Patent Description:
Food products and food product manufacturing systems are known. While existing food products and food product manufacturing systems and methods perform adequately for their intended purpose, improvements to food products and food product manufacturing systems and methods are continuously being sought in order to advance the arts.

Traditional high-protein food product bars, and particularly, food product bars having a high-protein nougat, are known to experience water migration over extended periods of time. This phenomenon is particularly common in high-protein nougats, as water content within the nougat may migrate towards relatively high-protein locals within the nougat. This migration of water to high-protein portions may result in minimized shelf life and/or undesirable, dry chew texture, and/or degraded aesthetics caused by the dehydrated portions of the nougat layer. To mitigate the dehydration of the high-protein nougat, food product bars of the prior art are often enrobed in a low-protein, high-sugar coating, such as chocolate. While suitable for preserving moisture, enrobing food product bars diminishes the overall nutritional value (i.e. lower protein content, higher fat and sugar content) and minimizes the aesthetics of the food product bar by concealing the nutritional, high-protein layers and giving the appearance of a candy product. Thus, products and methods for providing a high-protein food product bars including a high-protein nougat that is not enrobed continue to be sought.

In the state of the art are known the following documents:.

One aspect of the disclosure provides food product bar having a first layer comprising a conglomerate of edible particles, the first layer having a protein concentration of at least <NUM>% by weight, and a second layer covering the first layer and comprising a nougat, the second layer having a protein concentration of at least <NUM>% by weight, whereby a total protein concentration of the food product bar is at least <NUM>% by weight, wherein the first layer (<NUM>) comprises: rolled oats (22a) at a concentration of ranging from <NUM>% to <NUM>%, by weight; protein crisps (22b) at a concentration ranging from <NUM>% to <NUM>%, by weight; nuts (22c) at a concentration ranging from <NUM>% to <NUM>%, by weight; and binder syrup at a concentration ranging from <NUM>% to <NUM>%, by weight.

Implementations of the disclosure may include one or more of the following optional features. In some implementations each of the first layer and the second layer are exposed.

In some examples, the first layer is continuously formed from a first end of the food product bar to a second end of the food product bar, and the second layer includes a plurality of partitions spaced from the first end to the second end. Here, the partitions may be slices through an entire thickness of the second layer.

In some implementations, the first layer consists essentially of rolled oats, protein crisps, almonds, and binder syrup.

In some implementations a plurality additives deposited on the second layer. Here, the additives may include at least one of dried fruits, seeds, nuts.

Another aspect of the disclosure provides a food product bar consisting of a first layer comprising a conglomerate of edible particles, the first layer having a protein concentration of at least <NUM>% by weight, and a second layer covering the first layer and comprising a nougat, the second layer having a protein concentration of at least <NUM>% by weight, whereby a total protein concentration of the food product bar is at least <NUM>% by weight.

Yet another aspect of the disclosure includes a method of forming a food product bar. The method comprises mixing a first plurality of components to form a first layer conglomerate having a plurality of edible particles, the first layer conglomerate having a concentration of protein of at least <NUM>%, by weight. The method further includes mixing a second plurality of components to form a second layer conglomerate including a nougat, the second layer conglomerate having a concentration of protein of at least <NUM>%, by weight. A first amount of the first layer conglomerate is deposited to form a first layer, and a second amount of the second layer conglomerate is deposited atop the first layer to form a stratified base slab, whereby the base slab has a concentration of protein of at least <NUM>%, by weight.

In some examples, the method includes forming partitions in the second layer. Here, the partitions are formed through an entire thickness of the second layer. In some implementations, each of the first layer and the second layer is cold-formed.

In some examples, the method includes depositing an additive to at least one of the first layer and the second layer.

In some implementations, the method further comprises cutting the base slab into a plurality of the food product bars, wherein each of the food product bars includes the first layer and the second layer.

In the method of the invention, the first layer conglomerate comprises rolled oats at a concentration of ranging from <NUM>% to <NUM>%, by weight, protein crisps at a concentration ranging from <NUM>% to <NUM>%, by weight, nuts at a concentration ranging from <NUM>% to <NUM>%, by weight, and binder syrup at a concentration ranging from <NUM>% to <NUM>%, by weight.

In some implementations, the food product bar is individually packaged.

In some examples, the first layer and the second layer are exposed within the package.

