Low calorie fat substitute

Abstract: There is disclosed a low calorie fat substitute comprising an outer coating of a digestible fat sur­ rounding an inner core of a low caloric or non-caloric material.

Description: The present invention relates to low calorie fat substitutes. More particularly, it relates to a free-flowing low calorie fat substitute wherein an inner low caloric or non-caloric core material is surrounded by a digestible fat composition. In today's health conscious society, there is a growing demand for low-calorie foods. Excess body weight not only creates a feeling of low self-confidence in social situations but also has been shown to contribute to the impairment of the cardiovascular function of the individual. Moreover, the reduction of the physical performance capacity of the individual is another consequence of excess body weight. Many approaches have been suggested to control excess body weight. The use of chemical appetite suppressants and appetite inhibitors is a well known approach but these chemical agents are often unsafe for long-term use and/or have undesirable side effects and are usually available only through a physician's prescription. Low calorie foods have also been widely advocated as a diet regimen to control excess body weight. Such low-calorie foods include low calorie spreads, which are typically water-in-oil (w/o) emulsions; and low calorie sauces, such as salad dressings and mayonnaise, which are typically oil-in-water emulsions. Recently water-in-oil-in-water emulsions (w/o/w) have been proposed as an additive for low calorie foods. Such w/o/w emulsions are described in United States Patent Nos. 4,650,690, 4,632,840 and 4,590,086. Low-calorie food additives comprising hollow microspheres of saccharose polyester are described in German Offenlegungsschrift No. DE 30 03 401. Low calorie food additives comprising hollow microspheres of vinylidene chloride-acrylonitrile copolymers are described in German Offenlegungsschrift No. DE 25 30 118. United States Patent No. 4,198,400 refers to a water-reconstitutable juice or soup composition which contains cellulose dietary fibers coated with lipids to render the cellulose fiber hydrophobic. United States Patent No. 4,305,964 refers to an artificial cream-type food product having a continuous liquid aqueous phase comprising a dispersed oil phase and gelled water beads. United States Patent Nos. 4,734,287 and 4,744,521 refer to proteinaceous, water-dispersible macrocolloids comprising substantially non-aggregated particles of dairy whey protein. United States Patent No. 3,949,094 discloses a process for producing lipid coated condiments, particulary to such a process wherein spray chilling is employed for congealing the lipid. The present invention is directed to a microparticulate, free-flowing composition according to claim 1. In a preferred embodiment, the fat composition is useful as a low calorie fat substitute for foods served at or near ambient temperatures. More preferably the core material is selected from the group consisting of ultrafine microcrystalline cellulose, polydextrose, non-fibrous cellulose derivatives, micronized bran and waxes. Especially preferred is the composition wherein the core material is polydextrose. In another preferred embodiment, the composition comprises roughly spheroidal particles having a mean diameter of less than 250 microns (250 x 10⁻⁶ m), with an especially preferred mean diameter of from 2 to 50 (2 x 10⁻⁶ to 50 x 10⁻⁶ m) microns. Also preferred is the composition wherein the fat composition has a melting point of from 20° to 45°C. Preferred digestible fat coatings are animal fats, partially or totally hydrogenated vegetable oils, mono-, di- and tri-glycerides, and phospholipids. Preferred is the composition wherein the core material comprises from 50% to 95%, by volume, of the composition. Also included in the present invention is the inclusion of a layer of material between said core material and said shell, said layer different from said core material. Preferred layer materials are