SOLUBLE DIETARY FIBER COMPOSITIONS AND METHOD OF PREPARATION

Abstract: Soluble dietary fiber products can be prepared by hydrolyzing an oat or barley substrate with an alpha -amylase and recovering the soluble fraction. The recovered material comprises maltodextrins and beta -glucans and/or pentosans as the dietary fiber with small amounts of protein lipid and ash. These compositions are colorless and devoid of inherent undesirable flavors, and are, therefore, suitable for use in a variety of foods. By employing centrifugal separation at a temperature substantially below the hydrolysis temperature, the amounts of lipids and proteins in the dietary fiber product can be reduced, thereby further improving product quality.

Description: SOLUBLE DIETARY FIBER COMPOSITIONS AND METHOD OF PREPARATION Field of the Invention This invention relates to the conversion of milled cereal products to soluble dietary fiber compositions which are useful in a variety of foods as sources of soluble dietary fiber. Dietary fiber is considered to be the soluble and insoluble components of food that are not digested by enzymes in the human gastrointestinal tract. The primary sources of dietary fiber include such cell wall materials as cellulose, he icelluloses, lignin, and pectins, along with gums and mucilages. Dietary fiber has been considered an important food component since early times. Recently, Burkitt et al. [Lancet 2:1408-1411 (1972)] concluded that dietary fiber has a role in the prevention of certain large-intestine diseases, including cancer of the colon and diverticulitis. Diets containing large amounts of dietary fiber lead to stools that are softer and larger, and bowel movements are generally more frequent. Burkitt also mentioned that the serum cholesterol rises when dietary fiber is removed from the diet, and that eating a fiber-rich diet lowers serum cholesterol. Trowell [Am. J. Clin. Nutr. 25: 464-465 (1972)] reached a similar conclusion regarding the relationship between fiber and health benefits. It is now known that not all dietary fiber is the same and that different fibers provide different health benefits. For example, wheat bran is very rich in insoluble dietary fiber (mainly cellulose and hemicelluloses) and is excellent for decreasing the transit time of food through the digestive tract [Anderson et al., Am. J. Clin. Nutr. 32:346-363 (1979)]. Some fibers are reported to reduce total plasma cholesterol [Munoz et al., Am. J. Clin. Nutr. 32:580-592 (1979)]. Description of the Prior Art In recent years, considerable attention has been given to oats as a source of dietary fiber. It is the soluble fiber component that is effective in lowering serum cholesterol levels. Oatmeal, or rolled oats, and especially oat bran are rich sources of this soluble fiber. The first indication of serum cholesterol lowering by rolled oats was observed in rats by Degroot et al. [Lancet 2:303-304 (1963)]. Fisher et al. [Pro. Soc. Exp. Biol. Med. 126:108-111 (1967) ] report that the fiber fraction of oats is responsible for its unique effects on cholesterol. Over the years, numerous experiments with animals have shown that oat fiber has a hypocholesterolemic effect. Anderson et al. [Am. J. Clin. Nutri. 34:824-829 /(1981); 40:1146-1155 (1984)] have confirmed hypocholesterolemic effects of oats in humans. Oat fiber also reduces the amount of low-density lipoprotein (LDL) without lowering the beneficial high-density lipoprotein (HDL) . In fact, Anderson et al. [66th Annual Meeting, Am. Assoc. Cer. Chem., Abstr. No. 112 (1981)] teach that oat bran fed to humans can reduce LDL 58% while increasing HDL 82%. Other water-soluble fibers, such as pectin and guar gum, can lower serum cholesterol, but they are frequently accompanied by undesirable side effects such as nausea and vomiting. The results of another study by Anderson et al. (supra, 1984) indicate that oat bran diets decrease total serum cholesterol 19% and LDL 23% and that oat bran increases bile acid excretion 65%. These studies clearly document the hypocholesterolemic effects in humans of oat products which are rich in soluble fiber. Maltodextrins are successful commercial products prepared by hydrolysis of pure starch. The wet milling of corn is the primary source of starch from which maltodextrins are obtained. Other sources of starch for commercial products are tapioca, potato, and rice. Cereal flours are generally not used for maltodextrin production because of the flavors and colors that develop during processing [Katz, Cer. Foods World, 31:866-867 (1986)]. Also, when cereal flours are treated with amylases, a colloidal hydrolysate is obtained that is nonfilterable (U.S. Patent No. 4,894,242). However, some breakfast and related food products have been produced in which the characteristic cereal flavor is desired. Whole cereal flours have been subjected to starch-hydrolyzing conditions and have yielded, for example, a whole-grain hydrolyzed product [Conrad, U.S. Patent No. 4,377,602] and a ready-to-eat, enzyme-saccharified cereal [Fulger et al., U.S. Patent No. 4,710,286]. Ronai (U.S. Patent No. 3,640,729] arrives at a similar product by adding prehydrolyzed starch to oat flour to yield an instant oat cereal product. Summary of