CO-CRYSTALLIZED SURFACTANT BLEND

Abstract: This invention relates to a method for producing a particulate co-crystallized surfactant blend for use in food processing, comprising the steps of: (a) blending a first surfactant, comprising a compound selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglycerides and mixtures thereof, with the second surfactant, comprising a monoglyceride preparation selected from the group consisting of concentrated monoglycerides having an Iodine Value between 1 and 70, mono-diglycerides having an Iodine Value between 1 and 70 and mixtures thereof, to produce a combination, wherein the ratio of the first surfactant to the second surfactant is between 2:8 and 8:2, by weight; (b) processing the combination by mixing and heating to a temperature sufficient to produce a molten blend; and (c) processing the molten blend by cooling and forming particles. Preferably, the first surfactant comprises sodium stearoyl lactylate, the second surfactant comprises a distilled monoglyceride with an Iodine Value of between 1 and 30, and the ratio of the first surfactant to the second surfactant is about 1:1, by weight. The invention also relates to a particulate co-crystallized surfactant blend produced by this method, to methods for using this co-crystallized surfactant blend, and to foods incorporating it.

Description: Co-crystallized Surfactant Blend Background of the Invention Field of the Invention This invention relates to a novel, co-crystallized surfactant blend suitable for improving the quality of foods. The co-crystallized surfactant blend of this invention is, for example, suitable for use as a dough conditioner and staling inhibitor in the manufacture of baked goods such as bread. This invention also relates to methods for the manufacture of this co-crystallized surfactant blend and to foods incorporating it. Related Art Surfactants are used, as food additives, to improve the quality of food products by interacting with other food ingredients, by stabilizing emulsions, or by stabilizing the crystal structure of fats. Surfactants are widely used in food processing, for example in the production of margarine, shortenings, edible fats, bakery products, ice cream, sugar confectionery, pasta products, potato products and other starchy food products, deserts, whipped toppings, peanut butter, coffee whiteners, non-dairy creamers, sauces, dressings, and beverages. A variety of surfactants have been used in food processing including: (a) mono-diglycerides; (b) distilled monoglycerides (DMGs); (c) monoglyceride derivatives such as ethoxylated monoglycerides, diacetyl tartaric acid esters of monoglycerides (DATEMS), acetic acid monoesters of monoglycerides, citric acid esters of monoglycerides, and lactic acid esters of monoglycerides; (d) fatty acid esters of alcohols other than glycerol such as propylene glycol, lactic acid (as sodium, calcium, or potassium salts), sucrose, sorbitol; (e) polysorbates, i.e., fatty acid monoesters of sorbitol which are variably ethoxylated to produce a hydrophilic range of sorbitan esters; (e) polyglycerol esters of fatty acids; and (f) lecithin. See, Flack, E.A. and Krog, N., "The Functions and Applications of Some Emulsifying Agents Commonly Used in Europe," Binsted's Food Trade Review 40:27-33 (1970); Lauridsen, J.B., "Food Emulsifiers: Surface Activity, Edibility, Manufacture, Composition, and Application," J. Amer. Oil Chemists' Soc. 53:400-407 (1976); Matz, S.A., Ingredients for Bakers, Pan-Tech International, McAllen, Texas, pp. 88-95 (1987). Surfactants used in the manufacture of foods are also known by a variety of other terms such as emulsifiers, emulsifying agents, surface active agents, conditioning agents, and anti-staling agents. Surfactants are added to baked goods, specifically breads, as dough conditioners and staling inhibitors. See, e.g., Rusch, D.T., "Emulsifiers: Use in Cereal and Bakery Foods," Cereal Food World 26: 110-113, 115 (1975). Dough conditions improve the gas retention properties of bread dough by interacting with flour proteins resulting in greater loaf volumes. Dough conditioners are ionic surfactants, such as diacetyl tartaric acid esters of monoglycerides and edible salts of stearoyl lactylate, e.g., sodium stearoyl lactylate (SSL) and calcium stearoyl lactylate (CSL). See, Grosskreutz, J.C., Cereal Chemistry 38:336-349 (1961) and Flack, E.A. and Krog, N., "The Functions and Applications of Some Emulsifying Agents Commonly Used in Europe," Binsted's Food Trade Review 40:27-33 (1970). Starch consists of two types of carbohydrate: amylose and amylopectin; both are polymers of glucose. When amylose, amylopectin or a mixture thereof is mixed with water and heated, it swells and forms a gel. During storage the starch gel undergoes "retrogradation," wherein the starch recrystallizes resulting in increased firmness or staling. Staling inhibitors react with starches and protein/starch complexes retarding the process of retrogradation and thus retarding staling. It has been postulated that distilled monoglycerides, such as glyceryl monostearate, are particularly effective as staling inhibitors because these linear molecules form relatively stable complexes with the helical configuration of amylose. See, e.g., Zobel, H.F., "A Review of Bread Staling," The Bakers Digest 47:52-61 (October 1973); Knightly, W.H., "The Staling of Bread," The Bakers Digest 51:52-56, 144-150 (October 1977). More recently attention has focused on the role of distilled monoglycerides in forming relatively stable complexes with hydrated chains of amylopectin, slowing the rate at which amylopectin recrystallizes, and thus retarding bread staling. See, Rao, P.A., etal., "Effects of Selected Surfactants on Amylopectin Recrystallization and on Recoverability of Bread Crumb During Storage," Cereal Chemistry 69:613-618 (1992); Stauffer, C.E., "Surface-active agents in baking react to both interface phases," Milling & Baking News, pages 16, 18 (September 12, 1995). A number of alternative mechanisms have also been proposed. See, generally, Armero, E. and Collar, C, "Crumb Firming Kinetics of Wheat Breads with Anti-staling Additives," J. Cereal Sci. 28:165-174 (1998). A variety