MULTICOMPONENT FOOD PRODUCT AND METHODS OF MAKING AND USING THE SAME

Abstract: A dual component, increased palatability animal food product has an inner component surrounded by an outer matrix. The inner component is a mixture of lipids and solids.

Description: 1 - TITLE MULTICOMPONENT FOOD PRODUCT AND METHODS OF MAKING AND USING THE SAME BACKGROUND OF THE INVENTION Field of the Invention This invention relates to food products and, more particularly, to multicomponent dry pet or animal food products that significantly improve palatability. Related Background Art Semi-moist edible products are known in the art. Such products, for example, include those made by adding a water based soft component to a dry component. The water based component is typically stabilized using a variety of gelling agents, sugars, salts, glycols, and/or by using heat. U.S. Patent No. 4,190,679 describes a dual-textured pet food containing a soft moist meaty portion containing 15-25% moisture with a water activity of 0.5-0.90. U.S. Patent No. 3,916,029 describes a center filled pet food having a semi-moist inner matrix in an outer - 2 - pastry shell. The inner matrix has a moisture content of 15-40% by weight and a water activity below about 0.85. Antimycotic agents are required to prevent mold growth. U.S. Patent No. 3,922,353 relates to a center filled product which has a meat based filling having a water activity greater than about 0.90 and a water content greater than about 50 percent by weight. Pressure cooking, acidification and antimycotics are required. U.S. Patent No. 4,006,266 relates to a two- component pet food having a soft component made of water, sugar, proteinaceous adhesive, animal protein source, vegetable protein source, fat, and a plasticizing agent. The soft component has between 11- 14% moisture and a water activity of 0.60-0.75, and is subjected to elevated temperatures of 215-180 °F. The above U.S. patents are herein incorporated by reference in their entirety. U.S. Patent No. 4,508,741 describes a pet food having a doubly coated core. The core is made primarily of a farinaceous material. U.S. Patent No. 4,847,098 describes a dual textured food article having a relatively hard phase in contact with a relatively soft phase. The soft phase is a low fat content, water-in- oil emulsion made of a dispersed aqueous or syrup phase, at least one emulsifier, and a minor continuous oil phase. Ingredients for the soft portion include water, various grain and meat solids, propylene glycol, and high fructose corn syrup to help control water activity. U.S. Patent No. 4,900,572 describes a dual textured pet food that is made by co-extrusion. The soft textured inner component is subjected to heat and pressure and has water added for expansion. U.S. Patent No. 4,795,655 is a dual portion pet food. One portion is softer than the other hard dry portion. The soft portion contains egg solids, flour, meal, sugar and 30-40 wt% water. The finished product is baked to - 3 - ensure stability. U.S. Patent No. 4,364,925 is a dual textured dog chew designed to provide a long life bone that is molded into various shapes which may include baking to promote chewing. Cellulosic, collagen and protein fibers are combined with a cowhide derived binder to form a hard composition. The soft composition is not well defined. The above U.S. Patents are herein incorporated by reference in their entirety. U.S. Patent No. 5,695,797 describes a coextruded pet food product in which the outer casing has a moisture content of between 20% and 40% and the filling represents between 30% and 40% of the total volume. The product requires a preservative such as phosphoric acid, an additive to lessen the action of the water, an anti-mould ingredient, and an antioxidant because the product of U.S. Patent No. 5,695,797 has a high moisture content. The above U.S. Patent is herein incorporated by reference in its entirety. U.S. Patent Nos. 5,641,529 and 5,449,281 describe various equipment for preparing shaped co-extruded products and three-dimensional shapes. The above U.S. Patents are herein incorporated by reference in their entirety. U.S. Patent No. 4,273,788 describes a bulk mixture of hard and soft pet foods. The hard food is in the form of chunks and the soft food is in the form of slender strands. The soft strands are described as being semi- moist. Water is added to the soft composition prior to extrusion. The extruded composition is subjected to elevated temperatures of from approximately 215-280°F, thereby lowering the moisture content to about 11-14%. The above U.S. Patent is herein incorporated by reference in its entirety. U.S. Patent No. 4,574,690 - 4 - describes an apparatus and process for producing a co- extruded food product having a filling food material surrounded by a molded food material. U.S. Patent No. 4,025,260 describes a food extrusion capable of producing a curled food particle having a meat filling covered with dough. U.S. Patent No. 5,208,059 describes an apparatus and a method to produce dual textured food pieces. The food pieces have cavities filled with a heated, pumpable food material. The above U.S. Patents are herein incorporated by reference in their entirety. U.S. Patent. No. 5,194,283 describes a composite cheese product having a covered core. The core is relatively softer than the outer covering layer. Both outer layer and the inner core are cheeses and thus are both high fat compositions. The inner core is made softer than the outer layer by increasing the fat content of the inner curd core. This U.S. patent is incorporated by reference in its entirety. U.S. Patent No. 5,643,623 and International Patent Publication No. WO 96/39869 describe a health food product containing a lipid based core used to deliver blends of anti-oxidants such as alpha-carotene, zeta- carotene, phytofluene, phytoene, vitamin C, vitamin E, or curcumin. The antioxidants are fat soluble and are incorporated into the lipid based core. The above U.S. patent and International patent publication are incorporated herein in their entirety. It is desirable to provide a palatable edible product without the use of water. As described above, conventional products use water to increase the palatability of dry pet or animal foods thereby creating semi-moist pet or animal food products. It would be highly advantageous to improve shelf-stability - 5 - and other characteristics by avoiding the use of high levels of water in pet or animal food products. Additionally, it would be desirable to provide a palatable edible product which functions as a delivery system for various nutritional, functional or pharmaceutical ingredients. Conventional products typically cannot deliver these ingredients because conventional products require significant heat processes and/or acidic conditions for stability. Such harsh conditions alter or destroy the delicate nutritional, functional, or pharmaceutical ingredients. Furthermore, it would be desirable to provide a product which avoids the need for the elaborate packaging materials that are required for moisture control. SUMMARY OF THE INVENTION The present invention provides a shelf-stable multicomponent food product having improved palatability and methods of making and using the same. The