Invention The invention described and claimed herein is based on the further discovery that barley substrates in addition to oat substrates can be used to prepare soluble dietary fiber composition. Barley substrates can be used in the same form and in the same amounts as the oat substrates. It has been further discovered that in the processing of either oat substrates or barley substrates it is advantageous to carry out the centrifugal separation of the soluble and insoluble components at substantially lower temperature than employed for the enzymatic hydrolysis. In general, temperatures substantially below 60°C should be used, such as preferably within the range from 5 to 50°C. Under these lower temperature conditions of separation, the amounts of lipids and proteins in the dietary" fiber product are significantly reduced. Other objects and advantages of this invention will become apparent from the ensuing description. Detailed Description of the Invention Suitable substrates contemplated for use in the invention in addition to oat substrates include bariey substrates which may be in the form of cereal flours and milled cereal brans. Of particular interest are the whole or debranned flours of barley and oats. The substrate is slurried in a sufficient amount of water to give a concentration in the range of about 10-40% by weight. The water should contain a suitable calcium salt in an amount sufficient to stabilize the subsequently added α-amylase [preferably about 25-50 parts per million (ppm) of calcium] . The slurried substrate may be gelatinized prior to enzymatic treatment, using any method known in the art. The pH of the ungelatinized slurry or the gelatinized dispersion is adjusted to about 5.5-7.5, preferably about 6.0, with sodium hydroxide or phosphoric acid, and the α-amylase is then added. It is advantageous to use thermostable α-amylases referred to as 1,4-α-D-glucan glucanohydrolases and having the essential enzymatic characteristics of those produced by the Bacillus stearothermophilus strains ATCC Nos. 31,195; 31,196; 31,197; 31,198, 31,199; and 31,783. These strains are described in U.S. Patent No. 4,284,722, which is herein incorporated by reference. Other sources of this enzyme include organisms such as B_j_ subtilis which have been genetically modified to express the thermostable α-amylase of B^. stearothermophilus as described in U.S. Patent No. 4,493,893, herein incorporated by reference. These enzymes are available commercially under the name "G-zyme G995" (formerly called "Enzeco Thermolase"; Enzyme Development Div. , Biddle Sawyer Corp., New York, NY). Other suitable α-amylases are those having the essential enzymatic characteristics of those produced by I . licheniformis var. as described in U.S. Patent No. 4,717,662 and 4,724,208, herein incorporated by reference. These enzymes are available commercially under the name "Taka-Therm L-340" (formerly called "Takalite" Solvay Enzyme Products, Inc., Elkhart, IN). Of course, any α-amylase which is useful in the thinning of the starch is contemplated for use herein. The conditions of enzyme treatment, including the enzyme concentration and the time and temperature of reaction, are selected to achieve liquefaction of the starch in the substrate. When using a thermo¬ stable α-amylase, a preferred treatment temperature is in the range of 60° to 100°C, preferably above 70°C, such as from 90 to 100°C. At these temperatures, gelatinization of the starch in the substrate can occur concurrently with the hydrolysis. The preferred procedure is to pregelatinize the starch prior to adding the enzyme. The duration of the treatment at the desired conversion temperature depends on the desired product properties and will generally range from about 2-60 min. After completion of the enzymatic hydrolysis, the enzyme is inactivated, such as by passing the mixture through a steam injection pressure cooker at a temperature of about 140°C. Alternatively, the enzyme may be inactivated by acidification (pH 3.5-4.0) at 95°C for about 10 min. Optional neutralization with alkali increases the salt concentration of the product. After the enzyme has been inactivated, the soluble fraction comprising the soluble dietary fiber and the maltodextrins (maltooligosaccharides) is separated from the insoluble residue by centrifugation of the hydrolysates. • In a preferred embodiment of the invention, temperatures during centrifugation are maintained substantially less than 60°C, preferably at least 5 to 10°C less, and most preferably within the range of 5 to 50°C. Under these conditions of separation, the levels of lipids and proteins in the dietary fiber products are significantly reduced. Water is then removed from the soluble fraction by any of a variety of conventional techniques, whereby the products of this invention comprising the dietary fiber and maltodextrins are recovered. The maltodextrins produced by the process of the invention have a D.E. of 20 or less. These maltodextrins are substantially water soluble at elevated temperatures (e.g., 60-100°C). The soluble dietary fiber recovered from the centrifugate is principally in the form of 0-glucans and pentosans. Of course the relative amount of each fiber type varies with