selected from the group consisting of cellulose, methyl-cellulose, cellulose acetate phthalate, albumin, casein, zein, agar, gelatin, pectin and gum arabic. Also forming a parts of the present invention is a process for forming a low caloric fat substitute composition according to claim 6. Preferred processes for coating the core material are pan coating, spin disc coating, gas suspension coating, centrifugal coextrusion, rotational suspension, coacervation, inclusion complexation, spray coating and spray drying. Foods containing the fat substitute composition of the present invention also form a part of the present invention. Non-limiting examples of such foods are frozen deserts, salad dressings, mayonnaise, food spreads, spray coatings for crackers and snack chips, fillings for cakes or cookies, cake frostings, confections, gravies and peanut spreads. By the term "free-flowing composition" is meant a composition comprising a pourable, particulate solid material. Preferably, the composition is a dried solid composition. By the term "microparticulate" is meant a composition consisting of particles having a mean diameter of less than 250 microns (250 x 10⁻⁶ m). By the term "non-caloric or low caloric core material" is meant a core material which has a caloric value varying from 0 to 3.0 cal/gm. The composition is substantially insoluble under conditions of food formulation which means that the composition retains its structural integrity so that the fat coated core material does not dissolve to release the fat when it is incorporated into a food formulation. The core materials are ultrafine microcrystalline cellulose, polydextrose, erythritol, non-fibrous cellulose derivatives, micronized bran and waxes. All the above materials are commercially available items of commerce. In certain instances, it has been found useful to include an additional layer of material between the core material and the outer shell. Most advantageously, the additional layer is of a material different from the core material. Preferred materials for this layer material include cellulose, methylcellulose, cellulose acetate phthalate, albumin, casein, zein, agar, gelatin, pectin and gum arabic. Preferably, the composition of the present invention is in the form of roughly spheroidal particles having a mean diameter of less than about 250 microns (250 x 10⁻⁶ m). To form the roughly spheroidal particles, the core material chosen should be roughly spherical. In this respect, if the core material chosen is a non-fibrous cellulose material, ultrafine micro-crystalline cellulose is preferred. The term "fat" is used herein to mean glyceryl triesters of fatty acids and other fatlike compounds such as glyceryl mono and diesters of fatty acids, partially or totally hydrogenated vegetable oils and phospholipids. Processes for coating the core material with the fat composition also form a part of the present invention. The core material may be coated with the fat composition by means of pan coating, spin disc coating, gas suspension coating, centrifugal coextrusion, rotational suspension, coacervation, inclusion complexation, spray coating, and spray drying. All these coating techniques are well known in the art to which this invention applies and modifications of these techniques to coat various core materials can be easily determined by a person of ordinary skill in the art. Having described the invention in general terms, reference is now made to specific examples. It is to be understood that these examples are not meant to limit the invention, the scope of which is determined by the appended claims. Example 1 Fat on Hammer-milled Polydextrose . A slurry of 120 grams of polydextrose powder (hammer-milled to a mean particle size of 20-30 microns (20-30 x 10⁻⁶ m)) and 30 grams of fat in 350 grams of absolute ethanol was heated to reflux (78°C), then allowed to cool to about 25°C during a period of about 4 hours. Twenty-five grams of deionized water was then added slowly. The slurry was cooled to 0-5°C and held at this temperature for 30 minutes. The fat