shelf-stable multicomponent pet or animal food product of the present invention can function as a delivery system for various functional, nutritional, and/or pharmaceutical ingredients. Methods of making and using such delivery systems are also provided by the present invention. A dual texture animal food product of the present invention comprises (i) a first component containing at least an ingredient comprising a lipid, wherein the first component has a total moisture content less than about 25 wt% and wherein the first component does not contain an aqueous phase; and (ii) a second component containing at least one ingredient comprising a SUBSTΓΓUTE SHEET(RULE 26) - 6 - carbohydrate, fat, protein, or combination thereof, wherein the second component has a total moisture content less than about 25 wt% moisture; wherein the first component is in the form of at least one discrete portion from the second component, and the second component at least partially surrounds the discrete portions. A method of making a dual texture animal food product of the present invention comprises co-extruding a first component within a second component to form an extrudate, wherein (a) the first component contains at least one lipid and less than 25 wt% moisture, and (b) the second component contains less than 25 wt% moisture and contains at least a carbohydrate, a fat, a protein, or combinations thereof, and wherein the first component is in the form of a discrete portion from the second component. A method of delivering at least one ingredient selected from the group consisting of nutritional, functional and pharmaceutical compounds to an animal, according to the present invention, comprises the step of feeding the dual texture animal food product of the present invention to the animal. A method of increasing in vivo oxidant defense indices in an animal, according to the present invention, comprises administering an animal food product of the present invention to the animal. A method of attenuating in vivo exercise-mediated oxidative stress in an animal, according to the present invention, comprises administering an animal food product of the present invention to the animal. - 7 - Further, the present invention provides a functional delivery system for ingredients that provide responses such as skin and coat enhancement, anti-inflammatory functions, breath improvement functions, enhanced immune response functions, antioxidant functions and/or parasite control functions. The present invention provides a functional delivery system for antibiotics and/or prebiotics and/or probiotics for the maintenance of gastrointestinal health functions. The present invention provides a dual component pet or animal food product from an edible inner component and an edible outer component. The inner component is a mixture of lipids and solids which forms a soft cream-like matrix. Since this soft matrix is formed without needing any added water, it has minimal water content and very low water activity levels. Consequently, the soft lipid composition does not require rigorous sterilization techniques or antimicrobial/antimycotic agents for stabilization. Nor does the soft lipid composition require any moisture control ingredients. The outer component is cereal based and is preferably harder than the inner portion. The outer component can have an aligned "fibrous" texture created via extrusion process. The combination of the two components and textures provides an advantageous increase in palatability over the same compositional ingredients made into a ono- component product. Thus, surprisingly, the present invention provides a significant improvement in palatability by having a softer lipid based center surrounded by harder shell material. Furthermore, the present invention allows the use of simple packaging techniques because, by the lipid inner matrix being surrounded by the cereal based shell, the - 8 - lipid material is surprisingly protected from wicking through the shell. Accordingly, there is no wicking of lipids onto the packaging material for the dual component product of the present invention. Typically, high lipid content dry pet or animal foods wick onto packaging material thereby causing undesirable grease stains. The fact that the lipids are concentrated in the inner matrix and are surrounded by an outer shell component allows for the inner matrix to have a higher lipid content without wicking, than an unprotected lipid material of the prior art. Thus, the present invention provides a food component having a desirably high lipid concentration, yet still using simple packaging techniques, without any need for the specialized and costly packaging techniques usually associated with high lipid content products. The prior art products are not able to function as a delivery system for various nutritional, functional, or pharmaceutical additive ingredients because the prior art requires significant heat processes and/or acidic conditions for stability. Such harsh conditions would alter or destroy such additive. The present invention, however, does not utilize such harsh conditions. Furthermore, moisture must be controlled in the prior art in order to prevent the deterioration of the inherent nutritional ingredients from spoilage. However, as discussed above, more elaborate packaging materials and techniques, that are required for moisture control by the prior art, are not required by the present invention. Additional objects, advantages and features of the various aspects of the present invention will become apparent from the following description of its preferred embodiments, such description being given in conjunction with the accompanying drawings. - 9 - BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of a pet or animal food product of the present invention. Fig. 2 is a perspective view of a pet or animal food product of the present invention. Fig. 3 is a perspective view of a pet or animal food product of the present invention. Fig. 4 is a perspective view of a pet or animal food product of the present invention. Fig. 5 is a perspective view of a pet or animal food product of the present invention. Fig. 6A is a schematic perspective view of a pet or animal food product of the present invention. Fig. 6B is a schematic sectional view, along section lines AA of Fig. 6A, of a pet or animal food product of the present invention. Fig. 7 is a graphical representation of the relationship between consumption and time comparing the palatability of a dual texture embodiment of the present invention with the palatability of two monotexture products wherein the vertical axis represents consumption (grams) and the horizontal axis represents time (minutes) . - 10 - DETAILED DESCRIPTION OF THE INVENTION The invention provides a shelf-stable dual texture multicomponent pet or animal food product containing a softer lipid based portion connected to a shell or harder matrix material portion having significantly improved palatability, as compared to mono-texture pet or animal food products. The present invention provides increased palatability yet the food is nutritionally complete according to American Feed Controls Officials (AFCO) standards. One aspect of the invention provides a dual texture edible