Trans free hard structural fat for margarine blend and spreads

Abstract: A Trans free hard structural fat suitable for the manufacture of low SAFA (Saturated Fatty Acid) poly/mono unsaturated margarine and spreads and fat blends for margarine/spreads. The structural fat is made from selectively fractionated non-hydrogenated high melting palm oil fraction which is interesterified with dry fractionated non hydrogenated palm kernel fraction with high yield ratios that can be economically and commercially used as structural fat for the aforesaid manufacture.

Description: We hereby declare the invention for which we pray that a patent be granted for the product and the process by which it is performed which is particularly described by the following statements:- WO 96 19115 relates to fat blends suitable for manufacturing plastic w/o emulsion spreads having a high liquid oil content, little or no hardened fat, substantially no trans-unsaturated fatty acid content and a relatively low level of saturated fatty acids. GB-A-2 270 925 relates to a method for fractionating a fat composition containing a mixture of fatty glycerides into two or more fractions. CA-A-2 098 314 relates to margarine hard stocks and in particular to modified palm and palm kernel oil combinations in margarine hard stocks. The present invention is concerned with a Trans free hard structural fat suitable for the manufacture of low SAFA (Saturated Fatty Acid) poly/mono unsaturated margarine and spreads fat blends for margarine/spreads using the above mentioned structural fat. This structural fat is made from selectively fractionated non-hydrogenated palm oil fraction, which is interesterified with dry fractionated non-hydrogenated palm kernel fraction to obtain hard structural fat with high yield ratios that can be economically and commercially used as structural fat for the manufacture of Trans free low SAFA, poly unsaturated/mono unsaturated margarine/spreads. Historically emulsified fat system in margarine/spreads has been designed to satisfy customer requirements such as significant cooling impact, a rapid sharp melt sensation, and no coated or waxy feel on the tongue. In addition, it should impart temperature cycling stability (heat stability) as well as spreadability when taken out frequently from the refrigerators are the prominent features. To achieve these objectives, margarine fat blend is being formulated using hard stocks derived by hydrogenation of liquid oils. However, with the adverse effect of Trans fatty acids being published, consumers are looking for margarine / spreads with practically no Trans fatty acids. This can be achieved by using fully hydrogenated fats as structural fat, which usually does not contain Trans fatty acid or very negligible amount. Hydrogenation process is generally viewed as the main reason for the development of Trans fatty acids in oils and fats. Hence, there is a strong consumer perception against usage of and hydrogenated oil/fat in the food products including margarine / spreads. Hence research work is being carried out for developing margarine/spreads using no hydrogenated oils in their hard stock at the same time looking at the possibility of reducing the saturated fatty acid levels (SAFA) in the products The present invention relates to a margarine and spread fat blend according to claim 1. In further aspects, the present invention relates to a Trans free hard structural fat according to claim 3, a hard palm oil fraction according to claim 4, a method of producing a hard palm oil fraction according to claim 6, a method of producing a Trans free hard structural fat according to claim 9 and a Trans free hard structural fat according to claims 10 and 11. Theoretical Considerations The hard stock contributes triglycerides especially of the trisaturated type. A certain minimum quantity of these is essential to provide the "structural fat" and to prevent oiling out of the liquid oil. From the patent literature and general experience, this minimum quantity is around 6%. More is acceptable and desirable if the amount of H 3 tri-glycerides, and especially tristearin, is not greater than 2% otherwise poor mouth feel will result. Hence content of H 2 M triglycerides is valuable, to give the structuring effect, hence the need for a lauric oil. When the hard stock components are interesterified, the amounts of trisaturated triglycerides in the interesterified product are determined entirely by the content of saturated fatty acids in the blend. This relationship is very critical as shown by the results: % Saturated FA in the Oil blend % Trisaturated Triglycerides After Interesterification 50 13 60 22 70 34 80 51 90 73 Taking sunflower oil as the PUFA oil to be used in the blend, at a level of 80% (SAFA 10.3%) then the hard stock should not contribute more than 11.76% SAFA to the final blend considering that the SAFA content of polyunsaturated margarine should not exceed 20%. If 20% of the hard stock were used for the margarine blend along with Sunflower oil as above (a high usage level) - and if we also want a minimum of 6% trisaturated Tgs in the final blend, it can be seen from the above table that the SAFA content of the hard stock must be about 67% so that interesterified hard stock has 30% trisaturated triglyceride. Assuming only 15% hard stock is used then the SAFA content of the hard stock must be about 74%, so that it has 40% trisaturated triglyceride after interesterification. These are minimum requirements and a higher amount of trisaturated Tgs would be desirable. The usage of hard structural fat in the blend can be 5 to 25% and the liquid oil or its blends can be 95 - 75%.