In some implementations, the second layer includes light amber honey, hydrolyzed milk protein concentrate, hydrolyzed milk protein isolate, canola oil, almond butter, water, glycerin, milk protein isolate, flaxseed powder, oat fiber, and flour salt.

The drawings described herein are for illustrative purposes only of selected configurations and not all possible implementations, and are not intended to limit the scope of the present disclosure.

As referred to herein, all compositional percentages are by weight of the total composition, unless otherwise specified. Disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of "from A to B" or "from about A to about B" is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of <NUM>-<NUM>, or <NUM>-<NUM>, or <NUM>-<NUM>, it is also envisioned that Parameter X may have other ranges of values including <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and so on.

With reference to <FIG>, the present disclosure relates to a dual-textured food product bar <NUM> prepared using cold-forming processes and having a total protein content of at least <NUM>%, by weight. Specifically, the food product bar <NUM> is formed as a laminate structure having first layer <NUM> and a second layer <NUM>. The first layer <NUM> is formed of a conglomerate including edible particles 22a, 22b, 22c bound together with a binder syrup to provide a crunchy texture to the bottom portion of the snack bar <NUM>. The food product bar <NUM> further includes a second layer <NUM> disposed atop and covering the first layer <NUM>, whereby the second layer <NUM> has a substantially chewy nougat <NUM> composition with one or more solid additives <NUM> for flavoring and/or texture. In illustrated examples, the food product bar <NUM> is formed without any enrobing layers, whereby each of the first layer <NUM> and the second layer <NUM> are exposed. Accordingly, the food product bar <NUM> may be described as consisting of the first layer <NUM> and the second layer <NUM>.

The first layer <NUM> has a protein concentration of at least <NUM>% by weight, and accounts for about <NUM>% of the total weight of the food product bar <NUM>, while the second layer <NUM> has a protein concentration of at least <NUM>% by weight, and accounts for about <NUM>% of the total weight of the food product bar <NUM>. Accordingly, the total protein concentration of the food product bar <NUM> is greater than <NUM>%, by weight, and more particularly, at least <NUM>%, by weight. In other examples, the first layer <NUM> and the second layer <NUM> may account for lesser or greater amounts of the food product bar <NUM>, where the total protein concentration of the food product bar <NUM> is at least <NUM>%, by weight.

The layers <NUM>, <NUM> can be of any desired thickness and can be arranged in any suitable way. As shown, the first layer <NUM> and the second layer <NUM> are arranged horizontally in a laminate configuration, whereby the layers <NUM>, <NUM> are stratified. The food product bar <NUM> can be formed of any shape and size. In the illustrated example shown in <FIG>, the food product bar <NUM> is formed as a box-shaped bar. However, the food product bar <NUM> may be formed of any shape.

With continued reference to <FIG>, the first layer <NUM> of the food product bar <NUM> comprises a blend of edible particles 22a, 22b, 22c, which are joined together with a binder syrup (not shown) to form a first layer conglomerate composition. The edible particles 22a, 22b, 22c of the first layer may include a combination of grains, puffed protein crisps, and/or nuts to provide a crunchy, high-protein composition. Example formulations for the first layer conglomerate and the binder syrup are shown in Tables 1A, 1B, 2A, and 2B, below.

The grain 22a includes rolled oats (#<NUM>) provided at a concentration of <NUM>% to <NUM>% by weight of the first layer conglomerate, preferably in the range of about <NUM>% to about <NUM>%, and more at preferably <NUM>%. Although rolled oats were included in the first layer conglomerate, other types of grains 22a may be included in the conglomerate alternatively or in addition to the rolled oats.

The first layer conglomerate further includes protein crisps 22b having a protein content of at least <NUM>%, by weight. One suitable example of protein crisps includes milk protein crisps 22b, such as Crunchie™ brand milk protein crisps manufactured by Glanbia Nutritionals, for example. In other examples, the protein crisps may include other types of meat, dairy, or plant based protein crisps, such as whey protein crisps, pea protein crisps, wheat protein crisps, rice protein crisps, soy protein crisps, for example. The protein crisps 22b are provided at a concentration of <NUM>% to <NUM>% by weight of the first layer conglomerate, preferably at <NUM>%.