product having a lipid-containing softer portion and a cereal based harder portion. The softer component is preferably a mixture of lipids and solids which forms a soft cream-like matrix. Since this soft matrix has minimal water content and very low water activity levels, it does not require harsh sterilization techniques for preservation, additional ingredients for moisture control, or antimicrobial/antimycotic agents for stabilization. Ambient shelflife studies indicate that the product of the present invention is stable, while still maintaining superior feeding performance, even after one year. The cereal based component is preferably harder than the lipid-containing component. According to one embodiment, the cereal based component forms an outer shell that surrounds the soft component which is in the form of an inner portion. Referring to Fig. 1, a pet or animal food product 10 includes an outer portion 12 surrounding an inner portion 11. Although the ends of food product 10 can optionally have inner portion 11 exposed, it is preferred that - 11 - inner portion 11 is covered at the ends by outer portion 12. In one preferred embodiment of the invention, an extruded shell product includes an inner cream material pumped into a shell extruder die plate and distributed evenly within extruded ropes. The filled extruded ropes are then crimped and cut to form a shape known in the food and pet or animal food industry as "pillow" shapes. The extrusion can utilize, without requiring the use of water, any convenient extrusion process and apparatus such as, for example, those presently utilized that until now require the use of water to form semi-moist pet or animal food products. In other examples, the shell material that is extruded can include up to 25% water added to the meal ingredient, prior to extrusion, to improve extrusion. However, the soft center portion that is coextruded in the center of the extruded rope does not contain any added water. The amount of water that is added to the outer shell material does not require extreme heat for the water's removal because of the geometry of the extruded product. The water in this invention is only in the shell which is relatively thin compared to the overall thickness of the product. As a result, the water has a shorter pathlength to the surface, and can be driven off with relatively cooler temperatures and for shorter heating times, compared to the relatively longer pathlength for water in the prior art product that has water throughout the product which requires hotter temperatures and longer heating times. Thus, the ingredients of the present invention are not subjected to deleteriously extreme heat conditions. Referring to Fig. 6A, a pet or animal food product 60 has an outer portion 62. Referring to Fig. 6B, a cross - 12 - section of food product 60, outer portion 62 surrounds inner portion 61. Optionally, outer portion 62 has an aligned "fibrous" texture 69 created by an extrusion process. Other embodiments include a product wherein the soft component is partially surrounded by a matrix comprising the cereal based component. In this manner, the soft portion is still partially protected by the cereal based matrix portion. Moreover, the soft component is in the form of discrete portions within the product so than the "dual texture" is maintained. It is understood that the unexpectedly enhanced feeding performance of the present invention's dual texture aspect is maintained by such partially surrounded embodiments, while the stability and nonwicking aspects would be lower than the fully surrounded embodiments. Referring to Fig. 2, a pet or animal food product 20 includes a layer of a first softer component 21 sandwiched between a second harder component 22. Referring to Fig. 3, a pet or animal food product 30 includes a strip of a first softer component 31 on a second harder component 32. Referring to Fig. 4, a pet or animal food product 40 includes discrete chunks of a first softer component 41 within a second harder component 42. Referring to Fig. 5, a pet or animal food product 50 includes a first softer component 51 mixed with a second harder component 52 to form discrete striations within a marbleized product. The discrete striations may be random or predetermined in distribution or in quantity. - 13 - It should be appreciated that the food products illustrated in the figures can be in any convenient size and shape, including individual bite-sized pieces and other conventional confectionery food product sizes in square, rectangular, round, oval, spherical, elliptical, donut or other shapes. It would be apparent to one in the art to determine the appropriate size and shape for any particular animal application. The softer inner portion or component is a lipid based composition having a low total moisture content less than about 25 wt%, advantageously less than about 20 wt%, more advantageously less than about 15 wt% moisture, even more advantageously less than about 12 wt%, still more advantageously less than 10 wt%, even still more preferably less than 8 wt%, and most preferably less than 6 wt%. The softer inner portion or component includes lipids such as, for example, long or medium chain saturated or unsaturated, non- di, or tri-acylglycerols. Other ingredients such as, for example, carbohydrates, fats, proteins, and combinations thereof can be included. Additional ingredients can be, for example, nutritive, non-nutritive compounds, or combinations thereof. Examples of nutritive compounds that can be included in the softer inner portion or component include mineral supplements, B vitamins, and mixtures thereof. Non- nutritive compounds include, for example, herbal compounds, plant-based extracts or mixtures thereof. Further, the inner portion or component can include one or more antioxidant ingredients which may be nutritive or non-nutritive. Examples of nutritive antioxidants include provitamin A carotenes, vitamin C, vitamin E, and mixtures thereof. Examples of provitamin A carotenes include all trans and cis beta-carotenes, all trans and cis alpha-carotenes, and all trans and cis - 14 - gamma-carotenes. Examples of non-nutritive antioxidants include non-provitamin A carotenes, anti- inflammatory agents, and mixtures thereof. Examples of non-provitamin A carotenes are zeta-carotene, trans lycopene, cis lycopenes, phytofluene, phytoene, and curcumin. Examples of anti-inflammatory agents include a fatty acid, a turmeric extract such as curcumin, and mixtures thereof. It is advantageous that the softer inner portion or component has a water activity, a w , less than about 0.65, more advantageous that a w be less than about 0.50, still more advantageous that a w be less than about 0.40, and most advantageous that a w be less than about 0.35. It is advantageous for that the lipid content of the softer inner portion or component be greater than about 10% by weight, more advantageous that the lipid content be greater than about 15% by weight, still more advantageous that the lipid content be greater than about 20% by weight, and most advantageous that the lipid content be greater than about 30% by weight. It is advantageous for the inner portion or component to comprise about 40-90 wt% solids and about 10-60 