the species of substrate. Oat and barley substrates yield mostly the /3-glucans; whereas wheat, rice and corn yield the pentosans. It was surprising to find that the maltodextrin products of this invention are readily obtainable from barley substrates as well as oat substrates in a colorless, white, and smooth-textured form, devoid of inherent undesirable color, flavor and grittiness associated with the starting materials. These products are remarkably adapted for use as functional and nutritional components of many foods comprising a digestible food component including dairy products, dairy product substitutes, high-soluble fiber bakery products, salad dressings, meats, frozen foods, yogurt, snacks, confectioneries, coatings, dietary-fiber beverages, breakfast foods, and various low-calorie/low-fat products. Consumer preference dictates that additives intended for these applications be characterized by the virtual absence of the flavor, color, and grittiness inherent to the starting substrate and to most dietary fibers currently marketed. Characterization of the insoluble residue from the conversion mixture (supra) reveals a high proportion of protein. The protein is believed to complex with available lipid and to become insolubiϊized by heat denaturation. The residue also contains the insoluble fiber and the majority of the flavor and color components. This byproduct, therefore, has potential as an ingredient in foods or animal feeds and is considered an ancillary asset to the inventive process. The following examples are presented only to further illustrate the invention and are not intended to limit the scope of. he invention which is defined by the claims. All percentages herein disclosed are by weight unless otherwise specified. Examples 1-4 For each preparation, 100 g (dry basis) of oat flour (The Quaker Oats Company, Cedar Rapids, IA) was slurried in 400 ml of water containing 25 ppm of calcium (0.09 g/1 CaCl2 * 2H 2 ) and gelatinized by passage through a steam injection cooker at 138°-143°C (30-40 psi of steam pressure) . The gelatinized mix¬ ture was collected in a container, and the pH was adjusted with 1.0 N sodium hydroxide as desired (Table I) . "Enzeco Thermolase" (supra) was added to the mix¬ ture at 95°C in an amount sufficient to provide 24 units per gram of oat flour, where 1 unit of amylase activity is the amount of enzyme required to hydrolyze 10 mg of starch per minute under specified conditions [Enzyme Development Div. , Biddle Sawyer Corp., New York, NY, Technical Bulletin No. 20 (Revised 7/86)]. After 20 min. of stirring at 95°C, the starch was liquefied, and the enzyme was inactivated by passing the mixture through a steam injection cooker (supra) . The mixture was then allowed to cool to about 70°C, and it was centrifuged 30 min. at 5000 rpm. The water-soluble fiber product in the supernatant sol¬ ution was recovered by decanting the solution and freeze-drying. The insoluble residue obtained from centrifuging was removed and air-dried. The results in Table I show that the higher pH's (9 and 11) are accompanied by increased levels of protein in the soluble products and decreased protein amounts in the insoluble residues. Example 5 Four kilograms of oat bran [National Oats Company (supra) ] was slurried in 8 1 of water containing 25 ppm of calcium (supra) . The pH of the slurry was adjusted to 6.0 with 1.0 N sodium hydroxide, and "Taka-Therm L-340" (supra) was added to the slurry in a large Sigma mixer in an amount sufficient to provide 1632 Modified Wohlgemuth Units (MWU) per gram of substrate, where 1 MWU is that activity which will dextrinize 1 mg of soluble starch to a defined size dextrin in 30 min under specified conditions (Solvay Enzyme Products, Inc., Elkhart, IN) . During a period of about 10-15 min, the temperature was increased to a about 95°C with steam heat. After 20 min, the enzyme was inactivated by passing the mixture through a steam injection cooker. The warm slurry was centrifuged at 15,000 rpm by a large "Sharpies" centrifuge to separate the soluble components from the insoluble components. The soluble components of the oligo er composition (express on a percentage basis) were: DP>9, 32.3; DP 9, 0; DP 8, 0; DP 7, 1.0; DP 6, 13.0; DP 5, 13.9; DP 4, 6.4; DP 3, 13.0; DP 2, 12.1; DP 1, 5.6. Barley bran can be substituted for the oat bran on an equal weight basis. Example 6 Six kilograms of oat flour [National Oats Company (supra) ] was slurried in 18 1 of water containing 25 ppm of calcium (supra) . The pH of the slurry was 5.75. After gelatinization by passage of the mixture through .a steam injection cooker, the slurry was collected in a 30-gal steam-heated kettle. "Enzeco Ther olase" (supra) was added to the slurry in an amount sufficient to provide 1 unit per gram of oat flour. After 5 min of stirring at 80°-90°C, the enzyme was inactivated by passing the slurry through a steam injection cooker (supra) . The warm slurry was centrifuged at 15,000 rpm by a large "Sharpies" centrifuge to separate the soluble and insoluble components. The products were dried separately on hot rolls of a drum dryer. The oligomer composition indicated 98% DP 9 and larger. Barley flour can be substituted for the oat flour on an equal weight