coated polydextrose was recovered from the ethanol slurry by vacuum filtration and dried for 24 hours in a vacuum oven at a temperature of about 30°C and a pressure of about 50 torr. After drying, the particles were disaggregated by passing through a 200-mesh (75 micron (75 x 10⁻⁶ m)) sieve. The coated particles were determined by a chloroform extraction assay to contain 19.5% fat by weight. Mean particle diameter was 22 microns (22 x 10⁻⁶ m) before coating, 28 microns (28 x 10⁻⁶ m) after coating. Calculated caloric value was 2.6 calories per gram. Example 2 Fat on spray-dried Polydextrose . A slurry of 600 grams of spray-dried polydextrose powder with a mean particle diameter of 4 microns (4 x 10⁻⁶ m) and 150 grams of fat in 1750 grams of absolute ethanol slurry was heated to about 55°C, then cooled to 0-5°C during a period of about 2 hours and held at this temperature for an additional 2 hours. The fat coated polydextrose was recovered from the ethanol slurry by vacuum filtration and dried for 24 hours in a vacuum oven at a temperature of about 30°C and a pressure of about 50 torr. After drying, the particles were disaggregated by passing through a 200-mesh (75 micron (75 x 10⁻⁶ m)) sieve. The coated particles were determined by a chloroform extraction assay to contain 19.5% fat by weight. Mean particle diameter was 4 microns (4 x 10⁻⁶ m) before coating, and did not increase significantly (within the accuracy of the measurement) after coating. Calculated caloric value was 2.6 calories per gram. Example 3 Fat on Wet-milled Polydextrose . A slurry of about 200 grams of polydextrose in about 800 grams of ethanol (from wet-milling in an attritor to a mean particle diameter of 12 microns (12 x 10⁻⁶ m)) was mixed with 20 grams of fat. This slurry was heated to about 55°C then cooled to 25°C during a period of 4 hours. Fifty-one grams of deionized water was then added slowly. The slurry was cooled to 0-5°C and held at this temperature for about 2 hours. The fat coated polydextrose was recovered from the ethanol slurry by vacuum filtration and dried for 24 hours in a vacuum oven at a temperature of 30°C and a pressure of about 50 torr. After drying, the particles were disaggregated by passing through a 200-mesh (75 micron (75 x 10⁻⁶ m)) sieve. The coated particles were determined by a chloroform extraction assay to contain 8.3% fat. Mean particle diameter was 11 microns (11 x 10⁻⁶ m) before coating, 16 microns (16 x 10⁻⁶ m) after coating. Example 4 Fat on soft hydrated polydextrose beads. A mixture of 700 grams of polydextrose with 300 grams of water was heated to reflux (103-106°C) while stirring. Water was stripped from the refluxing polydextrose solution to provide a hot syrup containing about 15% water. This was poured into a cold pan (about 10°C). The cooled, hardened hydrated polydextrose was milled at low temperature (approximately -50°C) in a Waring blender with ethanol. The milled polydextrose was filtered from solution and air dried for about 1 hour. A portion of the product (120 grams) was slurried with 30 grams of fat in 350 grams of absolute ethanol. This slurry was heated to about 55°C, allowed to cool to 25°C during a period of 4 hours, then further cooled to about 5°C and held at this temperature for 30 minutes. The fat coated polydextrose was recovered from the ethanol slurry by vacuum filtration and dried for 24 hours in a vacuum oven at a temperature of about 30°C and a pressure of abut 50 torr. After drying, the particles were disaggregated by passing through a 200-mesh (75 micron (75 x 10⁻⁶ m)) sieve. The coated particles were determined by a chloroform extraction assay to contain 23.4% fat. Mean particle diameter was 25 microns (25 x 10⁻⁶ m) before coating, 34 microns (34 x 10⁻⁶ m) after coating. Calculated caloric value was 2.8 calories per gram. In each of Examples 1-4, certain variables can be chosen to provide the desired performance in targeted food applications. TABLE 1 lists the fats used to provide the range of melting points used in food applications: Trade Name Description Melting Point