wt% lipids; more advantageous for the inner portion or component to comprise about 50-80 wt% solids and about 20-50 wt% lipids; and still more advantageous for the inner portion or component to comprise about 55-65 wt% solids and about 45-35 wt% lipids, with the sum of the wt% of solids and lipids, in all cases, not to exceed 100 wt%. It is most preferred for the inner portion or component to comprise about 60 wt% solids and 40 wt% lipids. The softer inner portion or component can include an additive such as nutritional compounds, functional - 15 - compounds, pharmaceutical compounds, and mixtures thereof. Such additives can be additives effective to enhance pet skin or coat properties, to be anti- inflammatory, to be an antioxidant, to improve breath odor, to enhance the immune response functions, to combat parasites, or to combat microbes. Further, such additives can be, for example, an anti-inflammant, and antioxidant, an anti-parasite, a breath freshener, a skin coat enhancer, a humectant, or a mixture thereof. The softer inner portion or component is in the proportion of about 5 to about 50 wt% of the total product. The harder outer portion or component is a composition having a low total moisture content less than about 25 wt%. The harder outer portion or component is a composition which includes carbohydrates, fats, proteins, and combinations thereof. An aspect of the invention provides a shelf-stable dual texture food product which functions as a delivery system for various functional, nutritional, and/or pharmaceutical ingredients. Preferably, the soft component serves as a delivery system for functional ingredients, especially those that are sensitive to heat, light, and oxygen. Since the soft component is at least partially, and preferably totally, encapsulated by the shell/matrix portion, the functional ingredients are substantially protected from heat, light and oxygen. Thus, one aspect of the invention provides a shelf-stable multicomponent pet or animal food product in which various functional, nutritional, and pharmaceutical ingredients can be added and protected in the center inner matrix from - 16 - heat, light, and oxygen. Furthermore, some functional ingredients may exhibit an undesirable odor or color when mixed throughout a product. Partial or full encapsulation substantially overcomes such problems. Additionally, the functional ingredients, which are generally fat soluble, by being contained in the lipid-based material are more easily absorbed in the digestive tract. Accordingly, they are more effectively administered. Another aspect of the invention provides a product whereby the lipid inner matrix is surrounded by the cereal based shell which protects the lipid material from wicking, thereby allowing the use of simple packaging techniques. The present invention provides a functional delivery system for skin and coat enhancement. For example, the functional ingredient in sunflower or safflower oil, linoleic acid, can be mixed into the lipid based center filling material at targeted levels of 4-8g/400 K cal. It is difficult to add this much sunflower or safflower oil to conventional dry pet or animal foods because the added linoleic acid alters the extrusion parameters, thereby causing undesirable changes in texture, increased manufacturing costs, and increased packaging material costs to minimize and prevent wicking. By contrast, it is simple to incorporate linoleic acid into the lipid matrix portion of the present invention. Other ingredients such as, for example, sulfur amino acids can be added as part of the solids in the lipid matrix portion. Since these amino acids are heat sensitive, incorporation into the center filling, rather than passing through the elevated temperatures of conventional extruder processing, prevents degradation. - 17 - Another aspect of the present invention provides a functional delivery system for anti-inflammatory functions. For example, curcumin, can be added to the center filling material. Since this ingredient is bright yellow in color, addition of this ingredient to the outer shell makes the product an undesirable color. Addition of this ingredient in the center filling material hides the bright yellow color. Additionally, anti-inflammatory pharmaceutical ingredients may be incorporated into the center filled material to control inflammation. Yet another aspect of the present invention provides a functional delivery system for breath improvement functions. Ingredients such as rosemary, clove, and parsley seed oils can be added to the center filling material. Since these ingredients have strong flavors and aromas, mixing into a center filling material dampens the flavor and aroma or these functional ingredients and also allows for their increased stability. The present invention also provides a functional delivery system for enhanced immune response functions. For example, evening primrose oil or echinacea can be added to the center filling material, thereby preventing their degradation and enhancing their stability. Another aspect of the present invention provides a functional delivery system for antioxidant functions. There are various ingredients that can function as antioxidants including, for example, (i) vitamin E which is lipid soluble, thus easily and advantageously incorporated into the lipid matrix portion, and (ii) carotenoids which are a bright orange color and are heat, light and oxygen labile, thus advantageously - 18 - incorporated into the center lipid matrix portion surrounded by an outer shell material. The present invention further provides a functional delivery system for parasite control functions. Pharmaceutical ingredients are currently incorporated into tablets. Such tablets are often difficult to administer. There is an increasing desire by consumers for incorporating these ingredients in a pet or animal food product for ease of administration. Pharmaceutical ingredients such as, for example, those effective against heartworm, intestinal worms, fleas, and/or ticks could be incorporated into the center lipid matrix portion of the present invention for administration. Yet another aspect of the present invention provides a functional delivery system for antibiotics and/or prebiotics and/or probiotics for the maintenance of gastrointestinal health functions. Various antibiotics may be incorporated into the center lipid matrix portion. Prebiotics such as inulin or frutooligosaccharide (FOS) can be incorporated as part of the solids mix blended with the lipids. Probiotics, such as lyophilized lactobacillus or bifidobacterium can be added to the lipid and have greater survival rates than from their incorporation into conventional pet or animal food products because the harsh sterilization process of conventional pet or animal food manufacturing is not required. The lyophilized cells can thus remain dormant in the lipid matrix of the present invention and remain protected until the cells reach the GI tract where the cells can advantageously proliferate. The dual texture animal food product of the present invention can be any convenient size suitable for a - 19 - particular pet-type application. One of ordinary skill in the art knows what sizes are appropriate for a particular pet-type such