Squeezable Assembly for Pasty Products
A squeezable assembly (9) for shelf-stable, chilled or frozen pasty products comprising—a body formed by a tube or a container presenting a bottom (11), lateral walls (15) and a rim (12) in the accordion form,—a rigid plastic cap (13) attached to the end of the tube or the rim (12) of the container comprising an aperture (16),—a cover seal (14) to close the aperture (16) and—a product (2) contained in the assembly (19).
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The present invention concerns a squeezable assembly for pasty products.
BACKGROUND OF THE INVENTIONIt is already known on the market assembly which have a body and a piston for extruding the product contained in said body. The problem with such a solution is that the body and the piston are both rigid and represents a big amount of material for the packaging. One of the objectives of the to-day packagings is that for decreasing the price, it is necessary to decrease the weight of material used for said packagings.
The objective of the present invention is to develop an assembly, wherein the material's quantity is decreased without any drawback on the resistance of said final assembly.
There is need for providing packed frozen aerated confections wherein the package is sufficiently resistant to allow for extracting the soft frozen aerated confection portion at −180° C. or lower without breaking, is easily collapsible, leaves very little product inside it after the product has been extruded therefrom and in the same time uses a very small amount of packaging material.
Inside the ice cream there are ice crystals and air bubbles dispersed in a liquid phase. Softness generally is obtained by reducing the quantity of ice formed and this is mainly obtained by selecting the type and the amount of sugars, by adding salt or alkohol in the ice cream mix. There is some limitation in the possibilities to play with the low molecular components mentioned above for taste reasons. Thus, if further increase of softness is targeted, the only possibility is to use polyols, e.g. glycerol.
SUMMARY OF THE INVENTIONThe present invention concerns a squeezable assembly for shelf-stable, chilled or frozen pasty products comprising
a body formed by a tube or a container presenting a bottom, lateral walls and a rim in the accordion form,
a rigid plastic cap attached to the end of the tube or the rim of the container comprising an aperture,
a cover seal to close the aperture and
a product contained in the assembly.
According to the invention, it is important that the product is a pasty product. The product contained in the assembly is a shelf-stable product, like for example a mayonnaise. Concerning chilled product, it is possible to have in the assembly of the invention a dairy product, like a yoghurt. Most preferably, according to the invention, the product is a frozen product. More particularly, it is an ice-cream and more particularly a soft ice.
More particularly, the present invention is related to a cartridge containing a frozen aerated confection with high softness at −18° C. which can be extruded from the said cartridge at that temperature or lower.
The present invention thus concerns in particular a packed aerated frozen confection which comprises:
a cartridge and
a frozen aerated confection which is soft at storage temperature of −180° C. or less, and the soft frozen confection comprises by weight:
50 to 70% water,
5 to 20% fat,
0 to 5% polyol,
the balance being sugars, milk proteins, hydrocolloids and emulsifiers and
has an overrun of 20 to 150%.
DETAILED DESCRIPTION OF THE INVENTIONPreferably, the soft frozen confection contains 2 to 8% by weight proteins. Preferably the proteins are of milk origin and come from liquid skimmed milk, skimmed milk powder and whey powder, optionally recombined in water. Preferably, the protein source should undergo only one pasteurisation step in order to minimize thermal denaturation of proteins. Thus milk solid non fat aid in providing the desirable properties of whipability, smoothness, body and melt resistance.
In the context of the invention, a suitable polyol can be selected from the group consisting of sorbitol, mannitol, lactilol, xylitol, maltitol and glycerol, glycerol being preferred. The role of polyol is to further soften the frozen confection by making it sufficiently soft to be scoopable at home freezer temperature of −18° C. or less, so that it can be extracted from the pakage at that temperature. It is used to increase softness because it reduces ice content with less sweetening effect that sucrose.
Preferably, glycerol is used at a level of 0.5 to 2% by weight.
The soft frozen confection preferably contains Vegetable fibres may be added which can preferably be selected from the group consisting of oat fibres, fibres extracted from chicory taproots and fibregum from Acacia tree. Preferably they consist in fructo-oligosaccharides, most preferably they are inulin-oligofructoses extracted from chicory. Most preferably, inulin-oligofructoses are used at a level of 2 to 4% by weight. We have found that it has a strong effect to prevent shrinkage and ice layering, also in the presence of glycerol.