of surfactant compositions have been proposed for improving the quality of starch containing foods. U.S. Patent No. 3,443,965 (Birnbaum) discloses an emulsifier for use in the making of yeast-raised baked goods consisting essentially of: (a) about 15- 30% of a monoglyceride derived from a saturated fatty acid having an Iodine Value in the range of 0 to a maximum of about 60, (b) about 30-45% of monoglyceride derived from an unsaturated fatty acid having an Iodine Value in the range of 60 to at least 100, and (c) the remainder being diacetyl tartaric acid ester of mono- and diglycerides derived from unsaturated edible vegetable oil of commerce; provided that the total of monoglycerides in (a) and (b), above, does not exceed about 60% of the weight of the emulsifier. U.S. Patent No. 3,743,512 (Hansen) discloses a product for use in retarding the staling of yeast-raised bakery products in the form of a dry powder comprising particles of an edible base material selected from the group consisting of cereal flour and vegetable flour and cereal starch and vegetable starch and mixtures thereof wherein the particles have a film of a hard distilled monoglyceride wiped thereover. U.S. PatentNo.4,164,593 (Marnett, etal.) discloses a dough conditioning agent, comprising calcium and sodium salts of the acyl lactylates of C 14 -C 22 fatty acids, optionally with a mono- and diglyceride product (ALDO-HMS), a distilled monoglyceride product (Myverol-1800), or mixtures thereof, which have been commingled in a molten condition and thereafter cooled to the solid state and ground to produce a powder. U.S. Patent No. 4,178,393 (Gregersen) discloses a method for preparing a pulverulent, free-flowing monoglyceride additive in the form of individual particles for use in the preparation of farinaceous and starch-containing edible products wherein the individual particles contain in substantially constant proportion (a) at least one monoglyceride and (b) at least one lecithin; comprising the steps of melting at least one distilled monoglyceride of saturated C 12.24 fatty acids, adding at least one substantially dry lecithin in an amount so as to constitute 0.1-40% of the weight of the mixture and spray-cooling the resultant mixture substantially without adding water to obtain said individual particles. U.S . Patent Nos.4,264,639, 4,371,561 and 4,544,569 (Forsythe) discloses a stearoyl lactylate salt composition and method of production thereof wherein the lactylate salt is thermally mixed with from about 2% to about 30% (by weight) of hydrogenated stearin which has from about 50% to 100% (by weight of fatty acid) C 18 fatty acid and an iodine value of less than 7. U.S. Patent No. 4,315,041 (Fukuda, et al.) discloses an emulsifier composition for use in starch containing food which is prepared by melt mixing 90-95% of a distilled monoglyceride composition comprising 65-85% of saturated fatty acid monoglycerides and 35-15% of unsaturated fatty acid monoglycerides, having an Iodine Value of 10-40, with 20-5% of fats having a melting point of more than 45 °C, powdering the resultant mixture and thereafter tempering the powdered composition for more than 30 minutes at a temperature that is above 45 °C but does not melt the powdered composition. U.S. Patent No. 4,363,826 (Fukuda, et al.) discloses a powdered emulsifier composition which is prepared by powdering a monoglyceride composition consisting essentially of 65-85% of a saturated fatty acid monoglyceride and 35-15% of a cis-type unsaturated fatty acid monoglyceride, said composition having an Iodine Value of 10 to 40, tempering the powdered monoglyceride composition for more than 30 minutes at a temperature not below 45 °C to a temperature which does not melt the saturated fatty acid monoglyceride; and cooling. U.S. Patent No.4,483,880 (Koizumi) discloses an emulsifier composition for use in starch containing foods which is prepared by melt-mixing a composition consisting of 65 to 90 weight percent of saturated fatty acid monoglyceride and 35 to 10 weight percent of cis-type unsaturated fatty acid monoglyceride, having an Iodine Value of 10 to 40, with less than 10 weight percent of one or more monoglycerides selected from diacetyltartaric acid esters of monoglyceride, mixed tartaric and acetic acid esters of monoglyceride, tartaric acid esters of monoglyceride and citric acid esters of monoglyceride, and powdering the resultant mixture. U.S. Patent No.4,609,560 (Yuda, et al.) discloses a powdered emulsifier composition prepared by melt mixing 60-95% by weight of a saturated fatty acid monoglyceride and 40-5% by weight of a cis-type unsaturated fatty acid monoglyceride, optionally including hydrophilic fatty acid esters of polyols (such as Polysorbate 80, olive oil fatty acid distilled monoglyceride, diacetyl tartaric acid ester of olive oil fatty acid distilled monoglyceride, safflower oil fatty acid distilled monoglyceride, Polysorbate 60, and oleic acid diester of decaglycerol), converting the resultant mixture to a powder by spray cooling under atmospheric pressure at a temperature below 5 ° C and wherein the powdered product contains a major amount of the saturated fatty acid monoglyceride in a β-crystalline form. U.S. Patent No. 4,684,526 (Knightly) discloses a method of preparing a baked food product by mixing ingredients comprising flour, water, a leavening agent, and an anti-staling/conditioning agent, and then baking the mixed ingredients, where the anti-staling/conditioning aging consists essentially of: (a) 90 to 10 parts by weight of the blend of a hydrophilic fraction of naturally occurring lecithins having an HLB value of at least 6, and (b) 10 to 90 parts by weight of the blend of at least one of a monoglyceride, lactic acid esterified monoglyceride, succinic acid esterified monoglyceride, maleic acid esterified monoglyceride or edible salts of stearoyl lactylic acid. U.S. Patent No.4,826,699 (Soe) discloses a method for the production of a powdered emulsifier composition having improved leavening and aerating properties, comprising the steps of (a) heating an emulsifier composition to a temperature sufficient to melt the emulsifier, (b) gas treating the composition in a pressure