In addition to the grains 22a and protein crisps 22b, the first layer conglomerate includes one or more nuts 22c. In the illustrated example, the nuts 22c may be medium diced, dry roasted almonds. However, in other examples, the nuts may include pistachios, peanuts, cashews, pecans, hazelnuts, pine nuts, or walnuts, for example. Furthermore, the nuts may be provided in different states, such as whole, ground, sliced, or chopped. Different sizes of the nuts may also be considered. In the illustrated example, the almonds are provided at a concentration of <NUM>% to <NUM>% by weight of the first layer conglomerate, preferably at <NUM>%.

As shown above, the binder syrup makes up the balance of the concentration of the first layer conglomerate. Accordingly, the binder syrup is provided at a concentration of <NUM>% to <NUM>% by weight of the conglomerate, and preferably at <NUM>%.

The second layer <NUM> of the food product bar <NUM> is formed of a high-protein nougat material <NUM>, and includes one or more solid additives 34a, 34b, 34c for flavoring texture. Accordingly, although the second layer <NUM> provides a substantially chewy mouthfeel, the second layer <NUM> may include the solid additives to provide a non-homogenous composition. While the first layer <NUM> may generally be formed of similar components and concentrations across all varieties of the food product bar <NUM>, as set forth above, the second layer <NUM> is configured to provide a unique texture and flavor to each variety of the food product bar <NUM>, as described in greater detail below. Various examples of varieties of the second layer <NUM> are set forth below, and include a hazelnut latte flavored second layer (Example <NUM>), a raspberry almond flavored second layer (Example <NUM>), and a tropical citrus flavored second layer (Example <NUM>).

Generally, the second layer <NUM> includes a sweetener, hydrolyzed milk protein concentrate, hydrolyzed milk protein isolate, canola oil, almond butter, water, glycerin, milk protein isolate, flaxseed powder, oat fiber, and flour salt. However, in some examples, up to <NUM>% of the sugar may be substituted with one or more soluble fibers. The second layer may further include various flavorings and natural preservatives, as described in the examples provided below.

Optionally, one or more solid additives 34a, 34b, 34c can also be added to at least one of the first layer conglomerate or the second layer conglomerate, or can be deposited as a topping to the second layer <NUM> and can include natural additives 34a, such as seeds, nuts, nut pieces, and so forth. Additives further include any fruit flavors 34b such as fresh fruits, dried fruits, fruit products, and so on. Additives may also include flavoring additives 34c, such as candies, marshmallows, "marbits," chocolates and chocolate products, fats, salts, honeys, cheeses, frosting, powdered food products, sugar, sugar substitutes, gelatins and spices. Additives may also include colorings as well as any nut flavors as well as any sweet flavors such as chocolate, vanilla, caramel, butterscotch, lemon, malt, cinnamon, graham, coconut flavors, mint and so on. Additives additionally include any savory flavors such as all meat, game, fowl, fish, dairy, barbecue, smoke, pepper, spicy and vegetable flavors.

With reference to <FIG>, a process <NUM> for forming the food product bar <NUM> is described. Initially, the components forming the binder syrup (see Table <NUM>, above) are mixed in a standard mixing process at Step <NUM>. The binder syrup is then combined with the grains 22a, protein crisps 22b, and nuts 22c at the concentrations shown in Table <NUM> using a standard mixing process, to form the first layer conglomerate Step <NUM>. In a parallel Step <NUM>, the second layer conglomerate is prepared by mixing the components of the second layer conglomerate using a standard mixing process.

With the first layer conglomerate and the second layer conglomerate prepared, the first layer conglomerate is deposited at Step <NUM> to form the first layer <NUM>. The first layer <NUM> may be formed using a cold forming process, whereby first layer <NUM> is formed and cured without baking. In some examples, the first layer <NUM> may be formed as a continuous sheet having a substantially uniform thickness and composition.

At Step <NUM>, the second layer conglomerate is deposited upon the first layer <NUM> to form a base slab <NUM> including the first layer <NUM> and the second layer <NUM> arranged as a continuously formed laminate sheet, having the first layer <NUM> forming a bottom surface of the base slab <NUM> and the second layer <NUM> disposed atop the first layer <NUM>. As with the first layer <NUM>, the second layer <NUM> has a substantially uniform thickness and composition, such the thickness and composition of the resulting base slab <NUM> is substantially uniform.

