COATING COMPOSITION COMPROMISING SYRUP AND STARCH AND PROCESS FOR USING IT

Abstract: A coating composition for foodstuffs, in particular a microwavable coating composition comprising an aqueous mixture of syrup and starch which when applied to a foodstuff, such as crumbs, cereals, nuts, or the like, helps to prevent the movement of water, or oils and fats, either into or out of the coated foodstuff. The invention also relates to a process for coating foodstuffs using the coating composition, and to the coated foodstuff.

Description: COATING COMPOSITION COMPROMISING SYRUP AND STARCH AND PROCESS FOR USING IT. This invention relates to a coating composition for foodstuffs, in particular it relates to a coating composition which when applied to a foodstuff, such as crumbs, cereals, nuts, or the like, helps to prevent the movement of water, or oils and fats, either into or out of the coated foodstuff. This invention also relates to a process for coating foodstuffs using the coating composition, and to the coated foodstuff. Certain foodstuffs, such as fish or chicken, are sold in shops and supermarkets as convenience foods. For this purpose they are coated in breadcrumbs, flash fried or sprayed with hot fat and then frozen. In this form they can be cooked by baking in the oven, grilling or frying to produce quickly a nourishing meal. Alternatively, the coated food, such as a chicken leg, may be cooked and then chilled, making the food available for eating cold, or for reheating. By using the crumb coating the food, when cooked, is crisp and crunchy and appeals to the eye. The disadvantage of such crumb coatings, however, is that when cooked in a conventional microwave oven they neither brown nor crisp up, resulting in a rather soggy, unappetising texture to the food. The inability of conventional microwaves to brown and crisp such foodstuffs is due to the wavelength of the infrared used. The wavelength is too long to create the intense surface heat which occurs at higher infrared frequencies limiting the temperature to around the boiling point of water. Microwave ovens have been developed to cope with most food heating applications, gas and electrically heated forced air convection, steam and infrared or halogen grills combining with microwave energy to provide browning facilities. However such microwave ovens are considerably more expensive than a conventional microwave. \ ~~ <?Ά~ ~ " -~ A crumb coated foodstuff, such as a fish finger, is usually prepared by predusting the fish, coating it in batter, which may contain up to 60 % moisture, and finally coating it with breadcrumbs before freezing. It can be seen therefore that the crumb coating can pick up moisture from the inside of the product, ie the fish, from the batter and also from the freezer in which it is stored. When cooked in a microwave, water migrates from the fish to the outside of the fish finger, however there is little surface evaporation and it is therefore easy to understand how the resulting cooked fish finger has such a soggy unappetising texture. Another problem area in the food industry is in retaining the freshness of skinned nuts. When nuts are inserted into such foodstuffs as chocolate or ice cream the oils and fats within the nut gradually migrate out with time. When inserted in a chocolate bar such migration of oil or fat from the nut results in the chocolate having a 'bloom' or whitish appearance. The chocolate thus becomes unappealing to the customer and may in addition taste stale. Similarly with such cereals as muesli, with time the oils and fats within the nuts will migrate from them making the muesli taste unpleasant. It has now been found that by coating crumbs, such as breadcrumbs, with a coating composition comprising syrup, such as brewing syrup, water and starch, followed by drying the coated crumbs, to reduce the moisture content, a crumb is produced which when applied to a foodstuff will result in a microwaveable food product that has retained all its organoleptic qualities. According to one aspect of the invention there is provided a microwaveable coating composition suitable for coating foodstuffs comprising from 40 % to 75 % by weight I T T syrup, from 5 % to 35 % by weight water and from 10 % to 40 % by weight of starch. Preferably the composition comprises from 50 % to 65 % by weight syrup, from 5 % to 25 % by weight water and from 15 % to 35 % by weight starch. Most preferably the composition comprises from 55 % to 60 % by weight syrup, from 10 % to 20 % by weight water and from 20 % to 30 % by weight starch. By microwaveable it is meant that the coating composition, when applied to a foodstuff such as breadcrumbs, which in turn can coat food such as fish, permits the food to be cooked by microwaving resulting in a cooked product which is