vessel while the emulsifier is in the melted state with pressurized inactive gas until equilibrium is reached between the gas dissolved in the melted emulsifier and the gas in the atmosphere of the pressure vessel and (c) spray crystallizing the gas treated composition to evaporate the gas and cool the composition, thereby forming a powder. Despite the variety of surfactants that are commercially available, there is a present need for an improved surfactant composition for use in food processing. Summary of the Invention It has unexpectedly been discovered that a blend of (a) edible salts of stearoyl lactylate or diacetic tartaric acid esters of monoglycerides and (b) monoglyceride compositions, containing between 30% and 100%, by weight, monoglycerides and having an Iodine Value (TV) between 1 and 70, that has been melted together, cooled so as to co-crystallize, and made into a powder or beads produces an improved surfactant composition for use in food processing. Unexpectedly, a blend of sodium stearoyl lactylate and distilled monoglyceride, having an Iodine Value between 1 and 70, that has been melted together, cooled so as to co-crystallize, and made into a powder or beads provides a surfactant blend with dough conditioning and anti-staling properties superior to those properties that can be achieved by adding the same levels of sodium stearoyl lactylate and distilled monoglyceride separately, in accordance with present practice in the food processing industry. This invention relates to a method for producing a particulate, co- crystallized surfactant composition for use in food processing, comprising the steps of: (a) blending a first surfactant, comprising one or more compounds selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglycerides and mixtures thereof, with a second surfactant, comprising a monoglyceride preparation selected from the group consisting of concentrated monoglycerides having an Iodine Value between 1 and 70, mono-diglycerides having an Iodine Value between 1 and 70 and mixtures thereof, to produce a combination, wherein the ratio of the first surfactant to the second surfactant is between 2:8 and 8:2, by weight; (b) processing the combination by mixing and heating to a temperature sufficient to produce a molten blend; and (c) processing the molten blend by cooling and forming particles. The invention also relates to a co-crystallized surfactant composition produced by this method, to methods for using this co-crystallized surfactant blend, and to foods incorporating it. Detailed Description of the Preferred Embodiments In one embodiment, the present invention relates to a method for producing a particulate, co-crystallized surfactant composition for use in food processing, comprising the steps of: (a) blending a first surfactant, comprising a compound selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglycerides and mixtures thereof, with a second surfactant, comprising a monoglyceride preparation selected from the group consisting of concentrated monoglycerides having an Iodine Value between 1 and 70, mono- diglycerides having an Iodine Value between 1 and 70 and mixtures thereof, to produce a combination, wherein the ratio of the first surfactant to the second surfactant is between 2:8 and 8:2, by weight; (b) processing the combination produced in step (a) by mixing and heating to a temperature sufficient to produce a molten blend; and (c) processing the molten blend produced in step (b) by cooling and forming particles. In a preferred embodiment of the above-described method, at step (a) the weight ratio of the first surfactant and the second surfactant is between 3:7 and 7:3; more preferably between 4:6 and 6:4; most preferably, about 1 : 1. In another preferred embodiment, the first surfactant comprises an edible salt of stearoyl lactylate; preferably, sodium stearoyl lactylate or calcium stearoyl lactylate; most preferably, sodium stearoyl lactylate. In another preferred embodiment, the second surfactant comprises a monoglyceride preparation that is a distilled monoglyceride having an Iodine Value between 1 and 70; preferably, having an Iodine Value between 2 and 70; also preferably, between 5 and 70; and preferably, between 10 and 70; more preferably, between 1 and 30; more preferably, between 2 and 30; also preferably, between 5 and 30; and preferably, between 10 and 30. In another preferred embodiment, the second surfactant comprises a monoglyceride preparation that is a mono-diglyceride, having an Iodine Value between 1 and 70; preferably, having an Iodine Value between 2 and 70; also preferably, between 5 and 70; and preferably, between 10 and 70; more preferably, between 1 and 30; more preferably, between 2 and 30; also preferably, between 5 and 30; and preferably, between 10 and 30. In a further preferred embodiment, at step (c) the method of processing the molten blend and forming particles is either (i) spray chilling to form beads or powder or (ii) cooling on a chilled drum roller to crystallize flakes and passing the flakes through a cryo-grinder to produce a powder. Unless otherwise stated, all percentages herein are expressed as weight percent. Monoglyceride preparation, as used throughout, refers to a composition, suitable for use in food processing, comprising one or more monoglycerides, wherein the total monoglyceride content is between 30% and 100% of the composition, by weight. Mono-diglyceride, as used throughout, refers to a composition, suitable for use in food processing, comprising one or more monoglyceride, wherein the monoglyceride content is at least 30% and less than 80% of the composition, by weight. Preferably the mono-diglyceride of this invention has a monoglyceride content of at least 40%, by weight. Mono-diglycerides commercially available for use in food processing typically have a monoglyceride content of approximately 40-52%, by weight. Concentrated monoglyceride, as used throughout, refers to a composition suitable for use in food processing, comprising one or more monoglycerides wherein the total monoglyceride content is between 80% and 100% of the composition, by weight. Preferably, the concentrated monoglyceride of this invention has a