Durkee KLX Partially Hydrogenated Vegetable Oil (Cottonseed, Soybean) 45°C Paramount X Partially Hydrogenated Vegetable Oil (Palm Kernel, Soybean, Cottonseed) 45° Hydrol 100 Partially Hydrogenated Coconut Oil 43°C Code 321 Partially Hydrogenated Soybean Oil 38°C Satina 44 Partially Hydrogenated Palm Kernel Oil with Lecithin 35°C Centrmelt Palm Oil with Tocopherol 29°C In addition to fat melting point, the ratio of polydextrose substrate to fat coating provides the desired degree of caloric reduction for targeted food applications. TABLE 2 lists the design ratio of polydextrose to fat and resulting caloric values: Ratio of polydextrose to fat Calculated caloric value 1:1 5.0 cal/gm 2:1 3.6 cal/gm 3:1 3.0 cal/gm 4:1 2.6 cal/gm 5:1 2.3 cal/gm 10:1 1.7 cal/gm Reference Example 5 Gelled Agar Core . A mixture of 5 grams of Durkee KLX (trade name) fat, 5 grams of Atmos 150 (trade name) emulsifier and 100 grams of hexane emulsifier was charged into a water-jacketed Waring blender and stirred slowly at about 55°C until a homogeneous solution was obtained. The rate of stirring was then increased, and 50 grams of a 2% aqueous agar (Graceleria) solution was added to form an emulsion. After 5 minutes of blending, the emulsion was cooled to about 10°C by circulating ice water through the blender jacket. The fat coated gel product was recovered as free-flowing particles (27.6 g) by spray drying the emulsion. Characteristics of product: fat content 16.6%, caloric value 1.56 calories per gram Reference Example 6 Other fat-coated gels were prepared by the method of Example 5 except that different edible fats and emulsifiers were used, as summarized in Table 3. Fat Coated Agar Gels Ratio of 2% agar gel to fat to emulsifier Fat (trade name) Emulsifier (trade name) Caloric value (cal/gram) 1:1:0.05 KLX Lecithin 4.54 4:1:1 KLX Atmos 150 3.06 4:1:0.5 Durkee 17 Dur-Em 114 2.52 4:1:0.1 KLX Atmos 150 2.01 8:1:1 Satina 44 Atmos 150 1.87 Reference Example 7 Polydextrose/Pectin Core. To a Hobart mixer was added, in the order given: 50 grams of polydextrose, 20 grams of citrus pectin, and 300 grams of water. This mixture was blended at the high speed setting for 5 minutes, then allowed to harden for approximately five minutes. The material was washed with ethanol, dried under moderate vacuum for 48 hours at about 35°C, and ground into a fine powder. A portion of this material was then coated with fat as follows: 5.62 grams of polydextrose/pectin was slurried with 2.8 grams of fat in 60 grams of absolute ethanol. The slurry was heated to reflux (78°C), then cooled to room temperature during a period of about 3 hours. The resulting fat coated material was recovered by vacuum filtration and dried. Microscopic examination (dark field) revealed that the substrate had been successfully coated with fat. Reference Example 8 Agar gel core; n-propanol fat solvent A 2% agar gel (70 grams) was milled in 100 ml of n-propanol for three minutes at high speed in a Waring blender. The resulting slurry was transferred into a 500 ml round-bottom flask along with 49 grams of fat (mixture of 35 grams of Durkee KLX (trade name) and 14 grams of Gelucire 70/02 (trade name)) and 100 grams of additional n-propanol. This mixture was heated to about 70°C, then rapidly cooled in an ice bath. The resulting fat coated gel was recovered by vacuum filtration and washed with ethanol followed by distilled water. The particles were dried in a low vacuum oven for 48 hours at about 35°C. Microscopic examination (dark field) revealed that the gel particles, had been successfully coated with fat. Reference Example 9 Agar gel core; n-butanol fat solvent A 20% agar gel (70 grams) was milled in 100 ml of n-butanol for three minutes at high speed in a Waring blender. The resulting slurry was transferred into a 500 ml round-bottom flask along with 49 grams of fat (mixture of 35 grams of Durkee KLX (trade name) and 14 grams of Gelucire 70/02 (trade name)) and 100 grams of additional n-butanol. This slurry was heated to about 70°C, then rapidly cooled in an ice bath. The resulting fat