Patent Description:
Consumer snacking behavior is changing. Snacking has expanded to occur at all times in the day, and is often looked upon as a meal replacement. The demand for healthier snacks continues to grow with an emphasis on products bearing claims for protein, absence of gluten, and being made from a simple list of ingredients.

One category of popular snack products is the crisp snack foods known as "chips" in the United States and as "crisps" in Europe. These products are usually fried and have high fat and carbohydrate content. Very low density snack products are also common in the marketplace, such as popcorn and cheese curls or cheese puffs. These products often also have high fat and carbohydrate content.

US Patent Publication Nos. <CIT>; <CIT>; <CIT>; and <CIT>, all to Alden, describe crunchy egg products that are stated to comprise a high egg percentage by volume and a low water content by weight, audible fracturing characteristics, and brittleness characteristics.

<CIT> to Fannon describes a proteinacious food product formed by extrusion that is a stated to be a crisp or frangible product that is high in protein. The protein source for this product is preferably selected from seed products and legumes.

<CIT> to Olson relates to high protein, low carbohydrate meal replacements and food. The Summary of the Invention indicates that the invention described therein relates to a new class of food that is crispy, tasty, and low in carbohydrates and has substantial levels of egg white protein and suitable shelf life for packaging in ready to eat form. <CIT> describes an expanded extruded high protein product comprising an extrudate of a composition comprising about <NUM>-<NUM>% by dry weight of egg white and about <NUM>-<NUM>% by dry weight of an edible starch. <CIT> describes a method of manufacturing a puffed food containing a soybean protein.

The present invention provides a snack product that is an expanded food product that is high in protein, and prepared from egg as a major ingredient. The resulting product is a uniquely light, puffed product that is an expanded, cooked egg and added-protein snack food having a high protein content. This product enables consumers to enjoy a satisfying snack food treat while maintaining a high protein diet.

It has been discovered that an expanded, cooked egg and added-protein snack food can be prepared that comprises a highly desirable protein profile including egg protein. The extrusion composition comprises a select mixture of proteins and starch that provides excellent protein/nutritional content and density/crispness properties.

Specifically, the snack food of the claimed invention is prepared by a unique process comprising extruding an extrusion composition under heat and pressure to form an expanded, cooked, egg and added-protein snack food, wherein the extrusion composition comprises.

It has been found that whole egg may advantageously be used in preparation of an expanded food product made by an extrusion process. By use of the whole egg, a very high protein content composition having excellent extrusion properties with less addition of water can be obtained. The reduction of amount of added water (i.e. water that is added as a separate component and not already naturally associated with an ingredient, such as whole egg) is advantageous, because it simplifies the manufacturing process and takes advantage of a readily obtained, complete starting material that does not require intermediate processing steps, such as separation or drying. Use of the whole egg, rather than only the white or yolk, is advantageous as a superior source of a desirable array of proteins.

Additionally, it has surprisingly been found that when the extrusion composition comprises whole liquid egg present in an amount of from <NUM> to <NUM>% by weight, the composition exhibits excellent viscosity control, mixing and lubrication properties before and during the extrusion process.

Furthermore, the present extrusion composition exhibits excellent extrusion properties even when the composition does not comprise added hydrocolloids, oil or fat, or pH adjusting ingredients. Thus, in an embodiment of the present invention, the extrusion composition is free of added hydrocolloid. In an embodiment of the present invention, the extrusion composition is free of added oil and fat (other than is naturally present in the egg). In an embodiment of the present invention, the extrusion composition is free of pH adjusting ingredients in an amount that would modify the pH of the extrusion composition more than <NUM> pH unit or, in an embodiment, more than <NUM> pH units.

The final product unexpectedly has a "puff" consistency not previously associated with products containing egg as a major component. Additionally, it was not expected to be able to prepare a puffed snack product by a highly efficient extrusion process whereby a very simple egg-based composition may be extruded under heat and pressure to form an expanded, cooked, egg and protein snack food product.

The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather a purpose of the embodiments chosen and described is so that the appreciation and understanding by others skilled in the art of the principles and practices of the present invention can be facilitated.

For purposes of the present invention, the term "extrusion composition" refers to the identity and the relative amounts of the ingredients added to the extruder to produce the final product, whether these ingredients are pre-mixed and added in one addition, or are added separately at the same stage or at different stages in the extruder. Thus, the extrusion composition is essentially the starting recipe for the final product. For purposes of the present invention, the term "extruded product" refers to the product immediately after it exits the extruder, but before any additional processing step, such as drying or baking. For purposes of the present invention, the term "expanded, cooked egg and added-protein snack food" refers to the final product after completion of all processing steps, including, for example, final drying of the product.