monoglyceride content of at least 85%, by weight; more preferably, at least 90%, by weight; most preferably, at least 95%, by weight. A concentrated monoglyceride may be prepared by any suitable process, including but not limited to molecular distillation. Distilled monoglyceride, as used throughout, has the meaning customary to the food processing industry, provided that the monoglyceride content of the distilled monoglyceride is at least 80% by weight. Preferably, the distilled monoglyceride of this invention has a monoglyceride content of at least 85% by weight; more preferably, at least 90%, by weight; most preferably, at least 95%, by weight. A distilled monoglyceride is a concentrated monoglyceride within the meaning of this application. TV, as used throughout, refers to the Iodine Value, which indicates the number of grams of iodine equivalent to the halogen absorbed by a 100 gram sample of an oil or a fat. The Iodine Value may be determined by the Wijs method, see, e.g., the American Oil Chemists' Society (A.O.C.S.), Official Method Cd lb-87 (93). During hydrogenation, the consistency of a fat or oil becomes more solid as unsaturated triglyceride molecules become more saturated by the addition of hydrogen. Thus, in general, the lower the Iodine Value of a given sample, the greater will be its content of solids at a given temperature. HLB value, as used throughout, refers to the Hydrophobic Lipophobic Balance value which is a measure of the degree of hydrophillicity of a material. See, Becher, "Emulsions: Theory and Practice," Reinhold Publishing Corp., New York, pages 188-199 (1957), Becher, et al., J. Amer. Oil Chemists Soc, 41:169- 172 (1964). The values is determined by determining the molecular percentage of hydrophilic moieties in the overall molecule divide by the arbitrary number five. Typically fatty acid monoglycerides have an HLB of about 3.5. An HLB of 10 would indicate half hydrophobic character and half hydrophilic. An HLB of 5 would indicate 75% hydrophobic character. In a further embodiment, the present invention relates to a particulate, co- crystallized surfactant composition for use in food processing, produced by the method comprising the steps of: (a) blending a first surfactant, comprising a compound selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglycerides and mixtures thereof, with a second surfactant, comprising a monoglyceride preparation selected from the group consisting of concentrated monoglycerides having an Iodine Value between 1 and 70, mono- diglycerides having an Iodine Value between 1 and 70 and mixtures thereof, to produce a combination, wherein the ratio of the first surfactant to the second surfactant is between 2:8 and 8:2, by weight; (b) processing the combination produced in step (a) by mixing and heating to a temperature sufficient to produce a molten blend; and (c) processing the molten blend produced in step (b) by cooling and forming particles . In a preferred embodiment of the above-described surfactant composition, at step (a) the weight ratio of the first surfactant and the second surfactant is between 3:7 and 7:3; more preferably, between 4:6 and 6:4; most preferably, about 1: 1. In another preferred embodiment, the first surfactant comprises an edible salt of stearoyl lactylate; preferably, sodium stearoyl lactylate or calcium stearoyl lactylate; most preferably, sodium stearoyl lactylate. In another preferred embodiment, the second surfactant comprises a monoglyceride preparation that is a distilled monoglyceride having an Iodine Value between 1 and 70; preferably, having an Iodine Value between 2 and 70; also preferably, between 5 and 70; and preferably, between 10 and 70; more preferably, between 1 and 30; more preferably, between 2 and 30; also preferably, between 5 and 30; and preferably, between 10 and 30. In another preferred embodiment, the second surfactant comprises a monoglyceride preparation that is a mono-diglyceride, having an Iodine Value between 1 and 70, preferably, having an Iodine Value between 2 and 70; also preferably, between 5 and 70; and preferably, between 10 and 70; more preferably, between 1 and 30; more preferably, between 2 and 30; also preferably, between 5 and 30; and preferably, between 10 and 30. In a further preferred embodiment, at step (c) the method of processing the molten blend and forming particles is either (i) spray chilling to form beads or powder or (ii) cooling on a chilled drum roller to crystallize flakes and passing the flakes through a cryo-grinder to produce a powder. In .mother embodiment, the present invention relates to a co-crystallized surfactant composition comprising: (a) a first surfactant comprising a compound selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglyceride and mixtures thereof, and (b) a second surfactant comprising a monoglyceride preparation selected from the group consisting of concentrated monoglycerides having an Iodine Value between 1 and 70, mono-diglycerides having an Iodine Value between 1 and 70 and mixtures thereof, to produce a combination; wherein the weight ratio between said first surfactant and said second surfactant is between 2:8 and 8:2. In a preferred embodiment of the above-described surfactant composition, the weight ratio between the first surfactant and the second surfactant is between 3:7 and 7:3; more preferably, between 4:6 and 6:4; most preferably, about 1: 1. In another preferred embodiment, the first surfactant comprises an edible salt of stearoyl lactylate; preferably, sodium stearoyl lactylate or calcium stearoyl lactylate; most preferably, sodium stearoyl lactylate. In another preferred embodiment, the second surfactant comprises a monoglyceride preparation that is a distilled monoglyceride having an Iodine Value between 1 and 70; preferably, having an Iodine Value between 2 and 70; also preferably, between 5 and 70; and preferably, between 10 and 70; more preferably, between 1 and 30; more preferably, between 2 and 30; also preferably, between 5 and 30; and preferably, between 10 and 30. In a further preferred embodiment, the second surfactant comprises a monoglyceride preparation that is a mono-diglyceride, having an Iodine Value between 1 and 