Abstract: A process for removing digestible fat from a crude reaction mixture comprising nondigestible fat and at least one digestible fat selected from the group consisting of digestible fats having fatty acid chains, comprising the steps of: (1) treating the crude reaction mixture with an aqueous solution comprising lipase at a pH sufficient to obtain soaps from the fatty acid chains; and (2) removing the soaps.

Abstract: Methods of removing a lower alkyl alcohol from a polyester mixture of polyol fatty acid polyester and lower alkyl alcohol comprise (a) contacting the polyester mixture with a stripping mixture comprising an inert stripping gas, up to about 10,000 ppm lower alkyl alcohol and up to about 2000 ppm oxygen, wherein at least a portion of the lower alkyl alcohol is transferred from the polyester mixture to the stripping mixture, thereby increasing the concentration of lower alkyl alcohol in the stripping mixture, and (b) separating the stripping mixture from the polyester mixture.

Abstract: A process for synthesizing polyol fatty acid polyesters comprising the steps of (1) mixing ingredients comprising (a) unesterified first polyol having hydroxyl groups, (b) second polyol esterified with fatty acids, (c) basic catalyst, and (d) emulsifying agent to form a mixture of ingredients; (2) reacting the mixture of ingredients at a temperature sufficient to obtain a transesterification reaction products and by-products; and (3) removing at least a portion of the by-products from the transesterification reaction mixture; and (4) further heating the transesterification reaction products and ingredients from step (3) at a temperature and for a time sufficient to esterify at least about 50% of the hydroxyl groups of the first polyol.

Abstract: Process for synthesizing polyol fatty acid polyesters which includes the steps of reacting an excess of lower alkyl ester with polyol to esterify hydroxyl groups thereof and form polyol fatty acid polyester, separating at least a portion of the unreacted lower alkyl ester from the polyol fatty acid polyester, and recycling the separated unreacted lower alkyl ester for further reaction with polyol or partially esterified polyol. The recycled lower alkyl ester is substantially free of lower alkyl ester degradation reaction products, such as carbonyls and free fatty acids.

Abstract: Processes for the preparation of polyol fatty acid polyesters comprise heating a mixture of polyol, fatty acid ester, emulsifying agent and catalyst. In one embodiment, the fatty acid chains of the fatty acid ester have from about 6 to about 14 total carbon atoms and the emulsifying agent comprises a fatty acid soap having fatty acid chains of from about 16 to about 22 total carbon atoms.

Abstract: Reduced-fat, low-moisture lipid-based fillings. The lipid-based fillings can be used in a variety of food products. The low moisture, reduced fat, lipid-based filling comprises at least about 20% non-digestible lipid and other suitable optional ingredients. The filling has a water activity of less than about 0.6 and has at least about 20% less digestible fat than a comparable full-fat lipid-based filling. In one embodiment, the filling is a cheese filling. The low moisture, reduced fat, lipid-based cheese filling comprises: (a) from about 20% to about 60% non-digestible lipid; (b) from about 20% to about 75% dehydrated cheese powder; and (c) from about 0% to about 55% bulking agent. The fillings can be used with any suitable substrate to form a food product.

Abstract: A low-fat and low-calorie nut spread having at least about 50% less fat and at least about 33% fewer calories than full-fat peanut butter yet having a flavor and texture comparable to a full-fat nut butter or spread. The nut spread has a non-fat solids to oil ratio that is less than about 2.0:1, comprises nut solids that have a mono-modal particle size distribution where the D50 and D90 sizes are less than about 15 and about 30 microns, respectively. The level of fat-free nut solids is from about 34% to about 45%. The apparent viscosity of the nut spread is less than about 4500 cP. The nut spread comprises at least about 20% oil substitute, preferably a sucrose polyester that contains an anal leakage controlling agent. Also disclosed is a preferred process for making the nut spread.

Abstract: Reduced saturated fat lipid-based fillings. The fillings comprise: (a) at least about 20% lipid; and (b) from about 0.5% to about 35% crystallizing lipid. The fillings can additionally comprise other suitable optional ingredients. In one embodiment, a cheese filling comprises: (a) from about 20% to about 60% lipid; (b) from about 0.5% to about 35% crystallizing lipid; (c) from about 20% to about 75% dehydrated cheese powder; and (d) from about 0% to about 55% bulking agent.

Abstract: Filled snacks, particularly filled snacks having creamy lipid-based fillings and crispy-crunchy shells. The creaminess of the filling is maintained even though it is subjected to heat during co-baking with the shell. In one embodiment, the filled snack comprises: (a) an outer shell of from about 0.07 to about 0.3 inches after baking; and (b) a lipid-based filling having a viscosity of less than about 10,000 cP before baking. In a preferred embodiment, a lipid-based nut filling is prepared from a process comprising the steps of: (1) providing a nut paste; (2) defatting a first nut paste portion to form a defatted nut flour; (3) milling the defatted nut flour to form a mono-modal nut solids flour; and (4) refatting the mono-modal nut solids flour to form the nut filling by combining the mono-modal nut solids flour with a re-fatting ingredient selected from the group consisting of added oil, a second nut paste portion, or mixtures thereof.

Abstract: Creamy, reduced fat, low-moisture lipid-based fillings. The fillings comprise: (a) at least about 20% non-digestible lipid; and (b) from about 0.5% to about 35% crystallizing lipid. The fillings can additionally comprise other suitable optional ingredients. The filling has a water activity of less than about 0.6 and has at least about 20% less digestible fat than a comparable full-fat lipid-based filling. In one embodiment, a cheese filling comprises: (a) from about 20% to about 60% non-digestible lipid; (b) from about 0.5% to about 35% crystallizing lipid; (c) from about 20% to about 75% dehydrated cheese powder; and (d) from about 0% to about 55% bulking agent. The fillings can be used with any suitable substrate, but are especially suitable for use in random packed food products, especially sandwich biscuits. Sandwich biscuits made with the fillings adhere well to the biscuits so that the sandwich biscuits are not misaligned, smeared, or subject to splitting or decapping in production or after storage.

Abstract: Full-fat, reduced-fat, low-fat, and fat-free snack food products with enhanced flavor. The enhanced flavor is obtained by incorporating flavor enhancers, particulates, Vitamin C, herbs & spices, or mixtures thereof into the dough.

Abstract: A process for preparing esterified polyol fatty acid polyesters is provided, where the polyol has n hydroxyl groups. The process provides for independent control of the level of fully esterified polyols, on the one hand, and the level of n-3 and lower esters, on the other hand. The process is especially suited for preparing sucrose polyester, wherein the process provides for independent control of the level of octaesters, on the one hand, and penta and lower level esters, on the other hand. The process can be used to reduce the level of undesirable reaction byproducts, such as difatty ketone and beta ketoester.

Abstract: Methods for the solventless transesterification of a polyol comprise reacting polyol with fatty acid alkyl ester in the presence of a basic catalyst to produce polyol fatty acid polyester product and lower alkyl alcohol by-product, wherein a majority of the polyol is fully esterified. The reaction is conducted in a reactor at a temperature in the range of from about 60.degree. to about 180.degree. C. and at atmospheric or superatmospheric pressure. An inert gas is sparged through the reactor with sufficient mass transfer surface area contact between the inert gas and reactor liquid to transfer the lower alkyl alcohol by-product from a liquid mixture of reactant and product to the inert gas and promote full esterification of a majority of the polyol without the use of vacuum pressure.