As noted above, the extrusion composition comprises whole liquid egg in an amount of from <NUM> to <NUM>% by weight based on the total weight of the extrusion composition. It has been found that use of whole liquid egg in an amount that is less than <NUM>% does not provide the desired nutritional benefit of this ingredient. Additionally, use of whole liquid egg in an amount greater than <NUM>% results in a product that does not have the desired low density and bite characteristics. In an embodiment, the extrusion composition comprises whole liquid egg in an amount of from <NUM>% to <NUM>% by weight based on the total weight of the extrusion composition.

In an embodiment, the extrusion composition comprises whole liquid egg in an amount of from <NUM>% to <NUM>%, from <NUM>% to <NUM>%, by weight based on the total weight of the extrusion composition. This embodiment is particularly beneficial because very little or no added water is required in the extrusion composition, which nevertheless exhibits excellent extrusion performance properties. In an embodiment, the extrusion composition comprises whole liquid egg in an amount of from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, by weight based on the total weight of the extrusion composition, and less than <NUM>% or <NUM>% of added water by weight based on the total weight of the extrusion composition.

Optionally, the extrusion composition may be augmented by addition of less than <NUM> wt% based on the total weight of the extrusion composition of added egg components selected from the group consisting of powdered whole egg, powdered egg white, powdered egg yolk, liquid egg white, liquid egg yolk, and combinations thereof.

The extrusion composition comprises an added protein concentrate or isolate selected from the group consisting of rice protein, soy protein, whey protein or mixtures thereof, in an amount so that the total protein present (including, e.g., protein sourced from the whole egg) in the expanded, cooked, egg and added-protein snack food is from <NUM> to <NUM> % by weight. For purposes of the present invention, a protein concentrate is a protein formulation comprising from <NUM> to <NUM>% protein by weight and a protein isolate is a protein formulation comprising from <NUM> to <NUM>% protein by weight. In an embodiment, the added protein concentrate or isolate is a protein concentrate. In an embodiment, the added protein concentrate or isolate is a protein isolate. In an embodiment, the added protein concentrate or isolate is a mixture of at least one protein concentrates and one protein isolate.

The added protein concentrate or isolate is present in an amount of from <NUM> to <NUM> % by weight based on the total weight of the extrusion composition. It has been found that if the added protein concentrate or isolate is present in an amount less than <NUM>%, the final product does not exhibit the desired density and bite characteristics. It has been found that if the added protein concentrate or isolate is present in an amount greater than <NUM>%, the final product does not exhibit the desired density and bite characteristics and additionally may exhibit undesirable or "off" flavors. In an embodiment, the added protein concentrate or isolate is present in an amount of from <NUM> to <NUM> % by weight based on the total weight of the extrusion composition.

It has surprisingly been found that the selection of the source of the added protein concentrate or isolate is important to the texture of the final extruded product. Specifically, it has been found that adding pea and wheat based protein concentrate or isolate results in a product that has a dense and hard/crunchy product texture, rather than a desired puffy crisp product texture. However, the use of protein concentrate or isolate selected from the group consisting of rice protein, soy protein, whey protein or mixtures thereof provides a final product exhibiting a unique, desired density and light, crispness. In the claimed invention, the protein concentrate or isolate is rice protein, soy protein, whey protein or mixtures thereof.

In an embodiment, the added protein concentrate or isolate is a rice protein. In an embodiment, the added protein concentrate or isolate is a rice protein concentrate. In an embodiment, at least <NUM>% of the rice protein of the protein concentrate or isolate is brown rice protein. In an embodiment, all of the rice protein of the protein concentrate or isolate is brown rice protein. In an embodiment, all of the rice protein of the protein concentrate or isolate is obtained from non-germinated (i.e. non-sprouted) rice.

In an embodiment, the added protein concentrate or isolate is a soy protein. In an embodiment, the added protein concentrate or isolate is a soy protein isolate. In an embodiment, all of the soy protein of the protein concentrate or isolate is obtained from texturized soy.

In an embodiment, the added protein concentrate or isolate is a whey protein. In an embodiment, the added protein concentrate or isolate is a whey protein isolate. In an embodiment, all of the whey protein of the protein concentrate or isolate is obtained from whey hydrolysate.

In an embodiment, the added protein concentrate or isolate is provided in powder form. In an embodiment, the added protein has a particle size such that at least <NUM>% of the particles pass through a <NUM> mesh screen. In an embodiment, the added protein has a particle size such that at least <NUM>% of the particles pass through a <NUM> mesh screen. In an embodiment, the added protein has a particle size such that at least <NUM>% of the particles pass through an <NUM> mesh screen.

In an embodiment, the extrusion composition comprises a further added protein that is a non-concentrate protein selected from vegetable, grain or dairy protein. In an embodiment, non-concentrate protein selected from the group consisting of corn, rice and wheat. For purposes of the present invention, a non-concentrate protein is a protein formulation comprising less than <NUM>% protein by weight.