Optionally, at Step <NUM>, additives may be added to the base slab. In some examples, the additives may be sprinkled or deposited on a top surface of the second layer <NUM>. Additionally or alternatively, the additives <NUM> may be incorporated into at least one of the first layer <NUM> or the second layer <NUM>.

The base slab may be subjected to one or more forming steps before or after the additives <NUM> are added, whereby the relatively soft and deformable second layer <NUM> is pressed into top surface of the first layer <NUM>. Here, the soft nougat of the second layer <NUM> may flow under pressure into interstices formed between the edible particles <NUM> of the first layer <NUM> to form a mechanical bond between the first layer <NUM> and the second layer <NUM>. Here, the additives <NUM> applied to the top surface of the second layer <NUM> may be impressed into a top surface <NUM> of the second layer <NUM>, whereby the top surface <NUM> is substantially flush.

In another optional Step <NUM>, the second layer <NUM> of the base slab may have a plurality of partitions <NUM> formed therein. As shown in <FIG>, the partitions <NUM> are formed through an entire thickness of the second layer <NUM>, and allow the food product bar <NUM> to be portioned during consumption.

At Step <NUM>, the base slab is cut into a plurality of individual ones of the food product bars <NUM>, which are then packaged at Step <NUM>. In some examples, the food product bars <NUM> may be individually packaged. Alternatively, the food product bars <NUM> may be packed in bulk.

The following examples illustrate variations of the food product bar <NUM> and process <NUM> described above, wherein different compositions of the second layer <NUM> and additives <NUM> are provided for forming different varieties of the food product bar <NUM>.

In one example, hazelnut latte flavored food product bars <NUM> were prepared using the method described above. Here, the first layer conglomerate was prepared as provided using the components listed in Table <NUM>, above. As shown in Table 3A and 3B, below, the second layer conglomerate of Example <NUM> was mixed to form a hazelnut latte flavored nougat including diced almonds and hazelnuts.

As described above, the food product bar <NUM> is formed by depositing the first layer conglomerate and the second layer conglomerate to form a stratified or laminate base slab including the first layer <NUM> and the second layer <NUM>. In Example <NUM>, the laminate base is then topped with extra coarse sea salt, organic cocoa nibs, and diced hazelnuts, as shown in Tables 4A and 4B, below.

In another example, raspberry almond flavored food product bars <NUM> were prepared using the method described above. Here, the standard first layer conglomerate was prepared as provided in Table <NUM>, above. As shown in Tables 5A and 5B, below, the second layer conglomerate of Example <NUM> was mixed to form a raspberry flavored nougat including diced almonds.

As described above, the food product bar <NUM> is formed by depositing the first layer conglomerate and the second layer conglomerate to form a stratified or laminate base including the first layer <NUM> and the second layer <NUM>. In Example <NUM>, the laminate base was then topped with black chia seeds, freeze-dried raspberries, and almonds, as shown in Tables 6A and 6B, below.

In another example, tropical citrus flavored food product bars <NUM> were prepared using the method described above. Here, the standard first layer conglomerate was prepared as provided in Table <NUM>, above. As shown in Table <NUM>, below, the second layer conglomerate of Example <NUM> was mixed to form tropical citrus flavored nougat including diced almonds as a solid additive.

As described above, the food product bar <NUM> was formed by depositing the first layer conglomerate and the second layer conglomerate to form a stratified or laminate base including the first layer <NUM> and the second layer <NUM>. In Example <NUM>, the laminate base was then topped with freeze-dried pineapple, coconut chips, and freeze-dried pomegranate arils, as shown in Tables 8A and 8B, below.

The food product bar <NUM> and process <NUM> disclosed provide several benefits over prior food product bars. For example, by providing a crunchy first layer and a chewy second layer, without enrobing the food product bar <NUM> in an outer coating, the food product bar provides two exposed layers having different textures, which has been found to provide a favorable texture experience (i.e., mouthfeel) and visual appearance. The food product bar <NUM> of the instant disclosure has also been found to provide clean eating and portion control by incorporating partitions into the second layer.

Additionally, the continuous structure provided by the first layer contributes to increased durability of the food product bar during handling, while the functional fibers in the components forming the second layer lead to stability over the shelf life of the food product bar <NUM>. Thus, the food product bar <NUM> of the instant disclosure provides the structural advantages of an enrobed food product, but maintains a high protein concentration by eliminating the need for using a high-sugar enrobing composition, such as chocolate or syrup.