70; preferably, having an Iodine Value between 2 and 70; also preferably, between 5 and 70; and preferably, between 10 and 70; more preferably, between 1 and 30; more preferably, between 2 and 30; also preferably, between 5 and 30; and preferably, between 10 and 30. In another embodiment, the present invention relates to an edible product comprising the co-crystallized surfactant blend as herein described. In another embodiment, the present invention relates to a method for: (a) improving the quality of food, (b) emulsifying food, (c) retarding the oxidation of food, (d) leavening or conditioning starch-containing food, and (e) inhibiting staling in starch-containing food, which comprises adding to the food or a preparative component thereof an effective amount of the co-crystallized surfactant blend as herein described. The surfactant composition of this invention contains a first surfactant comprising a compound selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglycerides, or mixtures thereof. Preferably the first surfactant comprises a compound selected from the group consisting of sodium stearoyl lactylate, calcium stearoyl lactylate, and potassium stearoyl lactylate. More preferably the first surfactant comprises sodium stearoyl lactylate or calcium stearoyl lactylate; most preferably, sodium stearoyl lactylate. The surfactant composition of this invention contains a second surfactant comprising a monoglyceride preparation having an Iodine Value between 1 and 70; preferably, having an Iodine Value between 2 and 70; also preferably, between 5 and 70; and preferably, between 10 and 70; more preferably, between 1 and 30; more preferably, between 2 and 30; also preferably, between 5 and 30; and preferably, between 10 and 30. The monoglyceride preparation may comprise a mono-diglyceride, with at least 30% and less than 80% monoglycerides, by weight. Preferably the mono-diglyceride contains at least 40% monoglycerides, by weight. The monoglyceride preparation may comprise a concentrated monoglyceride, with between 80% and 100% monoglycerides, by weight. Preferably the concentrated monoglyceride comprises at least 85% monglycerides, by weight; more preferably, at least 90%, by weight; most preferably, at least 95%, by weight. Preferably the concentrated monoglyceride comprises a distilled monoglyceride, with at least 85% monglycerides, by weight; more preferably, at least 90%, by weight; most preferably, at least 95%, by weight. The surfactant composition of this invention comprises particles having an average size between approximately 10 and 500 μm; preferably, between 10 and 425 μm; more preferably, between about 150 and 425 μm. The surfactant composition of this invention may be mixed with an anti- caking agent to obtain improved flow properties. Suitable anti-caking agents include, but are not limited to, aluminum calcium silicate, magnesium silicate, sodium aluminosilicate, hydrated sodium calcium aluminosilicate, tricalcium silicate, and calcium silicate (e.g., Hubersorb 600 and Hubersorb 250, from J.M. Huber). The present invention is described in further detail in the following non- limiting examples: Examples Example I Co-Crystallized Surfactant Blend Prepared with 50% Sodium Stearoyl Lactylate: 50% Distilled Monoglyceride (22 IV) 500 g of sodium stearoyl lactylate (Paniplex SK, from ADM Arkady) and 500 g of distilled monoglyceride having an Iodine Value of 22 (DMG-40, from Archer-Daniels-Midland (ADM)) were mixed together and heated to in a microwave oven to 180 °F to produce a molten blend. The molten blend was mixed using a stainless steel spatula, poured onto a non-stick tray to a depth between 3 and 10 mm, and allowed to cool to 70 °F to produce a co-crystallized blend. The co-crystallized blend was broken into flakes, placed in a plastic container and chilled for 30 to 90 minutes to a temperature between 10 and 20 °F. The flakes were ground, with dry ice, into powder in a food grinder (Mister Coffee Model IDS-50). The powder was screened for size. The powder passing through 40 U.S. mesh screen (0.425 mm) and not passing through a 100 U.S. mesh screen (0.150 mm), was retained to provide a powdered co-crystallized surfactant blend. The powdered co-crystallized surfactant blend was dry mixed with the anti-caking agent calcium silicate (Hubersorb 600, from J.M. Huber) in the ratio of 19: 1, respectively, by weight, to produce a co-crystallized surfactant blend composition. The addition of calcium silicate had no functional effect on the performance properties of the co-crystallized surfactant blend in the baking of bread. The addition of calcium silicate did essentially prevent the co-crystallized surfactant blend composition from caking when stored above 85 °F. Example 2 Co-Crystallized Surfactant Blend Prepared with 50% Sodium Stearoyl Lactylate: 50% Distilled Monoglyceride (2 IV) 500 g of sodium stearoyl lactylate (Paniplex SK, from ADM Arkady) and 500 g of distilled monoglyceride having an Iodine Value of 2 (DMG-03, from ADM) were mixed together and processed by the method of Example 1 to produce a powdered co-crystallized surfactant blend. The powdered co-crystallized surfactant blend was dry mixed with calcium silicate (Hubersorb 600, from J.M. Huber) in the ratio of 19: 1 , respective, by weight, to produce a co-crystallized surfactant blend composition Example 3 Co-Crystallized Surfactant Blend Prepared with 50% DATEMS: 50% Distilled Monoglyceride (2 IV) 500 g of DATEMS (Polimix 2000, from Canamex) and 500 g of distilled monoglyceride having an Iodine Value of 2 (DMG-03, from ADM) were mixed together and processed by the method of Example 1 to produce a powdered co- crystallized surfactant blend. The powdered co-crystallized surfactant blend was dry mixed with calcium silicate (Hubersorb 600, from J.M. Huber) in the ratio of 19: 1, respectively, by weight, to produce a co-crystallized surfactant blend composition. Example 4 Co-Crystallized Surfactant Blend Prepared with 50% Calcium Stearoyl Lactylate: 50% Distilled Monoglyceride (2 IV) 500 g of calcium stearoyl lactylate (Paniplex CK, from ADM Arkady) and 500 g of distilled monoglyceride having an Iodine Value of 2 (DMG-03, from ADM) were mixed