The extrusion composition of the claimed invention comprises starch present in an amount of from <NUM>% to <NUM> % by weight based on the total weight of the extrusion composition; to provide an expanded, cooked, egg and added-protein snack food having a density no greater than <NUM> grams per <NUM><NUM> (<NUM> cubic inch). In an embodiment, the starch is derived from a vegetable. In an embodiment, the starch is derived from a grain. In an embodiment, the starch is derived from a material selected from corn, potato, sweet potato, cassava, rice, wheat, barley, millet, legumes, and mixtures thereof. In an embodiment, the starch is unmodified starch. In an embodiment, the starch is unmodified starch selected from corn starch, potato starch, rice starch and mixtures thereof.

In an embodiment, the starch is a component of an ingredient comprising from <NUM> to <NUM> % carbohydrate by weight. In an embodiment, the starch is a component of an ingredient comprising from <NUM> to <NUM> % carbohydrate by weight. In an embodiment, the starch is a component of an ingredient comprising no more than <NUM>% fiber by weight. In an embodiment, the starch is corn in the form of corn meal.

In an embodiment, the starch is a refined starch.

In an embodiment, the starch is selected from a starch having a peak viscosity of from <NUM> to <NUM> mPa·s.

In an embodiment, the expanded, cooked, egg and added-protein snack food comprises more starch by weight than protein by weight. The extrusion composition comprises from <NUM> to <NUM> % by weight starch based on the total weight of the extrusion composition.

The expanded, cooked, egg and added-protein snack food may comprise additional added ingredients, such as flavorants (including seasonings), salt, colorants, preservatives and other such additives appropriate for use in the snack industry. In an embodiment, the extrusion composition comprises food ingredients from additional food sources, such as fruits and nuts.

The expanded, cooked, egg and added-protein snack food prepared by the present process has a high protein content, but in an embodiment advantageously has a carbohydrate content of at least <NUM> per <NUM> serving.

In an embodiment, the extrusion composition comprises an ingredient declaration having no more than six ingredients. It has been found that presentation of a snack product having an ingredient list that is not complex provides substantial benefit to the consumer. The extrusion composition (and final product) is gluten free. In an embodiment, the extrusion composition (and final product) is lactose free. In an embodiment, the extrusion composition (and final product) is peanut free. In an embodiment, the extrusion composition (and final product) is nut free. In an embodiment, the extrusion composition (and final product) contains only ingredients defined as organic. In an embodiment, the extrusion composition (and final product) is made only using ingredients from non-gmo sources. In an embodiment, the extrusion composition (and final product) is made only using ingredients and processes that are Kosher.

The extrusion is carried out using any appropriate extruder fitted to provide heat and pressure thereto. In an embodiment, the extruder is a twin screw extruder. An example of such an extruder is the BMIN Buhler BCTG-<NUM> twin screw extruder.

The extruder is fitted with a die to produce a final product having a desired shape. In an embodiment, the die is a "W" shaped die. In an embodiment, the die is "wave" shaped, e.g. having <NUM>-<NUM> turns.

In an embodiment, the die is heated to a temperature of from about <NUM> to about <NUM>, more preferably from about <NUM> to about <NUM>. In an embodiment, the extruder is operated under a Head Pressure of from about <NUM> bar to about <NUM> bar, or from about <NUM> bar to about <NUM> bar.

In an embodiment, the extrusion composition comprises added water that is introduced to the composition prior to or during extraction. In an embodiment, the added water is introduced in liquid form. In an embodiment, the added water is introduced in steam form during the extrusion. In an embodiment, the added water is introduced downstream in the extruder from the place of introduction of dry ingredients in the extruder.

In an embodiment, the extrusion composition comprises water from any source in an amount so that immediately after extrusion, the composition comprises from <NUM> to <NUM>% water by weight based on the total weight of the extrusion composition.

In an embodiment, the process further comprises the step of drying the extrusion product to a water content of from <NUM>% to <NUM>% water by weight based on the total weight of the final product. Drying may be carried out by any appropriate technique, such as by passing the extruded and cut product through a drying oven. In an embodiment, the composition immediately after drying comprises no more than <NUM>% water by weight based on the total weight of the product.

The extruded product is cut or otherwise divided into snack portions after exiting the extruder in any manner appropriate under food processing conditions to form an expanded, cooked egg and added-protein snack food product.

The extrusion product may optionally be subjected to a final baking step. In an embodiment, the extrusion product is baked at a temperature of from about <NUM> (<NUM>°F) to about <NUM> (<NUM>°F), more preferably from about <NUM> (<NUM>°F) to about <NUM> (<NUM>°F), for a time of from about <NUM> to <NUM> minutes.