as, for example, kittens, cats, old cats, small dogs, medium size dogs, large dogs, and old dogs. In one example, dual texture animal food product of the present invention has a largest dimension less than about 20 mm and a second largest dimension less than about 15 mm. In another example, the largest dimension ranges from about 8 to about 10 mm and the second largest dimension ranges from about 8 to about 10 mm. Another has a largest dimension ranging from about 10 to about 12 mm and a second largest dimension ranging from about 14 to about 16 mm. Another has a largest dimension less than about 30 mm and a second largest dimension less than about 30 mm. The dual texture animal food product of the present invention, in another example, is in the shape of a substantially rectilinear box having a first dimension ranging from about 7 to about 15 mm, a second dimension ranging from about 7 to about 15 mm and a third dimension ranging from about 3 to about 10 mm. In another example, the box shape has a first dimension ranging from about 15 mm to about 30 mm, a second dimension ranging from about 15 mm to about 30 mm and a third dimension ranging from about 5 mm to about 15 mm. The dual texture animal food product of the present invention can be formed having any convenient individual weight appropriate to the particular pet- type application. For example, in one example for cats, the product weighs from about 0.1 to about 10 grams per piece. The present invention includes mixing different weight pieces for one application as well as uniform weight pieces. - 20 - Examples The following examples are illustrative of some of the products, and methods of making such dual-textured products, falling within the scope of the present invention. The examples are not to be considered in any way limitative of the invention. Numerous changes and modification can be made with respect to the invention by one of ordinary skill in the art without undue experimentation. In general, the specific processes, such as mixing, grinding, cooking, heating, extruding, or shell formation, used to make the pet or animal food products of the present invention are well known in the industry. Further, such safety procedures as are required to produce a suitable pet or animal food product are also well known in the art and are followed in practicing the present invention. When using a digest, safe digest conditions are also well known, such as maintaining a pH between about 1.0 to about 5.0. In general, the harder, shell ingredients are blended uniformly in the presence of a magnet before milling, a de-stoner is used during milling, and the milled product is tested with a metal detector to remove any potential damaging and unhealthy metal pieces. The mill and sifter should be capable of producing, for a feline directed product, for example, a mean particle size from about 200μ to about 300μ. Other animals would require different particle sizes, well known in the field. The sifter can be any convenient sifter such as, for example, an oscillating/vibrating bed sifter. - 2 1 - The safe handling of the softer core ingredients such as, for example, tallow, lard, digest, meat mix, and vegetable oil are also well known to one of ordinary skill in the pet or animal food industry. The storage conditions are well known such as, for example, keeping the tanks at a temperature between about 45 °C to about 75 °C. The tallow generally is preferably delivered from the bulk delivery system tempered to about 55 °C to about 65 °C. The tallow is preferably filtered through a U.S. Standard No. 18 Mesh filter (1,000 micron maximum opening) . Such procedures for tallow are well known in the industry in order to produce a suitable healthful pet or animal food product. In general, it is recommended that the dry meal component of the inner cream matrix be added to the mixer first, followed by the tallow and other fat and oil ingredients. Optionally, an emulsifier can be added to the tallow prior to mixing. Airborne particulates, dust, and splashing should be minimized as is known in the art in order to produce a suitable healthful pet or animal food product. The cream material should be added and mixed until the dry ingredients are well mixed and coated with the fat and oil ingredients so that no dry material is observed. The absolute viscosity is preferably below about 25,000 cP in the temperature range of about 32 °C to about 50°C. The cream tanks advantageously should be swept-surfaced and agitated, maintaining the product at a temperature of from about 40 °C to about 50 °C. The agitators advantageously should be sized to prevent air entrainment from vortex formation. The speed of mixing advantageously should be controlled to prevent air entrainment from vortex formation. - 22 - General procedures should be followed to prevent contamination from Salmonella and other microorganisms. Such procedures include, for example, maintaining sealed systems at positive pressure with filtered and UV treated air. Any convenient method can be used to form the cream, to form the outer shell material, to load the materials into an extruder, and to co-extrude the outer and inner materials. Such methods are well known to one of ordinary skill in the art in order to use the compositions of the present invention to produce the product of the present invention. It would be apparent to one of ordinary skill in the art the proper rheological properties necessary for the particular convenient extruder being used. The use of mills, screens, filters, temperature control devices, safety equipment, controllers, etc. are well known in the art. It would be apparent to one of ordinary skill in the art that the soft composition of the inner component of the present invention does not require addition of water for processing. The inner component of the present invention, however, should be kept at a temperature sufficiently high so that the mixture is sufficiently soft, and at a temperature sufficiently low so that the mixture is sufficiently stiff, to allow its effective processing in the convenient extrusion equipment . It would be apparent to one in the art to prevent particles from damaging the equipment, or from being a hazard to the consumer, by removing such particles be any convenient method such as, for example, by filtering, screening, magnetic exclusion, and sedimentation. - 23 - Although any convenient extruder can be used, in one example, an extruder was used configured with a co- extrusion die configuration in a twin screw extruder. In one configuration, the product streams to the extruder included mixed meal, potable water, steam injection, pumpable meat inclusion, optionally tallow, and a corn oil extrusion-aid additive to form the shell. A preconditioner was used to prepare meal for extrusion. In this case, although a small amount of water was added to the shell ingredients to aid in processing, the water was easily driven off by vaporization at the extrusion head or by low temperature drying at about 220 °F to about 250 °F (about 100 °C to about 116 °C) for about 20 minutes. The drying can be performed in two stages, about 10 minutes at about 220 °F (100 °C) followed by about 10 minutes at about 250 °F (116 °C) . The inner lipid based