just as crisp and appetising as if it had been prepared by grilling, frying or baking. The syrup used in the coating composition may be selected from brewing syrup, which contains about 70 % maltose, glucose, maltose or sugars obtained from raw cane sugar. Other syrups which may be used include corn syrup, barley syrup, malt syrup and even honey. Brewing syrup is preferred for coating savoury foods whereas glucose syrup is more suited to coat sweet foods. The starch used in the coating composition may be unmodified wheat starch, used preferably in powdered form. Alternatively, however, potato, tapioca, corn or any food starch may be used. The coating composition is prepared by heating the water in a suitable mixing vat to a temperature of at least 30 °C. The syrup, such as brewing syrup, is then added to the water and thoroughly mixed whilst the temperature of the mixture is maintained at 30 °C or above. The syrup is allowed to dissolve completely, a process which takes 2 to 3 minutes before the starch, preferably in powdered form, is added and mixed well for another 2 to 3 minutes. At all times the temperature of the composition should not rise above its gelatinous temperature, that is the temperature at which the starch SUBSTITUTE SHEET begins to gelatinise. Depending on the foodstuffs to be coated, and the product to which the coated foodstuff is to be added, appropriate flavouring(s) may be added to the coating composition. For example, where the crumb to be coated is eventually to be added to a hazelnut and chocolate spread, then such flavourings as hazelnut, golden crumble flavour, honey flavour and burnt sugar may be added to the coating composition. Alternatively, where the coating is for a crumb which is to be applied to a savoury product, such as a pizza, then de-activated yeast powder, salt and pepperoni flavour may be added to the coating composition. Such flavourings may be added during the preparation of the coating composition at the same time as the starch component is added. Once prepared the coating composition may be used to coat foodstuffs such as breadcrumbs, corncrumbs, nuts, extruded crisps, crisps, cereals both natural and manufactured such as cornflakes or other breakfast cereals, wafers, biscuits, biscuit crumbs or other snack food products. In order to coat a foodstuff such as breadcrumbs the coating composition is added to the selected breadcrumbs and mixed thoroughly until all the crumb has been coated. The mixing time will vary depending on the mixing equipment being used. The percentage of coating to foodstuff to be coated will vary enormously depending on the nature and type of foodstuff to be coated. After mixing, the coated crumb may be dropped into a feeder, such as a mass belt/rake feeder, which in turn can feed the crumb evenly onto the solid steel band of a travelling oven. The coated crumbs may then be tamped, using a tamping roller, to a selected thickness and density before being passed through a drying oven such as a Meincke Turbo travelling oven. This type of oven is an indirect fire oven which prevents any potential carcinogenic gas coming into contact with the foodstuff. The temperature of the oven is preferably at least 200 °C and may be as high as 250 °C, as determined from the flue temperature, depending on the type of foodstuff which has been coated. On leaving the oven the coated crumbs are cooled by electric fan, then broken into the desired particle size by a rubber breaking roller situated at the end of the belt. The breaking roller is adjustable in speed and height so that variable granule sizes can be achieved. The product may then be graded by a vibrating sieve. The coated crumbs instead of being cooked in a travelling oven may be prepared in a batch oven, a hot air oven or even a microwave oven. According to a second aspect of the invention there is provided a process for preparing a microwaveable coated foodstuff comprising adding the coating composition as defined above to a foodstuff, mixing until the foodstuff is evenly coated and heating the coated foodstuff to a temperature sufficient to evaporate moisture from it and to bring the moisture content of the coated foodstuff down to a chosen moisture level and colour. According to a further aspect of the invention there is provided a coated foodstuff when prepared by the process defined above. Once prepared, the coated foodstuff such as breadcrumbs can be applied to food such as fish fingers, chicken pieces or the like on a conventional three stage coating line using a predust, enrobing and crumbing system. In such a system the food is predusted, enrobed in a batter before the breadcrumbs, coated with the coating composition of the present invention, are SUBSTITUTESHEET applied. Following this the prepared food may be flash