together and processed by the method of Example 1 to produce a powdered co-crystallized surfactant blend. The powdered co-crystallized surfactant blend was dry mixed with the calcium silicate (Hubersorb 600, from J.M. Huber) in the ratio of 19:1, respectively, by weight, to produce a co-crystallized surfactant blend composition. Example 5 Co-Crystallized Surfactant Blend Prepared with 50% Sodium Stearoyl Lactylate: 50% Distilled Monoglyceride (2 IV) 1000 lbs of sodium stearoyl lactylate (Paniplex SK, from ADM Arkady) and 1000 lbs of distilled monoglyceride having an Iodine Value of 2 (DMG-03, from ADM) were delivered in a molten state from their respective manufacturing facilities, mixed together, and pumped onto a 62 inch diameter drum chiller (custom manufactured by Dedert Corporation). The mixture was solidified on the drum to produce a co-crystallized blend, scraped-off, and broken into flakes. The flakes were conveyed to a cryo-grinder (Emulator Series 30) and ground to produce a powder. The ground powder was screened in-line to produce a powdered co-crystallized surfactant blend with the following particle size distribution: 99% less than 0.85 mm, 70% less than 0.425 mm, and 30% less than 0.15 mm. The powdered co-crystallized surfactant blend was combined with the anti-caking agent calcium silicate (Hubersorb 600, from J.M. Huber) in the ratio of 19:1, respectively, by weight, to produce a co-crystallized surfactant blend composition. The composition was packed in units of 50 lbs in polyethylene lined boxes. The boxes were stored at 10 °F for 24 hours and subsequently stored at a temperature between 70 and 75 °F. Example 6 Comparison of Breads Containing Sodium Stearoyl Lactylate and Distilled Monoglyceride (22 IV): Added Separately and as a Co-Crystallized Blend A batch of 15 loaves of white pan bread was made according to the following standard formula and procedure. The emulsifier was the co-crystallized surfactant blend composition of Example 1. Standard Formula and Procedure for Baked Bread: Sponge: Flour (Pillsbury XXXX Patent) 60.00% Vital wheat gluten 6.00 Water 45.00 Yeast, dry, compressed 1.25 Sponge ingredients, other than flour, are listed as percentages by weight in comparison to the total weight of flour in the finished dough. Water was mixed with flour and wheat gluten for 4 minutes. Yeast was added and mixing continued for an additional 4 minutes. The resulting sponge was allowed to rise for 60 minutes at 85 °F. Dough: Flour (Pillsbury XXXX Patent) 40.00% Emulsifiers 1.00 Non fat dry milk 2.00 Sugar 8.00 Salt 2.25 Oil, soybean 2.00 Water 25.20 Yeast, dry, compressed 0.50 Dough ingredients, other than flour, are listed as percentages by weight in comparison to the total weight of flour in the finished dough. The oil and water were mixed with the dry ingredients for 4 minutes. Yeast was added, and mixing continued for an additional 2 minutes. The dough was mixed with sponge for 6 minutes to produce a finished dough. The finished dough was divided, scaled, molded, and proofed for approximately 55 to 60 minutes at 100 °F and 90 °F wet bulb, to reach a proof height of 10.5 cm. The proofed bread dough was baked at 420 °F for 18 minutes. Twenty-two pounds of finished dough yields one batch of 15 loaves of white pan bread. Test Procedures: Loaf volume was measured, one hour after baking, by the standard rapeseed displacement method. The loaves were then sliced and stored for seven days at ambient temperature in a sealed plastic bag. On the seventh day crumb texture was measured using a TA-TX2 texture analyzer with a 1.5 inch round acrylic probe. Texture was measured as the force in grams required to penetrate the probe 10 mm into the center of two bread slices each 12.5 mm thick. A second batch of 15 loaves of white pan bread was made and tested according to the preceding standard formula and method. In this second batch the emulsifier was a combination of an amount of sodium stearoyl lactylate (Paniplex SK, from ADM Arkady) and an amount of distilled monoglyceride having an Iodine Value of 22 (DMG-40, from ADM); each amount was equal to 0.5% of the weight of the flour contained in the finished dough, and each was added separately. The entire procedure was repeated in a second trial. The average values from the initial and the subsequent trial, for bread made with co-crystallized surfactant blend and for bread made with an equivalent amount of surfactants added separately, are shown in Table 1. Table 1. Comparison of Breads Containing SSL and DMG (22 IV): Added Separately and as a Co-Crystallized Blend The date in Table 1 indicates that bread made with a co-crystallized surfactant blend comprising equal weights of sodium stearoyl lactylate and distilled monoglyceride, having an Iodine Value of 22, is softer after seven days storage at room temperature than is bread made with the same amount of the same ingredients added separately. Thus, the co-crystallized surfactant blend of the present invention provides improved anti-staling properties to bread to a greater extent than can be achieved by adding the same levels of sodium stearoyl lactylate and distilled monoglyceride separately. Example 7 Comparison of Breads Containing Sodium Stearoyl Lactylate and Distilled Monoglyceride (2 IV): Added Separately and as a Co-Crystallized Blend A batch of 15 loaves of white pan bread was made and tested according to the standard formula and procedure of Example 6. The emulsifier was the co- crystallized surfactant blend composition of Example 2. A second batch of 15 loaves of white pan bread was also made and tested according to the standard formula and method of Example 6. In this second batch the emulsifier was a combination of an amount of sodium stearoyl lactylate (Paniplex SK, from ADM Arkady) and an amount of distilled monoglyceride having an Iodine Value of 2 (DMG-03, from ADM); each amount was equal to 0.5% of the weight of the flour contained in the finished dough, and each was added separately. The entire procedure was repeated in a second trial. The average values from the initial and the subsequent trial, for bread made with co-crystallized surfactant blend and for bread made with an equivalent amount of