portion has good heat insulating properties. Thereby, protecting the included ingredients from deterioration by the mild drying conditions. The extruded rope containing the softer lipid interior material surrounded by the harder outer shell material can be divided into convenient sized pieces that are closed at the ends to have the softer lipid interior material completely encased by the harder outer material. The dividing can be by any convenient process such as, for example, by using a crimper. Such crimpers are well known in the art. Condensation onto the product stream should be avoided, and the process equipment should be chemically or steam sanitized. Other sanitary measures well known to one in the art should be followed in order to provide a healthy pet or animal food product. - 24 - Feeding performance is usually expressed in grams, representing the average intake per cat per feeding. If the feeding performance is performed over a period of days, the grams represent the average intake per cat per day. Feeding preference is usually expressed in percent, representing the average percentage of animals that preferred one food over others. The test procedures for determining feeding performance and feeding preference are well known to one of ordinary skill in the art. In the examples below, the term "Chix" refers to a common commodity for pet foods. It is a ground meal made from clean parts of carcasses of slaughtered chicken and is manufactured by many suppliers known to one in the industry. Examples 1A, IB, Comparative Example 1, and Comparative Example 2 : Example 1A was a dual textured pet or animal food product of the present invention made with a shell composed of the ingredients shown in Table 1 and filled with the ingredients shown in Table 2 : Table 1 Ingredient wt.% Chix w. BHA/BHT 29.00 Corn whole, #2 Yellow 39.18 Rice Brewers 17.00 Soybean Meal 44% 13.00 Salt, iodized 0.40 Vitamins and Minerals 0.80 Antioxidant 0.02 Iron Oxide Colorant 0.60 - 25 - Table 2 Ingredient wt% Wheat Flour 10.00 Hydrolyzed Meat Protein 47.00 Tallow Beef Inedible 39.00 Natural Colorant 3.00 Lecithin 1.00 Example IB was made similar to Example 1A but with the optional meat inclusion of beef, beef/liver blends and salmon. The meat inclusion was added to the shell at 5 wt% of the total product. Comparative Example 1 was made by mixing all the ingredients, in the same amounts used to make Example 1, into one mono-textured pet or animal food product. Comparative Example 2 was just the shell. Referring to Fig. 7, the feeding performance for Example 1A is shown by a feeding curve 71. The feeding performance of the prior art Comparative Example 1 is shown by a feeding curve 72 for a mono-textured food product which contained in total the same ingredients as that used in Example 1A. The feeding performance of just the shell component of the present invention, Comparative Example 2, is shown by a feeding curve 73. Example 1A and Comparative Example 1 were subjected to a Shelf-Life/Feeding Performance test. Example 1A showed feeding performances of 88 g intake after 14 weeks of shelf-storage, 75 g intake after 32 weeks of storage, and 78 g intake after 59 weeks of storage. In comparison, conventional mono-textured product Comparative Example 1 showed feeding performances of 65 g intake after 14 weeks of shelf-storage, 65 g intake after 32 weeks of storage, and 62 g intake after 59 weeks of storage. - 26 - The data show the enhanced feeding performance for the dual texture Example 1A of the present invention when compared to a monocomponent product containing all the same ingredients (Comparative Example 1) or when compared to the outer shell only (Comparative Example 2) . Not only was the present invention more palatable, but the present invention kept its increased palatability through a storage period of over a year. Example 2: A dual textured pet or animal food product of the present invention was made with a shell composed of the ingredients shown in Table 3 and filled with the ingredients shown in Table 4 : Table 3 Ingredient wt.% Chix w. BHA 34.00 Corn whole, #2 Yellow 36.18 Rice Brewers 15.00 Soybean Meal 44% 13.00 Salt, iodized 0.40 EXP-04 0.80 PET-OX (BHA/BHT) 0.02 Iron Oxide (Brown) 0.40 Table 4 Ingredient wt% Wheat Flour 10.00 Hydrolyzed Meat Protein 47.00 Tallow Beef Inedible 39.00 Natural Colorant 3.00 Lecithin 1.00 - 27 - At extrusion, the filled shell comprised 62.000 wt% batch meal, 8.000% meats, and 30.000% filling. Example 2 showed enhanced feeding performances of 96 g after 6 weeks, 71 g after 26 weeks, and 88 g after 57 weeks. Example 2B was also made with the optional meat inclusion, similarly to Example IB. Other feline preference feedings demonstrated a greater than 8 to 10 times preference of the present invention over other dry products, including dry products containing high level of lipids. In one comparison test, a salmon flavored example of the present invention was compared to a similarly salmon flavored comparison mono-textured example. The feeding preference of the present invention was 90.1% while the comparison example had a feeding preference of 9.9%. In another comparison, using a beef flavored example of the present invention and a beef flavored comparison example, the present invention showed a feeding preference of 80.6% as compared to 19.4% for the comparison example. In yet another comparison, a 15 minute paired preference test showed, with 99% confidence, that the present invention example was preferred by 70.1% while the comparison example was preferred by 29.9% of the cats. The feeding performance was 41.8 g for the present invention example, compared to 17.7 g for the comparison example. These results for dry pet or animal food, especially for feline feeding behavior, are surprising and unexpected. The increased palatability resulting from the lipid based inner matrix, according to the present invention, provides a delivery system, as shown by the - 28 following examples, for a variety of nutritional, functional, and pharmaceutical ingredients - especially those that are (i) lipid soluble, (ii) are susceptible to degradation by heat, light or oxygen or (iii) otherwise difficult to administer because of taste, color or odor. The following examples show other embodiments of the present invention having an outer shell made with ingredients similar to that used in the above Examples and having inner lipid softer mixtures as indicated below. Example 3 : Example 3 is made by making the inner filling with the ingredients shown in table 5 below: Table 5 Ingredient wt.% beef tallow 38.9 animal and/or non- 30 animal protein solids carbohydrate-based 30 solids such as wheat flour emulsifier 1 antioxidant 0.1 - 5 Example 4: Example 2 is made by making the inner filling with the ingredients shown in table 6 below: - 29 - Table 6 Ingredient wt.% beef tallow 33.9-38-89 animal and/or non- 30 animal protein solids wheat flour 30 emulsifier 1 antioxidant 0.1 essential fatty acids 0.1-5% such as n3 and/or n6 series Example 5 : Example 5 is made by making the inner filling with the ingredients shown in table 7 below: Table 7 Ingredient wt.