fried before being deepfrozen. The coating composition as defined above, when applied to a foodstuff, forms a barrier coating upon heating which significantly reduces the migration of moisture and/or fats and oils both out of and into the coated foodstuff. The advantages of the coating composition of the present invention are that the end food product, such as a fish finger, has a four-way cooking capability, that is it can be deep fried, grilled, oven baked or microwaved. All four methods of cooking will produce a crisp and appetising end product. Another advantage is that the coating composition can be applied to foodstuffs using conventional machinery. There is no requirement for any special equipmen . The coating composition of the present invention can also be applied to foodstuffs other than breadcrumbs, for example nuts or cereals such as cornflakes. When applied to nuts, such as almonds, it minimises the oils and fats migrating out of the nut which would otherwise spoil the taste or appearance of any food in which the nut were incorporated, for example chocolate. The nut may be coated with the coating composition and then heated in an oven as described above, a process which may simultaneously roast the nut. The advantage of coating nuts in this way is that it ' increases the shelf life of the nut and any food product into which the nut is inserted. When foods such as extruded crisps, or cereals such as cornflakes, are to be coated it may be necessary to add a vegetable fat to the coated product prior to baking in an oven, in order to assist in the break-up of the product once baked. SUBSTITUTE SHEET The advantage of coating breakfast cereals in this way is that they do not go soggy so quickly following the addition of for example milk. The invention will be further described but not limited by way of reference to the following examples. Example 1 (a) Preparation of coating composition Water (33 Kg) was heated to a temperature of between 30 °C and 40 °C. To this was added glucose syrup (104 Kg) which was dissolved with stirring, whilst keeping the temperature of the liquid at between 30 °C and 40 °C. After 2 to 3 minutes, unmodified wheat starch powder (37.5 Kg) (Abrastarch) was added to the liquid and mixed well for a further 2 to 3 minutes. The temperature of the coating composition was not allowed to rise above 40 °C. The viscosity of the composition was 288.3 centipoise. (b) Preparation of coated crumb 50 Kg of RHM Fresco Crumb (RHM = Rank Hovis McDougall) was put into a mixer. To the crumb was added 35 Kg of the coating composition as prepared above. The crumb and coating were mixed for 30 seconds using a blade type mixer, or until all the crumb had been coated. The coated crumb was then put into a feeder which in turn fed the product onto a moving belt to give a thickness of about 15 mm. The product was then tamped using a tamping roller to a thickness of 14 mm. The belt carrying the coated crumb was then passed through an oven. The oven temperature, and the time the product spends in the oven, were adjusted to suit the customers' specification of colour, moisture etc. The coated product on leaving the oven had a moisture content of from 2 % to 6 % depending on the specification required. The product was then broken to the particle size required by the customer using a rubber roller located at SUBSTITUTE SHEET the end of the moving belt, after which the product was sieved to suit the customers requirements. Example 2 (a) Preparation of coating composition Using the method described in Example 1 (a) 104 Kg of brewing syrup (Abrusol VHM) were added to water (33 Kg) which had been heated to between 30 °C and 40 °C. Salt (3.5 Kg) and De-Activated Yeast Powder (2.0 Kg) were added to the mixture, followed by unmodified wheat starch powder (37.5 Kg) . The mixture was stirred well for 2 to 3 minutes whilst the temperature was not allowed to rise above 40 °C. (b) Preparation of coated crumb 35 Kg of the coating composition as prepared above were used to coat 50 Kg of Fresco Crunch Crumb RHM using the method described in Example 1 (b) . Example 3 Using the method described in Example 1 (b) 50 Kg of Pandora Crumb were coated with 40 Kg of the coating composition prepared as described in Example 2 (a) . Example 4 Using the method described in Example 1 (b) 50 Kg of NCB Crumb - Fro Crisp 2000 were coated with 30 Kg of the coating composition prepared as described in Example 2 (a) . Example 5 Using the method described in Example 1 (b) 50 Kg of Lucas Ingredients' Super Lite were coated with 38 Kg of the coating composition prepared as described in Example 2 (a) . Example 6 Using the method described in Example 1 (b) 50 Kg of Philips Ingredients' French Crumb were coated with 42 Kg of the coating composition prepared as described in