basis. Example 7 For each preparation 4000 g of whole barley flour, whole oat flour, or milled oat bran was slurried in 28-L of water containing 50 ppm of calcium (0.18 g/1 CaCl 2 * 2H 2 0) and gelatinized by passage through a steam injection cooker at 138°-143°C (30-40 psi of steam pressure) . The gelatinized mixture was collected in a container, and the pH was adjusted to 6.0. "G-zyme G995" (supra) was added to the mixture at 95°C in an amount sufficient to provide 1 unit per gram of substrate. After 5 min of stirring at 95°C, the starch was liquefied, and the enzyme was inactivated by adjustment of the pH to 4.0 and heating at 95°-100°C for 10 min. The pH was then adjusted to 6.0. In one trial, the mixture was centrifuged at about 70°-90°C at 15,000 rpm using a "Sharpies" centrifuge to separate the soluble and insoluble components. In a second trial, the separation was conducted as in the first trial, except the mixture was first cooled to about 25°- 40°C prior to centrifuging at 15,000 rpm. The supernatant was freeze-dried (D.E. value less than 10) . The insoluble residue was removed and air-dried or roll dried. The results in Tables II and III show that centrifugation at the lower temperatures resulted in the maltodextrin-containing soluble fraction containing significantly lower levels of lipid and protein compared to the soluble fractions obtained from centrifugation at higher temperatures (above 70°C) . -12- Table I Example Eϋ 1 6 2 7 3 9 4. 11 Table II Effect of Centrifugation Temperature on Lipid Content Substrate Lipids in Soluble Fraction. % by Weight Centrifuqate. °C 1 unit Enzyme/g flour 70-90 5-50 Whole barley flour Whole oat flour Oat Bran Table III Effect of Centrifugation Temperature on Protein Content Substrate Proteins in Soluble Fraction. % by Weight Centrifugate. "C 1 unit Enzyme/g flour 70-90 5-50 Whole barley flour Whole oat flour Oat Bran

Claims: Claims 1. A method for producing a water-soluble dietary fiber composition, comprising the steps of: (a) treating an aqueous dispersion of a gelatinized, milled, barley substrate with an α-amylase under conditions which will hydrolyze the substrate and yield a soluble fraction and an insoluble fraction; (b) separating said soluble fraction from said insoluble fraction; and (c) recovering from said soluble fraction a water-soluble dietary fiber composition substantially free of water-insoluble fiber. 2. The method as described in claim 1 wherein the solids content of said barley substrate dispersion is in the range of 10 to 40%. 3. The method as described in claim 1 wherein said barley substrate is whole barley flour. 4. The method as described in claim 1 wherein said barley substrate is debranned barley flour. 5. The method as described in claims 1, 2, 3 or 4 wherein the α-amylase is a thermostable α-amylase, the barley substrate is gelatinized either before or concurrently with the hydrolysis, and the substrate is treated with the α-amylase at a temperature in the range-of 60° to 100°C. 6. The product produced by the method of claims 1, 2, 3, 4 or 5. 7. A method for producing a composition consisting essentially of water-soluble dietary fiber and maltodextrins, comprising the steps of: a) treating whole or debranned barley flour in an aqueous dispersion at a temperature of 70 to 100"C with a thermostable α-amylase to obtain a soluble fraction and an insoluble fraction, the solids content of said barley substrate dispersion being in the range of 10 to 40%; b) separating the soluble fraction from the insoluble fraction; and (c) recovering from the soluble fraction a water-soluble, maltodextrin containing dietary fiber composition substantially free of water-insoluble fiber. 8. A method for producing a composition consisting essentially of water-soluble dietary fiber and maltodextrins, comprising the steps of: (a) treating an aqueous dispersion of a gelatinized, milled, oat or barley substrate with an α-amylase under conditions which will hydrolyze the substrate starch without appreciable solubilization of the substrate protein and thereby yield a soluble fraction and an insoluble fraction; (b) separating the soluble fraction from the insoluble fraction under conditions which minimize the level of protein in the soluble fraction; and (c) recovering from said soluble fraction the dietary fiber composition substantially free of water-insoluble fiber. 9. The method as described in claim 8 in which step (b) is carried out by centrifugal separation at a temperature of from 5 to 50°C. 10. The method as described in claims 8 or 9 wherein the substrate treated in step (a) is an oat substrate. 11. The method as described in claims 8 or 9 wherein the substrate treated in step (a) is a barley substrate. 12. The method as described in claims 8, 9, 10, or 11 wherein the α-amylase is a thermostable α-amylase and wherein the substrate is gelatinized before the hydrolysis, the gelatinized substrate being treated with the α-amylase at a temperature in the range of 60° to 100°C. 13. The products-produced by the method of claims 7, 8 , 9, ^ 10, 11, or 12.

Inventors: INGLETT GEORGE E, INGLETT, GEORGE, E.
Applicants: INGLETT GEORGE E, INGLETT, GEORGE, E.
Application year: 1991
Main classification: A23L1
IPC codes: A23L1