . The mixing process  170  produces a complete mixture  280  of the selected ingredients that is further processed as shown in  FIG. 2C  of one embodiment of the present invention. 
       Forming Process: 
       [0031]      FIG. 2C  shows a flow chart of an increased dietary fiber method and treatment for processed foods forming process of one embodiment of the present invention.  FIG. 2C  shows the continuation of the processes of  FIG. 2B . The forming process  180  is performed immediately to keep the complete mixture warm  282 . The warm complete mixture  280  of  FIG. 2  is processed through forming equipment used to form base shape  284  of the finished processed food product. The form could be rolled sheets using a slabber or continuous ropes using an extruder. The base shaped warm complete mixture  280  of  FIG. 2  is cut immediately  290  to a finished product size and shape  295 . The finished product size and shape  295  processed food servings are cooled in process transit to the packaging process  190  of one embodiment of the present invention. 
         [0032]    The final product is wrapped and boxed for distribution with an extended shelf life  195  created using the increased dietary fiber method and treatment for processed foods. The increased dietary fiber method and treatment for processed foods produces finished processed food products that contain higher fiber content, lower carbohydrates and extended shelf life  195  in a cost effective controlled process. The increased dietary fiber method and treatment for processed foods can be used to produce processed foods such as nutrition bars, candy bars, cookies, snack foods and other processed foods that contain high fiber to contribute to the USDA daily Adequate Intake of fiber recommendations of one embodiment of the present invention. 
       High Fiber Nutrition/Protein Bars: 
       [0033]      FIG. 3A  shows for illustrative purposes only shows an example of the increased dietary fiber method and treatment for processed foods for processing nutrition/protein bars of one embodiment of the present invention.  FIG. 3A  shows an example of the increased dietary fiber method and treatment for processed foods used to produce a processed food product that contains high fiber. Various nutrition/protein bars ingredients  300  are selected. The nutrition/protein bars ingredients  300  can be selected for taste, flavor and texture to create a desired product. The nutrition/protein bars ingredients  300  selected have the water activity (aw) measured  104  of one embodiment of the present invention. 
         [0034]    The water activity (aw) measured  104  and the desired nutrition/protein bar product characteristics of taste, flavor and texture are used to formulate specific nutrition/protein bars treatment ingredients  308 . The specific nutrition/protein bars treatment ingredients  308  include liquid soluble fiber  140 . The liquid soluble fiber  140  is added in either a liquid or powdered form mixed in solution. The liquid soluble fiber  140  includes dietary fiber ingredients such as IMO  310  and inulin  320  used to bind the water to control to control water activity (aw). The soluble fiber ingredients such as IMO  310  and inulin  320  are also used to add fiber in the increased dietary fiber method and treatment for processed foods will be used to contribute to the desired taste, flavor and texture of the finished product of one embodiment of the present invention. 
         [0035]    The pliability heat process  110  heats the sweetener  200  in this example inulin  320  to a suitable temperature, such as 110 degrees. The heated sweetener  200  such as inulin  320  is combined in a mix  215  with the flavorings  210  to form the flavored sweetener mixture  220 . The pliability heat process  110  continues heating the liquid soluble fiber  140  such as IMO  310  to a suitable temperature, such as 110 degrees, and the flavored sweetener mixture  220  in the combine and mix process  145 . The combine and mix process  145  produces a high fiber IMO and flavored sweetener mixture  340  of one embodiment of the present invention. 
         [0036]    The pliability heat process  110  applies heat to the binding agent  240  to reach a suitable temperature, such as 110 degrees, in this example fats (nut butters)  330 . The dry ingredients  250  and the protein powders  252  selected for the nutrition/protein bars are combined in a thorough dry mixing  254 . The heated fats (nut butters)  330  coat  260  the dry mixed ingredients creating a coated dry ingredients mixture  262  of one embodiment of the present invention. 
         [0037]    The heated high fiber IMO and flavored sweetener mixture  340  and the heated coated dry ingredients mixture  262  are combined in the controlled blending process  150 . The controlled blending process  150  prevents over mixing of the combination of ingredient mixtures. Over mixing can produce clumps which are difficult to form into the desired product shape. The process continues as shown in  FIG. 3B  of one embodiment of the present invention. 
       Nutrition/Protein Bars Forming: 
       [0038]      FIG. 3B  shows for illustrative purposes only an example of the increased dietary fiber method and treatment for processed foods nutrition/protein bars forming process of one embodiment of the present invention.  FIG. 3B  shows the continuation of the processes in  FIG. 3A . The other additives  160  are salt  270 , water  272  and other ingredients  274  such as peanuts  350 . The proportions of the other additives  160  are measured to reach the desired finished processed food product characteristics including taste, texture and the desired level of water activity (aw)  165 . The heated blended mixtures from  FIG. 3A  are combined with the other additives  160  in the mixing process  170 . The result of the mixing process is a complete nutrition/protein bar mixture  360  of one embodiment of the present invention. 
         [0039]    The forming process  180  is performed immediately to keep the complete nutrition/protein bar mixture warm  362  to roll  364  sheets through a slabber  366 . The rolled sheets from the slabber  366  are cut immediately  290  using rotary knives  370  to form strips  372 . The strips  372  are passed through a guillotine cutter  380  and cut into bar length  385 . The bar length sections cool during the process to the packaging process  190  of  FIG. 1 . The packaging process  190  of  FIG. 1  continues to wrap  390  each bar length section into individual nutrition/protein bar servings which are placed into a box  395  for shipping. The increased dietary fiber method and treatment for processed foods controls the water activity (aw) which provides extended shelf life  195  to the finished nutrition/protein bars products. The nutrition/protein bars produced using the increased dietary fiber method and treatment for processed foods contains high fiber. In addition the liquid soluble fiber  140  ingredients used to add fiber also are non-digestible carbohydrates, provide heath benefits and are low in calories of one embodiment of the present invention. 
         [0040]    The foregoing has described the principles, embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed. The above described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as defined by the following claims.