Preferably, the product of the invention comprises sweetener ingredients which are a combination of sucrose, dextrose and glucose sirup, preferably from corn syrup solids, preferably of high dextrose equivalent (DE), from DE 40 to DE 60 or more that provide a desired level of sweetness and texture and decrease the freezing point of the mixture.
The fat may be of milk or vegetable origin and its level may be within a broad range. If less fat is used in combination with a polyol and vegetable fibre, it is then possible to manufacture a cheaper ice cream or an ice cream which is more dietetic with the same softness as a regular high fat ice cream.
Another advantage achieved by the soft frozen composition is that live probiotic lactic acid bacteria, can be incorporated, e.g. in encapsulated form or in the form of separately cultured portion of the milk solid non fat which is added to the mix, in this latter case after pasteurisation. These probiotic bacteria can thus act in combination with the fermentescible prebiotic vegetable fibres to provide upon consumption a beneficial positive influence on the development of the intestinal flora with the consumer.
The frozen confections may comprise an emulsifier, preferably propylene glycol monoester of fatty acid is used as a primary emulsifier in an amount of 0.2 to 0.5% and most preferably in an amount of at least 0.26%. Preferably propylene glycol monostearate/palmitate is used.
The frozen confections may optionally comprise one additional emulsifier, for example, unsaturated monoglyceride or saturated mono-di glyceride in an amount of at least 5% of the total emulsifiers, preferably in an amount of 0.04 to 0.16% by weight as partial replacement of propylene glycol monoester of fatty acid.
The frozen confections may comprise stabilizing agents; these may include carob flour, guar flour, alginates, carboxymethyl cellulose, xanthan, carrageenan, gelatin, starches used alone or in the form of a mixture at a dose of 0.1 to 0.5 by weight, preferably about 0.25%.
The formulation of the product in the invention may in addition comprise colourings such as beta-carotene, for example, and/or any type of flavourings or perfumes customarily used to flavour frozen confections, such as vanilla, strawberry or chocolate for example.
The compositions used in the invention may optionally comprise additions such as fruit or fruit pieces, for example, or nuts, or hazelnuts, whole or in pieces, for example.
Furthermore, the organoleptic qualities of the frozen compositions are not reduced compared with the traditional products. Thus, the characteristics of smoothness and creaminess are increased and in particular, better preserved during the period of storage. In the frozen confections, it is the use of propylene glycol monoester of fatty acid, as emulsifier which makes it possible in addition to reduce remarkably the growth of water crystals in the products subjected to heat shock and thus it confers greater stability to heat shocks on the product.
Size of the Ice Crystals in an Ice Confection
An aliquot of ice confection is mixed with an equivalent quantity of glycerol and observed under a microscope at a temperature of −100° C. The measurement may be carried out in a chamber at −100° C. equipped with microscope and a camera. It is thus possible to measure the mean diameter of the crystals (in μm) in the finished products and in the products which have been subjected to a heat shock (microscope magnification 129).
The frozen confections exhibit improved stability and organoleptic characteristics compared to traditional products. These products exhibit remarkable reduced ice crystal growth compared with traditional products when submitted to heat shock treatment. This property confers to the product smooth texture, which is considerably preserved after unfavourable storage conditions. Such functionalities make it possible to envisage production, storage and distribution of the products according to the invention extending over time.
The expression “reduced crystal growth” is understood to mean an increase in the mean diameter of the ice crystals of less than 50% after heat shock.
Preferably, the freezing step is carried out in a scraped surface freezer at a draw temperarure at the freezer outlet of −5 to −100° C., most preferably at a draw temperature as low as possible of about −9 to −100° C.
After freezing, the frozen confection can be packed into the cartridges and hardened to storage temperature of −180° C. or less, for example −300° C.
Alternatively, following freezing, the frozen confection can be further cooled under shear to lower temperatures of −180° C. or less with the aid of a cold extrusion device such as a twin screw extruder and filled into the cartridges.