surfactants added separately, are shown in Table 2. Table 2. Comparison of Breads Containing SSL and DMG (2 IV): Added Separately and as a Co-Crystallized Blend The date in Table 2 indicates that bread made with a co-crystallized surfactant blend comprising equal weights of sodium stearoyl lactylate and distilled monoglyceride, having an Iodine Value of 2, is softer after seven days storage at room temperature than is bread made with the same amount of the same ingredients added separately. Thus, the co-crystallized surfactant blend of the present invention provides improved anti-staling properties to bread to a greater extent than can be achieved by adding the same levels of sodium stearoyl lactylate and distilled monoglyceride separately. Example 8 Comparison of Breads Containing DATEMS and Distilled Monoglyceride (2 IV): Added Separately and as a Co-Crystallized Blend A batch of 15 loaves of white pan bread was made and tested according to the standard formula and procedure of Example 6. The emulsifier was the co- crystallized surfactant blend composition of Example 3. A second batch of 15 loaves of white pan bread was also made and tested according to the standard formula and procedure of Example 6. In this second batch the emulsifier was a combination of an amount of DATEMS (Polimix 2000, from Canamex) and an amount of distilled monoglyceride having an Iodine Value of 2 (DMG-03, from ADM); each amount was equal to 0.5% of the weight of the flour contained in the finished dough, and each was added separately. The entire procedure was repeated in a second trial. The average values from the initial and the subsequent trial, for bread made with co-crystallized surfactant blend and for bread made with an equivalent amount of surfactants added separately, are shown in Table 3. Table 3. Comparison of Breads Containing DATEMS and DMG (2 IV): Added Separately and as a Co-Crystallized Blend The date in Table 3 indicates that bread made with a co-crystallized surfactant blend comprising equal weights of DATEMS and distilled monoglyceride, having an Iodine Value of 2, is softer after seven days storage at room temperature than is bread made with the same amount of the same ingredients added separately. Thus, the co-crystallized surfactant blend of the present invention provides improved anti-staling properties to bread to a greater extent than can be achieved by adding the same levels of DATEMS and distilled monoglyceride separately. Example 9 Comparison of Breads Containing Co-Crystallized Blends: SSL and 2 IV Monoglycerides; CSL and 2 IV Monoglycerides A batch of 15 loaves of white pan bread was made and tested according to the standard formula and procedure of Example 6. The emulsifier was the co- crystallized surfactant blend composition of Example 2. A second batch of 15 loaves of white pan bread was also made and tested according to the standard formula and procedure of Example 6. In this second batch the emulsifier was the co-crystallized surfactant blend composition of Example 3. The entire procedure was repeated in a second trial. The average values from the initial and the subsequent trial, for bread made with co-crystallized surfactant blend comprising sodium stearoyl lactylate and for bread made with the same amount of co-crystallized surfactant blend comprising calcium stearoyl lactylate, are shown in Table 4. Table 4. Comparison of Breads Containing Co-Crystallized Blends: SSL and 2 IV Monoglycerides; CSL and 2 IV Monoglycerides The data in Table 4 indicates that a co-crystallized surfactant blend composition made with CSL and a co-crystallized surfactant blend composition made with SSL produce similar results when used in bread baking. Thus, CSL and SSL are interchangeable in the co-crystallized surfactant blend of this invention. Example 10 Comparison of Breads Containing Co-Crystallized Blends: From Plant Production Procedures and Laboratory Procedures A batch of 15 loaves of white pan bread was made and tested according to the standard formula and procedure of Example 6. The emulsifier was the co- crystallized surfactant blend composition of Example 2. A second batch of 15 loaves of white pan bread was also made and tested according to the standard formula and procedure of Example 6. In this second batch the emulsifier was the co-crystallized surfactant blend composition of Example 5. The entire procedure was repeated in a second trial. The average values from the initial and the subsequent trial, for bread made with a co-crystallized surfactant blend composition from a laboratory-scale procedure and for bread made with a co-crystallized surfactant blend composition manufacturing by a plant-scale procedure, are shown in Table 5. Table 5. Comparison of Breads Containing Co-Crystallized Blends: From Plant Procedures and Laboratory Procedures The date in Table 5 indicates that bread made with a co-crystallized surfactant blend composition of this invention from a laboratory-scale procedure and bread made with the same composition manufactured by a plant-scale procedure were equivalently soft after seven days storage at room temperature. The breads also had equivalent loaf volumes. Thus, these differences in processing methods do not effect the performance properties of the co- crystallized surfactant blend compositions of this invention. It was observed that variations between different lots of the same brand of flour may produce significant variations in the experimentally obtained values for texture and for loaf volume. The breads made in Examples 7, 8 and 10 were made from the same lot of flour. Therefore, the results shown in Tables 2, 3 and 5 may be directly compared. The breads made in Examples 6 and 9 were each made from different lots of flour. Therefore, the results shown in Tables 1 and 4 are not directly comparable with each other or with the results shown in Tables 2, 3 and 5. All publications mentioned herein are hereby incorporated in their entirety by reference. In view of the foregoing description taken with the examples, those skilled in the art will be able to practice the invention in various enablements without departing from the spirit and scope of the invention as defined in the appended claims.