Yet another benefit of the food product bar <NUM> disclosed herein includes improved lubricity of chew that the binder syrup of the first layer <NUM> provides to the second layer <NUM> when the food product <NUM> is chewed down. As discussed above with respect to food product bars of the prior art, high-protein nougat layers are known to become difficult to chew when not enrobed due to natural migration of moisture within the high-protein layers, over time. However, in the food product bar <NUM> of the instant disclosure, the binder syrup of the first layer <NUM> is formulated to moisturize and improve lubricity of the nougat of the second layer <NUM> during chewing. Thus, shelf life of the food product bar <NUM> can be extended without negatively affecting lubricity and mouthfeel during consumption.

In one example, the food product bar (<NUM>) comprises a first layer (<NUM>) comprising a conglomerate of edible particles (22a, 22b, 22c), the first layer (<NUM>) having a protein concentration of at least <NUM>% by weight; and a second layer (<NUM>) covering the first layer (<NUM>) and comprising a nougat (<NUM>), the second layer (<NUM>) having a protein concentration of at least <NUM>% by weight, whereby a total protein concentration of the food product bar (<NUM>) is at least <NUM>% by weight.

The food product bar may further comprise a plurality of additives (34a, 34b, 34c) deposited on the second layer (<NUM>). Here, the additives (34a, 34b, 34c) may include at least one of dried fruits, seeds, or nuts.

Alternatively a food product bar (<NUM>) may consist of: a first layer (<NUM>) comprising a conglomerate of edible particles (22a, 22b, 22c), the first layer (<NUM>) having a protein concentration of at least <NUM>% by weight; and a second layer (<NUM>) covering the first layer (<NUM>) and comprising a nougat (<NUM>), the second layer (<NUM>) having a protein concentration of at least <NUM>% by weight, whereby a total protein concentration of the food product bar (<NUM>) is at least <NUM>% by weight.

Complementarily, the first layer (<NUM>) of the food product bar consists of: rolled oats (22a) at a concentration of ranging from <NUM>% to <NUM>%, by weight; protein crisps (22b) at a concentration ranging from <NUM>% to <NUM>%, by weight; nuts (22c) at a concentration ranging from <NUM>% to <NUM>%, by weight; and binder syrup at a concentration ranging from <NUM>% to <NUM>%, by weight.

The method of forming a food product bar (<NUM>), may include mixing a first plurality of components (<NUM>) to form a first layer conglomerate having a plurality of edible particles (22a, 22b, 22c,), the first layer conglomerate having a concentration of protein of at least <NUM>%, by weight; mixing a second plurality of components (<NUM>) to form a second layer conglomerate including a nougat (<NUM>), the second layer conglomerate having a concentration of protein of at least <NUM>%, by weight; depositing a first amount of the first layer conglomerate (<NUM>) to form a first layer (<NUM>); and depositing a second amount of the second layer conglomerate (<NUM>) atop the first layer (<NUM>) to form a stratified base slab (<NUM>) including the first layer (<NUM>), whereby the base slab (<NUM>) has a concentration of protein of at least <NUM>%, by weight. The method previously exposed may comprise forming partitions (<NUM>) in the second layer (<NUM>).

Claim 1:
A food product bar (<NUM>) comprising:
a first layer (<NUM>) comprising a conglomerate of edible particles (22a, 22b, 22c), the first layer (<NUM>) having a protein concentration of at least <NUM>% by weight; and
a second layer (<NUM>) covering the first layer (<NUM>) and comprising a nougat (<NUM>), the second layer (<NUM>) having a protein concentration of at least <NUM>% by weight, whereby a total protein concentration of the food product bar (<NUM>) is at least <NUM>% by weight,
wherein the first layer (<NUM>) comprises:
rolled oats (22a) at a concentration of ranging from <NUM>% to <NUM>%, by weight;
protein crisps (22b) at a concentration ranging from <NUM>% to <NUM>%, by weight;
nuts (22c) at a concentration ranging from <NUM>% to <NUM>%, by weight; and
binder syrup at a concentration ranging from <NUM>% to <NUM>%, by weight.