Another objective of the invention is to have an assembly, wherein the extrusion of the product is convenient for the consumer, that means with a device, which is relatively simple and therefore not expensive.
According to the invention, the tube or the container is made from a plastic material taken from the group consisting of Polystyrene, Polyethylene, Polyactic acid, Polyethylen Terephthalate, Polypropylene, blend and coextrusion of different plastics aimed to increase the oxygen barrier or any folding properties of said main container.
The plastic material of the tube is preferably Polyethylen Terephthalate and the wall of said tube has a thickness comprised between 30 and 100 μm. More specifically, the thickness of the wall of the tube is comprised between 30 and 70 μm.
The production process for the tube is thermoforming combined with blow moulding. Normally, by thermoforming, it is not possible to produce a tube longer than the diameter of said tube. By combining the blowforming step with thermoforming it is possible to achieve a much longer tube, whilst maintaining an even wall thickness.
The plastic material of the container is preferably Polyethylen and said container has a wall thickness comprised between 30 and 500 μm. More specifically, the thickness of the wall is comprised between 100 and 300 μm. The polyethylen is preferably high density.
The container is manufactured according to the Form-Fill-Seal technology. This technology is based on different types of machines, for example from Erca, Bosch, Hassia, wherein a main container is manufactured from a material roll going through a heating box, through a forming tool, through a station disposing the rigid means, a filling station and finally the sealing of a plastic cap is carried out on the main container. The forming tool has opening moulds.
The Polyethylen Terephthalate is preferably a semi-crystalline Polyethylen Terephthalate (PET). Semi-crystalline PET means in the present specification a PET having a cristallinity comprised between 10 and 60%. More preferably, the crystallinity is comprised between 20 and 40%.
The measure of the crystallinity is made on a density column from Lloyd-Davenport, according to following procedure. The column is filled with a salted solution (calcium nitrate) having a density gradient. The column is calibrated with balls having known density between 1.335 and 1.455. Then small pieces of the container of the invention are immerged in the column and after a certain time, they stay at a certain height of the column corresponding to a certain density. The measures are made at 23° C. The following correspondance table with ρc of 1.455 gives the cristallinity
The rigid plastic cap has a thickness comprised between 500 and 2000 μm. The aperture on the rigid plastic cap has the form of a star or any other shape.
The rigid plastic cap is in a material taken from the group consisting of Polystyrene, Polyethylene, Polyactic acid, Polyethylen Terephthalate, Polypropylene, blend and coextrusion of different plastics aimed to increase the oxygen barrier or any folding properties of said main container.
The cover seal finally is made in the same material as for the rigid plastic cap. The cover seal has a thickness comprised between 30 and 100 μm.
The volume of the tube or the container is comprised between 30 and 250 ml.
The attachment of the tube or the container to the rigid plastic cap can be carried out according to different techniques. The most common way is to proceed by welding, typically by ultrasonic means, by heat sealing means or by spin welding. This last technique involves bringing the cap and tube together and spinning the cap against the tube to create a friction between the two materials, which in turn creates sufficient heat to weld. By welding, it is easier to weld same material together. Therefore, in the case of a tube in PET, it is preferred to weld a rigid plastic cap in PEZ. In the case of a container in Polyethylen, it is preferred to weld a plastic cap also in Polyethylen.
According to another feature of the invention, said invention concerns a squeezable assembly for frozen pasty products comprising
a container presenting a bottom, lateral walls and a neck with an opening,
a closing means to close the opening and
a frozen product contained in the assembly.
In this assembly, the frozen product is ice-cream and more specifically soft ice-cream. As already mentioned before, the container is preferably a semi-crystalline Polyethylen Terephthalate (PET), as defined above.
Concerning the closing means, every type of closing means known in the technique can be used, like a sealed membrane or a screw cap.
The walls of the container have a thickness comprised between 30 and 100 μm. The volume of the container is comprised between 0.3 and 6 liters.
The tube and the container comprises normally oxygen barrier, like Polyvinylidene Chloride (PVDC) or Ethylene Vinyl Alcohol Copolymer (EVOH).