coated gel was recovered by vacuum filtration and exhaustively washed with ethanol, followed by distilled water. The particles were dried in a vacuum oven for 48 hours at 35°C. Microscopic examination (dark field) revealed that the gel particles had been successfully coated with fat. Reference Example 10 Fat-impregnated agar gel core; n-propanol fat solvent A mixture of 2 grams of agar, 2 grams of Durkee KLX fat (trade name) and 96 grams of distilled water was heated to boiling, then allowed to cool to room temperature while being vigorously stirred. The resulting agar gel contained 2% fat. The fat-impregnated agar gel (70 grams) was then milled in 100 ml of n-propanol for five minutes at high speed in a Waring blender. The resulting slurry was transferred into a 600 ml round-bottom flask along with 49 grams of fat (mixture of 35 grams of Durkee KLX (trade name) and 14 grams of Gelucire 70/02 (trade name)) and 100 grams of additional n-propanol. This slurry was heated to about 70°C, then rapidly cooled in an ice bath. The resulting fat coated gel was recovered by vacuum filtration and washed with ethanol followed by distilled water. The particles were dried in a vacuum oven for 48 hours at about 35°C. Microscopic examination (dark field) revealed that the gel particles had been successfully coated with fat. Reference Example 11 Coated rigid foam. Agar gel (2%, 100 grams) was freeze dried to a solid foam material. This was frozen in liquid nitrogen and ground to a powder with a mortar and pestle. The powdered material (9.34 grams) was transferred into a 500 ml round-bottom flask with 150 ml of n-propanol and 2.8 grams of Durkee KLX (trade name) fat. With rapid stirring, the slurry was heated to about 70°C then cooled rapidly by immersion of the flask in a dry ice-acetone bath. The material was recovered by vacuum filtration and washed with ethanol followed by distilled water. The particles were dried under vacuum for 36 hours at about 35°C. Microscopic examination (dark field) revealed that the foam particles had been successfully coated with fat. Reference Example 12 Coated micelles . Into a 1000 ml, 4-neck round-bottom flask was added in the order given: 413.5 grams of distilled water, 24 grams of Durkee KLX (trade name) fat, and 8 grams of Triton X100 (trade name) emulsifier. With vigorous stirring, the mixture was heated to reflux, then rapidly cooled using an ice bath. The material was recovered by vacuum filtration and dried under vacuum. Microscopic examination of the material (SEM) showed fat coated spheres with a mean diameter of about 100 microns (100 x 10⁻⁶ m). Example 13 CORN CHIPS Ingredients Weight percent Baked corn chips 75 Fat-coated polydextrose (FC-PDX) comprised of 10:1 polydextrose:fat (fat m.p. 97°F)(36°C) 15 Seasonings 10 100 The cold chips were dusted with FC-PDX, followed by sieving of the excess FC-PDX. The coated chips were then heated at 140°C for 3 minutes, followed by a recoating and reheating at 140°C for 3 minutes and then another recoating and reheating at 140°C. The coated chips were coated with seasonings, excess seasoning was sieved off, and the coated chips were heated at 140°C for three minutes followed by recoating with additional seasonings and removal of the excess seasoning by sieving. The chips were held in an atmosphere of steam for 1-2 minutes, then heated at 140°C for 2 minutes. Reference Example 14 CREAMY FRENCH DRESSING Ingredients Weight percent Fat-coated agar gel comprised of 4:1.85 gel:fat 46.48 Distilled Water 37.55 Vinegar 9.47 Sugar 2.00 Maltodextrin 1.70 Salt 1.00 Xanthan Gum 0.35 Propylene glycol alginate 0.16 Polysorbate 60 0.10 Lemon Juice 0.10 Sodium Benzoate 0.10 Potassium Sorbate 0.10 Spices 0.77 Flavors 0.12 Total 100.00 Water, vinegar, sugar, maltodextrin, salt, polysorbate 60, lemon juice, sodium benzoate and potassium sorbate were blended and while mixing, xanthan gum and propylene glycol alginate were slowly added. The mixture was blended for 5 minutes. After blending, spices and flavors were added and the mixture was stirred for 5 minutes. The fat