Claims: A margarine and spread fat blend comprising 60 - 95% of a liquid oil selected from a group consisting of sunflower oil, Canola oil, soy oil, peanut oil, rice bran oil, olive oil, safflower oil, corn oil or marine oil or the blend of any of the above liquid oils with a Trans free hard structural fat at 40 - 5% level having C-16 carbon chain fatty acid residue level of at least 75% wherein said Trans free hard structural fat is made from a selectively fractionated non-hydrogenated palm oil fraction, which is interesterified with lauric fat such as dry fractionated non-hydrogenated palm kernel oil fraction without using a hydrogenation process and without using organic solvent or detergent for fractionation. A margarine and spread fat blend according to claim 1, wherein said liquid oil or said blend of liquid oils has a high poly/mono unsaturated level such that in the total fat blend the poly/mono unsaturation level exceeds 40%. A Trans free hard structural fat for the use in an amount of 40-5% level in the margarine and spread fat blend as defined in claim 1, wherein said Trans free hard structural fat is free from Trans fatty acid residue that may be produced if hydrogenation were used and having C-16 carbon chain fatty acid residue level of at least 75%. A hard palm oil fraction for use in the Trans free hard structural fat as defined in claim 3, having a C16 carbon chain fatty acid residue greater than 75%, preferably greater that 80% and most preferably greater than 84%. A hard palm oil fraction according to claim 4, having a melting point higher than 57°C, preferably greater than 60°C and which hard palm oil fraction can be flaked for easy handling because of its high melting point in spite of not being required to undergo hydrogenation and has a solid fat content of > 75% at 40°C, preferably > 80% solids at 40°C. A method of producing a hard palm oil fraction as defined in claim 4 or 5, wherein palm fat/palm oil or its stearin fraction is selectively dry fractionated by a melt crystallization process to harvest the hard palm oil fraction with C16 level of > 75%, preferably > 83% with a total unsaturation level of < 15%, preferably less than 10%. A method according to claim 6, wherein palm oil is dry fractionated using a two steps melt crystallization process, the first step being performed between 20-25°C, preferably between 22-24°C, to obtain a medium hard palm oil fraction, and wherein the medium hard palm oil fraction is then once again dry fractionated between 45-55°C, more preferably 49-52°C, to harvest a very hard palm oil fraction with a C16 fatty acid residue level of at least 75%. A method according to claim 7, wherein the medium hard palm oil fraction in the second fractionation step is separated in a high pressure membrane type filter wherein a pressure of 10-35 bar, preferably > 20 bar, most preferably > 30 bar, is used to inflate the membrane so as to remove the liquid fraction occluded in the hard palm oil fraction. A method of producing a Trans free hard structural fat as defined in claim 3, comprising an interesterification reaction of a hard palm oil fraction with a hard palm kernel oil fraction, the resultant hard fat not being further fractionated but used as such as a Trans free hard structural fat. A Trans free hard structural fat for use in an amount of 40-5% in the margarine and spread fat blend according to claim 1, wherein said hard structural fat is produced by an interesterification reaction of a hard palm oil fraction with a hard palm kernel oil fraction, the resultant fat not being further fractionated having C-16 carbon chain fatty acid residue level of at least 75%. A Trans free hard structural fat for use in an amount of 5-40% in the margarine and spread fat blend as defined in claim 1, wherein the hard structural fat is produced by an interesterification reaction of a hard palm oil fraction with a hard palm kernel oil fraction, in such a way that the hard structural fat has a trisaturated triglyceride of H 3 type that is less than 25%, preferably less than 20% and having C-16 carbon chain fatty acid residue level of at least 75%.

Inventors: SAHASRANAMAM ULLANOOR MADAM RA, SAHASRANAMAM, ULLANOOR MADAM RAMASUBRAMANIAM
Applicants: PREMIUM VEGETABLE OILS BERHAD
Application year: 2001
Main classification: A23D9
IPC codes: A23L1, A23D9, A23D7, C11B1, C11B7, C11C3