The invention finally concerns a process for the manufacture of a squeezable assembly according to the invention, wherein
each tube or container is disposed in a conveyor pocket
the product is filled in each tube or container and
each tube or container is closed with the plastic cap comprising the cover seal or with the closing means, wherein the extruding of the product is carried out on the same side as the filling.
The extrusion of the product will be more clearly described in relation with the following figures.
Detailed Description of Preferred EmbodimentsThe present invention will be further illustrated in the following examples wherein, unless indicated otherwise, the percentages are by weight.
The overrun is expressed as a percentage by volume and defined as the percentage by which the volume of the liquid mix for a product is increased with air during whipping and freezing.
EXAMPLES Examples 1 to 4Ice confections are formulated and produced according to the following processing conditions:
Vegetable fibre when used is mixed with some sugar or predispersed in some water at temperature of 45° C. and added with all the powdery ingredients to liquid ingredients and glycerol in an agitated mixing tank. Once all ingredients have been thoroughly blended together, the mixture was heated at 65° C. for 20 min. in order to hydrate the hydrocolloids.
For pasteurisation, the mixture is then heated to a temperature of 87° C. for 24 s. to achieve satisfactory treatment to confrm public health requirements and also avoiding as much as possible any significant denaturation of proteins.
The mixture is then subjected to an homogenisation stage to reduce the dimensions of the fat droplets, by homogenising the mixture at a pressure of 120 to 160 bar, at a temperature of 70 to 85° C. The homogenised mix is rapidly cooled to chill temperatures, typically 4° C. and then aged by holding it for 4 to 12 h at that temperature.
The mixture is frozen using ice cream continuous freezer known as scraped surface heat exchangers where it is aerated by incorporating sufficient air to give the desired overrun. The ice confections were frozen down to draw temperatures lower than −6° C., typically of −8 to −10° C. Sauce and inclusions can be added.
After being extruded and packed into the cartridges, the products are subjected to hardening in a hardening tunnel and stored at −30° C.
Formulations of examples 1-4 indicated in table 1 below concern the ice creams without the sauce and inclusions.
The products of examples 1 to 4 are very soft. Their overrun is 143-147%. They can easily be extracted from the cartridges at −18° C.
Example 5 Example 5, Comparative Example 5 Use of PEFA in the Presence of Freezing Point Depressing SugarsThe objective of these examples is to produce soft aerated frozen confections with freezing point depressing sugars showing texture and sensory attributes which are comparable to a conventional product made with conventional ingredients currently used in the aerated frozen dessert preparation.
To evaluate the remarkable properties of the emulsifier applied, various textural, microscopic and macroscopic tests may be carried out.
Standard heat shock: the samples initially stored at −30° C. are subjected, for 7 days, to temperature cycles of −8° C./12 h followed by −20° C./12 h. After 7 days of stabilisation at −30° C., the melting parameters are evaluated for these samples which were subjected to a heat shock.
We were surprised to find that the use of polyol esters of fatty acids (PEFA), preferable propylene glycol monostearate (PGMS) alone or in combination with other food-grade emulsifiers, such as unsaturated monoglyceride, produces aerated frozen products with outstanding texture properties and with good heat shock stability.
An example of frozen confections made according to the present invention and comparative example are produced according to the formulations indicated in Table 2 below.
The various ingredients are dispersed at 65° C. and then undergo a hydration step at 60° C. for 20 minutes. The mixture is then homogenized at 180 bar with the aid of homogenizer and then pasteurized at 86° C. for 32 s. After cooling to 4° C., the mixture is aged for 24 hours at 4° C., without stirring. Finally, the mixture is frozen at about −7.5° C. draw temperature (example 5) and at about −5.7° C. draw temperature (comparative example 5) with a degree of overrun of about 100%. The ice confection obtained is hardened at −30° C. by conventional means.
Vegetable lauric fat blend: Blend of palm and palm kernel oil;
Sweet whey powder: whey proteins, non demineralised from Euroserum, 10 to 12% protein;
Skim milk powder from BBA;
PGMS: Propylene glycol monostearate PGMS SPV® from Danisco;
UMG: Unsaturated monoglyceride DIMODAN UP/B® from Danisco;
SMDG: Saturated Mono-diglycerides: CREMODAN 60 Veg® from Danisco;
Stabilizers: Guar gum (Procol G2 from Habgen) or Sodium alginate (Manucol DM from ISP Alginates);
Glucose syrup: Glucose MD 40 from Roquette.