The prepared expanded, cooked, egg and protein snack food has a density of less than <NUM> grams per <NUM><NUM> (<NUM> cubic inch). In an embodiment, the prepared expanded, cooked, egg and protein snack food has a density of from <NUM> to <NUM> grams per <NUM><NUM> (<NUM> cubic inch). In an embodiment, the prepared expanded, cooked, egg and protein snack food has a density of from <NUM> to <NUM> grams per <NUM><NUM> (<NUM> cubic inch).

In an embodiment, the prepared expanded, cooked, egg and protein snack food exhibits a desirable light crunch bite as is recognizable by consumer testing panels, in contrast to a chewy or tough textured food snack.

In an embodiment, the prepared expanded, cooked, egg and protein snack food has a water content of no more than <NUM>% water by weight based on the total weight of the final product. In an embodiment, the prepared expanded, cooked, egg and protein snack food has a water content of from <NUM>% to <NUM>% water by weight based on the total weight of the final product.

Representative embodiments of the present invention will now be described with reference to the following examples that illustrate the principles and practice of the present invention.

The compositions described below are extruded in a twin screw extruder, by premixing of addition of dry ingredients and introduction of the mixed dry ingredients to the extruder. The liquid ingredients (including egg) are introduced downstream in the extruder. The extruder is operated at a conventional, uniform temperature and pressure with respect to all samples, so that product characteristics may be evaluated based on the extrusion compositions alone without variation of process conditions.

An extrusion composition was prepared comprising the following ingredients:.

The resulting product, after drying to <NUM>% moisture, had a total protein content of <NUM> grams per <NUM> grams of product and <NUM> grams of carbohydrate per <NUM> grams of product. The product had an acceptable puff characteristic and flavor that was influenced by the rice protein.

The resulting product, after drying to <NUM>% moisture, had a total protein content of <NUM> grams per <NUM> grams of product and <NUM> grams of carbohydrate per <NUM> grams of product. The product had an overall density of <NUM> +/- <NUM> grams per <NUM><NUM> (<NUM> cubic inch). The product had an excellent puff characteristic, color and flavor.

The resulting product, after drying to <NUM>% moisture, had a total protein content of <NUM> grams per <NUM> grams of product. The product was unacceptably dense and had an unacceptably intense rice protein flavor. The product also exhibited an unacceptable level of hardness.

The resulting product, after drying to <NUM>% moisture, had a total protein content of <NUM> grams per <NUM> grams of product. The product was unacceptably dense and exhibited a poor flavor profile.

The resulting product, after drying to <NUM>% moisture, had a total protein content of <NUM> grams per <NUM> grams of product. The product had an overall density of <NUM> +/- <NUM> grams per <NUM><NUM> (<NUM> cubic inch). Use of pea protein in the formulation with whole liquid egg caused a portion of the extrudate to exhibit an unacceptable degree of dark color and dense texture.

The resulting product, after drying to <NUM>% moisture, had a total protein content of <NUM> grams per <NUM> grams of product. The product had an overall density of <NUM> +/- <NUM> grams per <NUM><NUM> (<NUM> cubic inch). Use of wheat protein in the formulation with whole liquid egg caused a portion of the extrudate to exhibit an unacceptable degree of dark color and local regions of dense texture.

As used herein, the terms "about" or "approximately" mean within an acceptable range for the particular parameter specified as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, e.g., the limitations of the sample preparation and measurement system. Examples of such limitations include preparing the sample in a wet versus a dry environment, different instruments, variations in sample height, and differing requirements in signal-to-noise ratios. For example, "about" can mean greater or lesser than the value or range of values stated by <NUM>/<NUM> of the stated values, but is not intended to limit any value or range of values to only this broader definition. For instance, a concentration value of about <NUM>% means a concentration between <NUM>% and <NUM>%. Each value or range of values preceded by the term "about" is also intended to encompass the embodiment of the stated absolute value or range of values. Alternatively, particularly with respect to biological systems or processes, the term can mean within an order of magnitude, preferably within <NUM>-fold, and more preferably within <NUM>-fold, of a value.

Claim 1:
A process for preparing an expanded, cooked, egg and added-protein snack food comprising
extruding an extrusion composition under heat and pressure to form an expanded, cooked, egg and added-protein snack food;
wherein the extrusion composition comprises
a) whole liquid egg present in an amount of from <NUM> to <NUM>% by weight based on the total weight of the extrusion composition,
b) an added protein concentrate or isolate selected from the group consisting of rice protein, soy protein, whey protein or mixtures thereof, in an amount of from <NUM> to <NUM> % by weight based on the total weight of the extrusion composition, so that the total protein present in the expanded, cooked, egg and added-protein snack food is from <NUM> to <NUM> % by weight, and
c) starch present in an amount of from <NUM>% to <NUM> % by weight based on the total weight of the extrusion composition;
wherein the expanded, cooked, egg and added-protein snack food has a density no greater than <NUM> grams per <NUM><NUM> (<NUM> cubic inch) and is gluten free.