substitute was slowly added while mixing followed by an additional 2 minutes of mixing and homogenization at 500-1,000 psi. (3447-6894 x 10³ Pa). Example 15 CREAMY ITALIAN DRESSING Ingredients Weight percent Distilled Water 47.87 Fat-coated polydextrose comprised of 4:1 polydextrose:fat 35.00 Vinegar 8.37 High Fructose corn syrup #42 2.67 Lemon Juice 2.60 Salt 1.63 Avicel PH 105 (trade name) 1.10 Dried Cream extract 0.65 Avicel RC 581 (trade name) 0.62 Xanthan gum 0.37 Polysorbate 60 (trade name) 0.26 Gum tragacanth 0.20 Sodium benzoate 0.07 Spice 0.59 Total 100.00 Water, Polysorbate 60, Avicel RC 581, Avicel PH 105, high fructose corn syrup and salt were blended and while being mixed, gums were added and the mixture was stirred for 5 minutes. After stirring, sodium benzoate, vinegar and remaining ingredients (spices, lemon juice and dried cream extract) were added and mixed for 2 minutes. The fat substitute was added slowly while mixing followed by an additional 2 minutes of mixing and homogenization at 500-1,000 psi (3447-6894 x 10³ Pa). Example 16 SANDWICH COOKIE FILLING Ingredient Weight percent Shortening - Crisco 15.96 Vanilla flavor 0.05 NaCl 0.10 Alitame (trade name) 10% triturate in mannitol 0.11 Confectionary sugar 10X 25.93 Polydextrose Type N Powder 42.89 Fat-Coated polydextrose comprised of 4:1 neutralized polydextrose containing 15% water:fat (fat m.p. 97°F)(36°C) 14.96 Total 100.00 The shortening was heated to about 45°C, the vanilla flavor, salt, alitame triturate, sugar and polydextrose powder were added slowly one at a time while mixing manually, and the mixture was allowed to cool to room temperature. The fat-coated polydextrose was added with manual mixing, then the mixture was blended for 3-4 minutes with a Sunbeam Mix Master R at speed setting 4.

Claims: A free-flowing, microparticulate composition for use as a low calorie fat substitute that is substantially insoluble under conditions of food formulation, each particle comprising an outer shell of a digestible solid or semi-solid fat surrounding an inner non-caloric or low caloric core material which has a caloric value of from 0 to 3 calories per gram and which is selected from the group consisting of polydextrose, erythritol, a non-fibrous cellulose derivative, micronized bran and a wax, or is a mixture thereof. A composition as claimed in claim 1 wherein the core material is polydextrose. A composition as claimed in claim 1 or 2 wherein the composition comprises roughly spheroidal particles having a mean diameter of from 2 to 50 (2 x 10⁻⁶ to 50 x 10⁻⁶ m) microns. A composition as claimed in any one of claims 1 to 3, each particle further comprising a layer of material between the core material and the shell, said layer of material being different from the core material and preferably being selected from the group consisting of cellulose, methylcellulose, cellulose acetate phthalate, albumin, casein, zein, agar, gelatin, pectin and gum arabic. A food comprising, as an ingredient, a composition as claimed in any one of claims 1 to 4. A process for the preparation of a free-flowing, microparticulate composition as claimed in any one of claims 1 to 4 comprising, for each particle, coating a non-caloric or low caloric core material which has a caloric value of from 0 to 3 calories per gram and which is selected from the group consisting of polydextrose, erythritol, a non-fibrous cellulose derivative, micronized bran and a wax, or is a mixture thereof, the core material being optionally coated with a layer of material different to the core material, with a digestible solid or semi-solid fat. A process as claimed in claim 6 wherein the coating is carried out by pan coating, spin disc coating, gas suspension coating, centrifugal coextrusion, rotational suspension, coacervation, inclusion complexation, spray coating or spray drying.

Inventors: HENDRICK MICHAEL E, REIMER ROBERT A, HENDRICK, MICHAEL E., REIMER, ROBERT A.
Applicants: PFIZER, PFIZER INC.
Application year: 1990
Main classification: A23L1
IPC codes: A23L1, C08B37, A21D13, A23G3, A23D9