The freezing point achieved in this examples is an average value, to keep a very soft product at a serving temperature below −18° C. it can be necessary to decrease the freezing point down to −4.5° C. e.g. by addition of 2.5% of ethanol (at 98 volume) or 4% glycerol, based on the total composition of the recipe.
Table 3 below describes the measured mean ice crystal size of bothe recipes, example 5 and comparative example 5 after heat shock. Sample of example 5 which contains a blend of PGMS and UMG has smaller ice crystals and the crystals are significantly more resistant to growth following heat shock treatment compared to the other sample of comparative example 5.
The heat shock samples were also evaluated for the texture attribute smoothness by a trained testing panel. The texture of the product of example 5 was showing a very high smoothness and the aspect was good.
We were surprised to find that with the use of polyol esters of fatty acids (PEFA), preferably PGMS alone or in combination with other food grade emulsifiers, such as unsaturated mono glyceride, we were able decrease the freezing point in aerated frozen products and keep the same smoothness and heat shock stability of a standard version.
Other features and advantages of the invention will become apparent from the description which follows, given by way of example and with reference to the appended drawings in which
The assembly (1) contains a soft ice-cream (2), said assembly comprising a tube (3), the opening side of the tube being welded in (7) to a rigid plastic cap (4). The welding has been carried out by ultrasonic sealing. The cap has an aperture (6) having the form of a star. This aperture is closed by sealing with a cover seal (5). The tube is made of Polyethylen Terephthalate having a thickness of 70 μm.
The assembly (9) of
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Claims
1. A squeezable assembly for shelf-stable, chilled or frozen pasty products comprising
- a body having a bottom, lateral walls and a rim, the body having an accordion form,
- a rigid plastic cap attached to an end of the body comprising an aperture,
- a cover that closes the aperture and
- a product contained in the assembly.
2. A squeezable assembly according to claim 1, wherein the body is made from a plastic material selected from the group consisting of Polystyrene, Polyethylene, Polyactic acid, Polyethylene Terephthalate, Polypropylene, and blends thereof.
3. A squeezable assembly according to claim 1, wherein the plastic material of the tube is Polyethylene Terephthalate and the wall of the body has a thickness of between 30 and 100 μm.
4. A squeezable assembly according to claim 1, wherein the plastic material of the body is polyethylene and a wall thickness of between 30 and 500 μm.
5. An assembly according to claim 3, wherein the Polyethylene Terephthalate is a semi-crystalline Polyethylene Terephthalate.
6. An assembly according to claim 1, wherein the rigid plastic cap is constructed of a material selected from the group consisting of Polystyrene, Polyethylene, Polyactic acid, Polyethylene Terephthalate, Polypropylene, and blends thereof.
7. An assembly according to claim 6, wherein the rigid plastic cap has a thickness of between 500 and 2000 μm.
8. An assembly according to claim 1, wherein the aperture on the rigid plastic cap has the form of a star.
9. An assembly according to claim 1, wherein
- the cover constructed of a material selected from the group consisting of Polystyrene, Polyethylene, Polyactic acid, Polyethylen Terephthalate, Polypropylene, and blends thereof.
10. An assembly according to claim 9, wherein the cover has a thickness of between 30 and 100 μm.
11. An assembly according to claim 1, wherein the product is a frozen product.
12. An assembly according to claim 11, wherein the frozen product is a soft ice-cream.
13. An assembly according to claim 11 wherein the frozen product is an aerated frozen confection which is soft at a storage temperature of −18° C. or less, and the soft frozen confection comprises by weight:
- 50 to 70% water,
- 5 to 20% fat,
- 0 to 5% polyol,
- a balance being sugars, milk proteins, hydrocolloids and emulsifiers and
- has an overrun of 20 to 150%.
14. An assembly according to claim 13, wherein the sugars comprise freezing point depressing sweeteners selected from the group consisting of sucrose, dextrose, fructose, glucose syrup, polydextrose, inulin or mixtures thereof.