Example 2 (a) . SUBSTITUTE The resulting product was a free flowing light golden yellow coated breadcrumb which was granular and irregularly shaped. The breadcrumbs had a moisture content of 2 % to 5 % and a bushell weight (density) of 380 q/i to 430 g/( . Using different sized sieves the coated crumbs were found to have the following particle sizes: On 4.0 mm mesh size - 3 % crumb was retained; On 2.8 mm mesh size - 40 % to 60 % crumb was retained; On 1.0 mm mesh size - 30 % to 45 % crumb was retained; Through 1.0 mm mesh size - 2 % crumb passed. Example 7 Using the method described in Example 1 (b) 65 Kg of RHM Corncrumb were coated with 40 Kg of the coating composition prepared as described in Example 1 (a) . Example 8 Using the method described in Example 1 (b) 50 Kg of RHM Fresco Crumb were coated with 40 Kg of the coating composition prepared as described in Example 2 (a) . Example 9 (a) Preparation of coating composition Using the method described in Example 1 (a) 104 Kg of brewing syrup (Abrusol VHM) were added to water (33 Kg) which had been heated to between 30 °C and 40 °C. Unmodified wheat starch powder (37.5 Kg) was added to the mixture which was then stirred well for 2 to 3 minutes, whilst the temperature was not allowed to rise above 40 °C. (b) Preparation of coated nibbed almonds 15 Kg of the coating composition as prepared above were used to coat 100 Kg of 6 mm nibbed almonds using the method described in Example 1 (b) . Example 10 SUBSTITUTE SHEET 35 Kg of the coating composition as prepared in Example 9 (a) were used to coat 50 Kg of small extruded crisps using the method described in Example 1 (b) . AVR 60 Vegetable Fat (5 Kg) was then added to the coated crisps in order to assist in the break up of the crisps. Example 11 (a) Preparation of coating composition Using the method described in Example 1 (a) 172 Kg of brewing syrup (Abrusol VHM) were added to water (35.6 Kg) which had been heated to between 30 °C and 40 °C. Unmodified wheat starch powder (80.5 Kg) was added to the mixture which was then stirred well for 2 to 3 minutes, whilst the temperature was not allowed to rise above 40 °C. (b) Preparation of coated crisps 58 Kg of coating composition as prepared above were used to coat 60 Kg of 6 mm crisps using the method described in Example 1 (b) . AVR 60 Vegetable Fat (14 Kg) was then added to the coated crisps. Example 12 24 Kg of the coating composition as prepared in Example 11 (a) were used to coat 50 Kg of cornflakes using the method described in Example 1 (b) . AVR 60 Vegetable Fat (16 Kg) was then added to the coated cornflakes. Example 13 Rectangular fingers of fish were prepared and predusted, after which they were coated in an industrial batter mixture. The battered fish fingers were coated with the breadcrumbs prepared according to Example 6, flash fried and then blast frozen. After 8 months storage in a deep freeze the coated fish fingers were removed and cooked in a conventional microwave oven on a high setting. The cooked fish fingers were compared with other fish fingers which had not been covered in crumbs coated with the composition of the present invention and which had been cooked by grilling or frying. It was found that the fish fingers coated with the crumbs prepared according to Example 6 had the same golden colour and crisp texture as fish fingers which had been fried or grilled. Example 14 Using the method described in Example 1(a), 104 Kg of brewing syrup were added to water (33 Kg) , which had been heated to between 30 °C and 40 °C. Hazelnut flavour, golden crumb flavour, honey flavour, burnt sugar were added to the liquid, followed by wheat starch (37 Kg) . The mixture was stirred well for two to three minutes whilst the temperature was not allowed to rise above 40 °C. 40 Kg of the coating composition, as prepared above, were used to coat 50 Kg FroKrisp Crumb RHM and 5 Kg nibbed hazelnuts using the method described in Example 1(b) . The coated crumb and, nut mixture (15 % by weight) was added to hazelnut spread (85 % by weight) and mixed fully. Example 15 50 Kg of the coating composition, as prepared in Example 14, were used to coat 50 Kg Fresco Crunch Crumb RHM and 5 Kg nibbed hazelnuts using the method described in Example 1 (b) . The coated crumb and nut mixtμre (20 % by weight) was added to melted chocolate (80 % by weight) , thoroughly mixed and then used to coat frozen ice cream. Example 16 50 Kg of the coating composition as prepared in Example- 14 were used to coat 50 Kg Fresco Crumb RHM and 5 Kg nibbed hazelnuts using the method described in Example SUBS T ITUTE S 1 (b) . The coated crumb and nut mixture (20 % by weight) was added to a crunchy muesli mixture (80 % by weight) and placed in a first compartment of two compartment pot with the second compartment containing