Claims: What Is Claimed Is: 1. A method for producing a particulate, co-crystallized surfactant composition for use in food processing, comprising the steps of: (a) blending a first surfactant, comprising a compound selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglycerides and mixtures thereof, with a second surfactant, comprising a monoglyceride preparation selected from the group consisting of concentrated monoglycerides having an Iodine Value between 1 and 70, mono-diglycerides having an Iodine Value between 1 and 70 and mixtures thereof, to produce a combination, wherein the ratio of said first surfactant to said second surfactant is between 2:8 and 8:2, by weight; (b) processing the combination produced in step (a) by mixing and heating to a temperature sufficient to produce a molten blend; and (c) processing the molten blend produced in step (b) by cooling and forming particles. 2. The method of claim 1 , further comprising the step of (d) mixing the product of step (c) with an anti-caking agent. 3. The method of claim 2, wherein said anti-caking agent is calcium silicate. 4. The method of claim 1, wherein at step (a) said first surfactant comprises a compound selected from the group consisting of sodium stearoyl lactylate, calcium stearoyl lactylate, potassium stearoyl lactylate and mixtures thereof. 5. The method of claim 4, wherein said first surfactant comprises sodium stearoyl lactylate. 6. The method of claim 1 , wherein at step (a) said second surfactant comprises a monoglyceride preparation having an Iodine Value between 1 and 30. 7. The method of claim 6, wherein said monoglyceride preparation has an Iodine Value between 2 and 30. 8. The method of claim 1 , wherein said second surfactant comprises a concentrated monoglyceride. 9. The method of claim 8, wherein said concentrated monoglyceride is a distilled monoglyceride. 10. The method of claim 1 , wherein said second surfactant comprises a mono-diglyceride. 11. The method of claim 10, wherein said mono-diglyceride comprises between 40% and 60% monoglycerides, by weight. 12. The method of claim 1, wherein at step (a) the ratio of said first surfactant to said second surfactant is between 3:7 and 7:3, by weight. 13. The method of claim 12, wherein the ratio of said first surfactant to said second surfactant is between 4:6 and 6:4, by weight. 14. The method of claim 13, the ratio of said first surfactant to said second surfactant is about 1 : 1 , by weigh. 15. The method of claim 1, wherein at step (b) said combination is processed by mixing and heating to a temperature of between 150 and 190 °F. 16. The method of claim 1 , wherein at step (c) the method for cooling and forming particles is spray chilling to form beads or powder. 17. The method of claim 1 , wherein at step (c) the method for cooling and forming particles is cooling on a chilled drum roller to crystallize flakes and passing said flakes through a cryo-grinder to produce a powder. 18. A particulate, co-crystallized surfactant composition for use in food processing, produced by the method of claim 1. 19. A particulate, co-crystallized surfactant composition for use in food processing, produced by the method of any one of claims 2-17. 20. A co-crystallized surfactant composition comprising: (a) a first surfactant comprising one or more compounds selected from the group consisting of edible salts of stearoyl lactylate, diacetic tartaric acid esters of monoglycerides and mixtures thereof; and (b) a second surfactant comprising a monoglyceride preparation selected from the group consisting of concentrated monoglycerides having an Iodine Value between 1 and 70, mono-diglycerides having an Iodine Value between 1 and 70 and mixtures thereof; wherein the ratio of said first surfactant to said second surfactant is between 2:8 and 8:2, by weight. 21. The composition of claim 20, further comprising an anti-caking agent. 22. The composition of claim 21, wherein said anti-caking agent is calcium silicate. 23. The composition of claim 20, wherein said first surfactant comprises one or more compounds selected from the group consisting of sodium stearoyl lactylate, calcium stearoyl lactylate, potassium stearoyl lactylate and mixtures thereof. 24. The composition of claim 23, wherein said first surfactant comprises sodium stearoyl lactylate. 25. The composition of claim 20, wherein second surfactant comprising a monoglyceride preparation having an Iodine Value between 1 and 30. 26. The composition of claim 25, wherein said monoglyceride preparation has an Iodine Value between 2 and 30. 27. The composition of claim 20, wherein said second surfactant comprises a concentrated monoglyceride. 28. The composition of claim 27, wherein said concentrated monoglyceride is a distilled monoglyceride. 29. The composition of claim 20, wherein said second surfactant comprises a mono-diglyceride. 30. The composition of claim 29, wherein said mono-diglyceride comprises between 40% and 60% monoglycerides, by weight. 31. The composition of claim 20, wherein the ratio of said first surfactant to said second surfactant is between 3:7 and 7:3, by weight. 32. The composition of claim 31, wherein the ratio of said first surfactant to said second surfactant is about 1 : 1 , by weight. 33. An edible product comprising the composition of any one of claims 18 and 20. 34. A method for improving the quality of food which comprises adding to said food or to a preparative component thereof an effective amount of the composition of any one of claims 18 and 20. 35. A method for emulsifying food which comprises adding to said food or to a preparative component thereof an effective amount of the composition of any one of claims 18 and 20. 36. A method for retarding the oxidation of food which comprises adding to said food or to a preparative component thereof an effective amount of the composition of any one of claims 18 and 20. 37. A method for leavening or conditioning starch-containing food which comprises adding to said food or to a preparative component thereof an effective amount of the composition of any one of claims 18 and 20. 38. The method of claim 37, wherein said starch-containing food is a baked good. 39. The method of claim 38, wherein said baked good is bread. 40. A method for inhibiting staling in starch-containing food which comprises adding to said food or to a preparative component thereof an effective amount of the composition of any one of claims 18 and 20. 41. The method of claim 40, wherein said starch-containing food is a baked good. 42. The method of claim 41 , wherein said baked good is bread.

Inventors: WIDLAK NEIL, WIDLAK, NEIL
Applicants: ARCHER DANIELS MIDLAND CO, ARCHER-DANIELS-MIDLAND COMPANY
Application year: 2000
Main classification: A23L1
IPC codes: A21D2, A23G3, A23G9, A23L1, A23L3