% beef tallow 33.9-38.89 animal and/or non- 30 animal protein solids wheat flour 30 emulsifier 1 antioxidant 0.1 n-3 series essential .01-5% fatty acids and/or curcumin - 30 - Example 6 : Example 6 is made by making the inner filling with the ingredients shown in table 8 below: Table 8 Ingredient wt.% beef tallow 34.9-38.89 animal and/or non- 30 animal protein solids wheat flour 30 emulsifier 1 antioxidant 0.1 vitamin E/Curcumin/ 0.01-4% Carotenes Example 7 : Example 7 is made by making the inner filling with the ingredients shown in table 9 below: Table 9 Ingredient wt.% beef tallow 36.9-38.89 animal and/or non- 30 animal protein solids wheat flour 30 emulsifier 1 antioxidant 0.1 rosemary, clove, 0.01-2.0% eucalyptus and/or parsley seed oils - 3 1 - Example 8 : Example 8 is made by making the inner filling with the ingredients shown in table 10 below: Table 10 Ingredient wt.% beef tallow 33.9-38.89 animal and/or non- 30 animal protein solids wheat flour 30 emulsifier 1 antioxidant 0.1 flax seed, evening 0.01-5% primrose, brewers yeast and/or kelp Example 9 : Example 9 is made by making the inner filling with the ingredients shown in table 11 below: Table 11 Ingredient wt.% beef tallow 33.9-38.89 animal and/or non- 30 animal protein solids wheat flour 30 emulsifier 1 antioxidant 0.1 parasite control 0.01-5% ingredients such as a dewormer or anti-flea agent 32 - Example 10 : Example 10 is made by making the inner filling with the ingredients shown in table 12 below: Table 12 Ingredient wt.% chicken meal 35.2% corn 35% rice 14% soybean meal 13% salt 0.4% vitamins/minerals/ 2.4% antioxidants/ colors Example 11: Example 11 is made by making the inner filling with the ingredients shown in table 13 below: Table 13 Ingredient wt.% chicken meal 15 rice 25.3 corn 25 wheat 13.3 corn gluten meal 12 salt 0.9 milk protein 1 yeast 2 egg 0.8 vitamins/minerals/ 4.7 antioxidants/colors - 33 - In general, the proximates for the lipid center matrix of Examples 3-11 would be 36 wt% protein, 6 wt% ash, 42 wt% fat, 10 Wt% carbohydrate, and 6 wt% moisture. The proximates for the raw batch meal used in the outer shell prior to extrusion is about 13 wt% protein, 7 wt% ash, 6 wt% fat, 4 wt% fiber, 40 wt% carbohydrate, and 10 wt% moisture. Fresh meat can be optionally added to the batch meal prior to extrusion. The protein/carbohydrate would be adjusted to accommodate the meat addition, but the meat would nonetheless raise the fat content. The final product would have a moisture content less than about 12 wt% and a water activity below 0.6. The above description of the invention is intended to be illustrative and not limiting. Various changes or modifications in the embodiments described may occur to those skilled in the art. These can be made without departing from the spirit or scope of the invention.

Claims: - 34 - WHAT IS CLAIMED IS: 1. A dual texture animal food product comprising: a first component containing at least an ingredient comprising a lipid, wherein said first component has a total moisture content less than about 25 wt% and wherein said first component does not contain an aqueous phase; and a second component containing at least one ingredient comprising a carbohydrate, fat, protein, or combination thereof, wherein said second component has a total moisture content less than 20 wt% moisture; wherein the first component is in the form of at least one discrete portion from the second component, and said second component at least partially surrounds said at least one discrete portion. 2. The dual texture animal food product as claimed in claim 1, wherein said first component comprises less than 20 wt% moisture. 3. The dual texture animal food product as claimed in claim 1, wherein said first component comprises less than 15 wt% moisture. 4. The dual texture animal food product as claimed in claim 1, wherein said first component comprises less than 12 wt% moisture. 5. The dual texture animal food product as claimed in claim 1, wherein said first component comprises less than 10 wt% moisture. 6. The dual texture animal food product as claimed in claim 1, wherein said first component comprises less than 8 wt% moisture. - 35 - 7. The dual texture animal food product as claimed in claim 1, wherein said first component comprises less than 6 wt% moisture. 8. The dual texture animal food product as claimed in claim 1, wherein said second component comprises less than 20 wt% moisture. 9. The dual texture animal food product as claimed in claim 1, wherein said second component comprises less than 15 wt% moisture. 10. The dual texture animal food product as claimed in claim 1, wherein said second component comprises less than 10 wt% moisture. 11. The dual texture animal food product of claim 1, wherein said at least one lipid comprises long- or medium-chain saturated or unsaturated, mono-, di-, or tri-acylglycerols . 12. The dual texture animal food product of claim 1, wherein said first component further contains an ingredient selected from the group consisting of carbohydrates, fats, proteins, and combinations thereof. 13. The dual texture animal food product of claim 1, wherein the first component further contains at least one additional ingredient selected from the group consisting of nutritive compounds, non-nutritive compounds , or mixtures thereof . 14. The dual texture animal food product of claim 13 , wherein the nutritive compounds are selected from the group consisting of mineral supplements, B vitamins and mixtures thereof. - 36 - 15. The dual texture animal food product of claim 13 , wherein the non-nutritive compounds are selected from the group consisting of herbal compounds, plant- based extracts or mixtures thereof. 16. The dual texture animal food product of claim 1, wherein the first component has an a w less than 0.65, a fat content of at least 10% and comprises a mixture of lipids and solids containing proteins and carbohydrates . 17. The dual texture animal food product of claim 16, wherein the first component comprises about 40-90% solids and 10-60% lipids, with the sum of the wt% of solids and lipids not to exceed 100 wt%. 18. The dual texture animal food product of claim 16, wherein the first component comprises about 50-80% solids and 20-50% lipids, with the sum of the wt% of solids and lipids not to exceed 100 wt% . 19. The dual texture animal food product of claim 16, wherein the first component comprises about 55-65% solids and 45-35% lipids, with the sum of the wt% of solids and lipids not to exceed 100 wt%. 20. The dual texture animal food product of claim 16, wherein said first component comprises about 60% solids and 40% lipids, with the sum of the wt% of solids and lipids not to exceed 100 wt%. 21. The dual texture animal food product of claim 1, wherein said first component comprises at least one antioxidant. - 37 - 22. The dual texture animal food product of claim 16, wherein the first component comprises at least one anti-inflammatory agent. 23. The dual texture animal food product of claim 1, wherein said first component has an a w less than 0.65. 24. The dual texture animal food product of claim 1, wherein said first component has an a w less than 0.50. 25. The dual texture animal food product of claim 1, wherein said first component has an a w less than 0.40. 26. The dual texture animal food product of claim 1, wherein said first component has an a w less than 0.35. 