yoghurt, and sealed. Example 17 The coated crumb and nut mixture prepared as described in Example 16 was frozen and then sprinkled on frozen chocolate dessert and packaged up. Example 17 The coated crumb and nut mixture (20 % by weight) prepared as described in Example 16 was added to melted chocolate (80 % by weight) thoroughly mixed and then used to coat biscuits. The coating was allowed to dry before packaging the biscuits. Example 18 Using the method described in Example 1(a) 104 Kg of brewing syrup were added to water (33 Kg) which had been heated to between 30 °C and 40 °C. Salt (3.5 Kg), de-activated yeast powder (2.0 Kg), sweetness inhibitor, pepperoni flavour, together with wheat starch (37 Kg) were added to the liquid. The mixture was stirred well for two to three minutes whilst the temperature was not allowed to rise above 40 °C. 50 Kg of the coating composition as prepared above was used to coat 50 Kg Fresco Crumb using the method described in Example 1(b) . The coated crumb was sprinkled on top of a pizza to about 4 % by weight, and the pizza was then frozen. Example 19 Using the method described in Example 1(a) 180 Kg of raw cane sugar were added to water (90 Kg) which had been heated to between 30 °C and 40 °C. Orange oil together with wheat starch (50 Kg) were added to the liquid. The mixture was stirred well for two to three minutes whilst the temperature was not allowed to rise above 40 °C. Extruded cereal (10 Kg) , Fresco Crumb (5 Kg) , porridge oats (7 Kg) , ground micronized wheat (5 Kg) , desiccated coconut (3 Kg) , jumbo oats (8 Kg) and nibbed hazelnuts (1.5 Kg) were mixed together for 30 seconds before vegetable fat (5.5 Kg) and 26 Kg of the coating composition as prepared above were added. The dry ingredients were coated using the method described in Example 1(b) . The orange flavoured coated mixture, or Krocant, was subsequently coated in chocolate and glaze. Example 20 A wafer biscuit (17.5 g) was coated with the coating composition (5 g) prepared according to Example 1(a). The coated wafer biscuit was then dried in a microwave oven on full power for 1% minutes. The coated wafer biscuit was held under running cold water for 1 minute, at the end of which time there was no loss of crispness. An identical, but uncoated, wafer biscuit was subjected to the same wetting treatment, however this uncoated wafer biscuit lost its crispness within 20 seconds. tUBSTITUT ! ϋ ii

Claims: CLAIMS 1. A microwaveable coating composition suitable for coating foodstuffs comprising from 40% to 75% by weight syrup, from 5% to 35% by weight water and from 10% to 40% by weight starch. 2. A coating composition according to Claim 1 which comprises from 50% to 65% by weight syrup, from 5% to 25% by weight water and from 15% to 35% by weight starch. 3. A coating composition according to Claim 1 which comprises from 55% to 60% by weight syrup, from 10% to 20% by weight water and from 20% to 30% by weight starch. 4. A coating composition according to any one of Claims 1 to 3 wherein the syrup is selected from glucose syrup, maltose syrup, brewing syrup, corn syrup, barley syrup, malt syrup, honey or syrup from raw cane sugar. 5. A coating composition according to any one of the preceding claims wherein the starch is selected from unmodified wheat starch, potato starch, tapioca starch, corn starch or any food starch. 6. A coating composition according to any one of the preceding claims also comprising a food flavouring. 7. A method of preparing a coating composition according to any one of Claims 1 to 6 wherein the water is heated to at least 30°C, the syrup is added to the water and thoroughly mixed and dissolved whilst the temperature of the mixture is maintained at 30°C or above, the starch is added to the mixture and mixed well whilst not permitting the temperature of the composition to rise above its gelatinous temperature. 8. A process for preparing a microwaveable coated foodstuff comprising adding the coating composition according to any one of Claims 1 to 6 to a foodstuff, mixing until the foodstuff is evenly coated and heating the coated foodstuff to a temperature sufficient to evaporate moisture from it and to bring the moisture content of the coated foodstuff down to a chosen moisture level and colour. 9. A process according to Claim 8 wherein the foodstuff is selected from breadcrumbs, nuts, natural or manufactured breakfast cereals or crisps or other savoury snack product. 10. A coated foodstuff when prepared by the process of Claim 8 or Claim 9. Έ SHEET

Inventors: I ANSON BAZIL RICHARD, PARSONS KENNETH MICHAEL, I'ANSON, BAZIL, RICHARD, PARSONS, KENNETH, MICHAEL
Applicants: ANSON BROTHERS LIMITED I, I'ANSON BROTHERS LIMITED
Application year: 1992
Main classification: A23P1
IPC codes: A21D13, A23B7, A23B9, A23G3, A23G9, A23L1