15. An assembly according to claim 14, wherein the freezing point depressing sweeteners also comprise a polyol selected from the group consisting of sorbitol, mannitol, lactilol, xylitol, maltitol, glycerol, ethanol and their mixtures, glycerol and ethanol.
16. An assembly according to claim 13, wherein polyol esters of fatty acids is added as an emulsifier in an amount of at least 0.2% by weight in the preparation of an aerated frozen confection.
17. An assembly according to claim 16, comprising food-grade emulsifier selected from the group consisting of unsaturated monoglyceride, saturated mono-di glyceride and their mixtures in an amount of 0.04 to 0.16% by weight.
18. An assembly according to claim 13, wherein the aerated confection comprises at least one stabilizer selected from the group consisting of carob flour, guar flour, alginates, carboxymethyl cellulose, xanthan, carrageenan, gelatin, starches used alone or in the form of a mixture at a dose of 0.1 to 0.5%.
19. An assembly according to claim 1, wherein the housing has a volume of between 30 and 250 ml.
20. A squeezable assembly for frozen pasty products comprising
- a container having a bottom, lateral walls and a neck with an opening,
- a closure for closing the opening, and
- a frozen product contained in the assembly.
21. A squeezable assembly according to claim 20, wherein the frozen product is soft ice-cream.
22. An assembly according to claim 21 wherein the frozen product is an aerated frozen confection which is soft at a storage temperature of −18° C. or less, and the soft frozen confection comprises by weight:
- 50 to 70% water,
- 5 to 20% fat,
- 0 to 5% polyol,
- a balance being sugars, milk proteins, hydrocolloids and emulsifiers and
- has an overrun of 20 to 150%.
23. An assembly according to claim 22, wherein the sugars comprise freezing point depressing sweeteners selected from the group consisting of sucrose, dextrose, fructose, glucose syrup, polydextrose, inulin and mixtures thereof.
24. An assembly according to claim 23, wherein the freezing point depressing sweeteners also comprise a polyol selected from the group consisting of sorbitol, mannitol, lactilol, xylitol, maltitol, glycerol, ethanol and their mixtures.
25. An assembly according to claim 22, wherein polyol esters of fatty acids is added as an emulsifier in an amount of at least 0.2% by weight in the preparation of an aerated frozen confection.
26. An assembly according to claim 25, comprising other food-grade emulsifier selected from the group consisting of unsaturated monoglyceride, saturated mono-di glyceride and their mixtures in an amount of 0.04 to 0.16% by weight.
27. An assembly according to claim 22, wherein the aerated confection comprises at least one stabilizer selected from the group comprising carob flour, guar flour, alginates, carboxymethyl cellulose, xanthan, carrageenan, gelatin, starches used alone or in the form of a mixture at a dose of 0.1 to 0.5%.
28. A squeezable container according to claim 22, wherein the material of the container is a semi-crystalline Polyethylene Terephthalate.
29. A squeezable container according to claim 28, wherein the walls of the container have a thickness of between 30 and 100 μm.
30. A squeezable container according to claim 28, wherein the volume is between 0.3 and 6 liters.
31. A process for the manufacture of a squeezable container comprising the steps of:
- providing a container comprising a squeezable assembly for shelf-stable, chilled or frozen pasty products comprising a body having a bottom, lateral walls and a rim, the body having an accordion form, a rigid plastic cap attached to an end of the body comprising an aperture, and a cover that closes the aperture,
- the container is disposed in a conveyor pocket
- a product is filled in the container and
- the container is closed with the plastic cap and,
- an extrusion of the product is performed on a same side as the filling.
Type: Application
Filed: Sep 6, 2005
Publication Date: Nov 29, 2007
Applicant: NESTEC S.A. (Vevey)
Inventors: Stefano Bertini (Parma), Mario Ambrogi (Parma), Myriam Schlegel (Fouquenies), Josello Vieira (York), Bruce Funnell (Singapore)
Application Number: 11/577,486
International Classification: B65D 81/32 (20060101); B65D 35/28 (20060101);