27. The dual texture animal food product of claim 1, wherein said first component has a lipid content greater than 10% by weight. 28. The dual texture animal food product of claim 1, wherein said first component has a lipid content greater than 15% by weight. 29. The dual texture animal food product of claim 1, wherein said first component has a lipid content greater than 20% by weight. 30. The dual texture animal food product of claim 1, wherein said first component has a lipid content greater than 30% by weight. - 38 - 31. The dual texture animal food product of claim 1, wherein said first component comprises at least one additive selected from the group consisting of nutritional compounds, functional compounds, pharmaceutical compounds and mixtures thereof. 32. The dual texture animal food product of claim 1, wherein said first component comprises at least one compound that functions to enhance animal skin and/or coats. 33. The dual texture animal food product of claim 1, wherein said first component comprises at least one compound that functions to enhance anti-inflammatory functions. 34. The dual texture animal food product of claim 1, wherein said first component comprises at least one compound that functions to enhance antioxidant functions. 35. The dual texture animal food product of claim 1, wherein said first component comprises at least one compound that functions to improve breath. 36. The dual texture animal food product of claim 1, wherein said first component comprises at least one compound that functions to enhance immune response functions. 37. The dual texture animal food product of claim 1, wherein said first component comprises at least one compound that functions as an anti-parasite agent. 38. The dual texture animal food product of claim 1, wherein said first component includes at least a pre-biotic or a pro-biotic. - 39 - 39. The dual texture animal food product of claim 1, wherein said first component comprises about 5 to 50% by weight of the product. 40. The dual texture animal food product as in claim 1, wherein the second component comprises a carbohydrate, a fat, protein and mixtures thereof. 41. The dual texture animal food product as in claim 1, wherein the second component includes a fibrous texture. 42. The dual texture animal food product of claim 1, wherein said product is coated with at least one flavor enhancer. 43. The dual texture animal food product of claim 42, wherein said at least one flavor enhancer comprises 1-10% lipid material, 1-15% digest material or mixtures thereof . 44. The dual texture animal food product of claim 1, wherein the first component is at least partially surrounded by the second component or components effective to protect the first component product from heat, light, and oxygen. 45. The dual texture animal food product of claim 1, wherein the first component is at least partially surrounded by the second component or components effective to protect the lipid material in the first component . 46. The product as in claim 1, wherein the first component is in the form of an internalized core. - 40 - 47. The product as in claim 1, wherein the first component is in the form of a layer. 48. The product as in claim 1, wherein the first component is in the form of a strip. 49. The product as in claim 1, wherein the first component is in the form of a chunk within said second component . 50. The dual texture animal food product of claim 1, wherein said second component surrounds at least 75% of said first component. 51. The dual texture animal food product of claim 1, wherein said second component surrounds at least 80% of said first component. 52. The dual texture animal food product of claim 1, wherein said second component surrounds at least 85% of said first component. 53. The dual texture animal food product of claim 1, wherein said second component surrounds at least 90% of said first component. 54. The dual texture animal food product of claim 1, wherein said second component surrounds at least 95% of said first component. 55. The dual texture animal food product of claim 1, wherein said second component surrounds about 100% of said first component. 56. The dual texture animal food product of claim 1, wherein said product is nutritionally complete according to AFCO standards . - 41 - 57. The dual texture animal food product of claim 1, wherein said food product is formed by extrusion of the shell, as a continuous rope, along with the core portion simultaneously co-extruded or pumped into the hollow portion of the shell. 58. A method of making a dual texture animal food product which comprises: co-extruding a first component within a second component to form an extrudate, wherein (a) said first component contains at least one lipid and less than 25 wt% moisture, and (b) said second component contains less than 25 wt% moisture and contains at least a carbohydrate, a fat, a protein, or combinations thereof, and wherein said first component is in the form of a discrete portion from said second component. 59. The method of claim 58, further comprising the step of subdividing the extrudate into shaped pieces and drying said shaped pieces. 60. The method of claim 58, further comprising the step of coating the extrudate with a flavor enhancer. 61. The method of claim 58, wherein said first component forms a core within said second component. 62. The method of claim 61, wherein said extrudate is subdivided by a crimping. 63. The method of claim 62, wherein said crimping forms shaped pieces. 64. The method of claim 63, wherein said shaped pieces are pillow shaped with the first component being substantially enclosed by said second component. - 42 - 65. A method of delivering at least one ingredient selected from the group consisting of nutritional, functional and pharmaceutical compounds to an animal comprising the step of feeding the dual texture animal food product of claim 1 to said animal. 66. The method of claim 65, wherein said at least one ingredient includes at least one compound that functions to enhance animal skin and/or coat. 67. The method of claim 65, wherein said at least one ingredient includes at least one compound that functions to enhance anti-inflammatory functions. 68. The method of claim 65, wherein said at least one ingredient includes at least one compound that functions to enhance antioxidant functions. 69. The method of claim 65, wherein said at least one ingredient includes at least one compound that functions to improve breath. 70. The method of claim 65, wherein said at least one ingredient includes at least one compound that functions to enhance immune response functions. 71. The method of claim 65, wherein said at least one ingredient includes at least one compound that functions as an anti-parasite ingredient. 72. A method of increasing in vivo oxidant defense indices in an animal, which comprises administering an animal food product as defined in claim 1. 73. A method of attenuating in vivo exercise- mediated oxidative stress in an animal, which comprises - 43 - administering an animal food product as defined in claim 1.

Inventors: PALUCH LAURA, PALUCH, LAURA
Applicants: KAL KAN FOODS, KAL KAN FOODS, INC.
Application year: 1999
Main classification: A23K1
IPC codes: A23K1, A23L1