Starch-Based Texturizing Agent

The health advantages of a diet low in fat are well documented. Attempts to formulate low-fat versions of food products that typically contain a high percentage of fat are made difficult due to the many functional roles that fats play in foods. Removal of fat from a food often leads to negative effects on structure and organoleptic properties such as smoothness, flavor profile, opacity, lubricity, etc. The consumer's demand for low-fat foods that retain the quality of the corresponding full-fat formulation has led to the development of a large number of potential texturizing agents and fat replacers based on proteins, polyesters, and a variety of other approaches.

Several examples of fat replacers derived from starch include: a partially debranched starch used for providing fat-like texture, forming opaque clouds and producing thermoreversible gels (EP Application 0 372 184 A1 and U.S. Pat. No. 4,971,723 issued to Chiu); cold-water soluble and pregelatinized converted starches (by acid, enzyme or oxidation treatment) for use as fat or oil replacement in ice cream and mayonnaise (U.S. Pat. No. 4,510,166 issued to Lenchin et al.); enzyme-hydrolyzed thermoreversible starch gels as fat substitutes in mayonnaise, cream cheese, whipped cream and meat applications (U.S. Pat. Nos. 3,962,465 and 3,986,890 issued to Richter et al.); aqueous dispersion of granular starch hydrolysate (EP Application 0 443 844 A1 issued to Chiu et an.); macrocolloid carbohydrate particles for use in ice cream, yogurt, salad dressings, mayonnaise, coffee whitener and sour cream (PCT Application WO 89/12403 to Singer et al.); two-phase protein and carbohydrate fat substitute for use in salad dressings and cookie fillings (EP Application 0 441 494 A1 to Reimer); fat substitute comprising hydrated alginate and a complex carbohydrate (PCT Application WO 92/02147 to Shemer and Shemer); and insoluble modified starch used as a bulking agent, filler or texturizing agent in low-fat formulations (U.S. Pat. No. 5,051,271 issued to Iyengar et al.).

A number of methods have been developed to modify starches for use in food formulations and include: subjecting defatted amylose containing starch to high temperature and shear to disrupt the starch granules thereby producing a gel (U.S. Pat. No. 3,666,557 issued to Jensen and Long); cooking high amylose starch at 140.degree.-170.degree. C. to produce a solubilized cold water dispersible starch (U.S. Pat. No. 3,515,591 issued to Feldman et al.); cooking high amylose starch under shear at a temperature higher than the gelatinization temperature to produce a yellow gel (U.S. Pat. No. 3,836,677 issued to Freck et al.); and subjecting high amylose starches to a jet cooking/spray drying process to produce a pregelatinized starch (E.P. Application 0 366 898 A1 and U.S. Pat. No. 5,131,953 issued to Kasica and Eden).

The invention relates to methods for producing pregelatinized, starch-based texturizing agents, to novel texturizing agents, and to food formulations containing the texturizing agents. The texturizing agents of this invention are derived from high amylose starch which has been processed under specific conditions of temperature, pressure and shear, and has a dextrose equivalent (DE) value for the starch component of less than about 5, with about 1.5 being preferred as determined by the Luff-Schoorl method, Procedure D52, Corn Industry's Research Foundation, 6th Edition. The novel texturizing agents have unique properties in that they can stabilize fat containing food formulations and can be used to fully or partially replace the fat content of foods that traditionally contain fat.

According to the method of the invention, the starch-based texturizing agent is made by heating a slurry of high amylose starch in an acidic aqueous medium at a temperature sufficient to disrupt the starch granules and to substantially solubilize the starch therein; filtering the solubilized starch, preferably by treatment with diatomaceous earth and activated charcoal to reduce off-flavor and off-color; and reducing the temperature of the solution to a temperature and for a period of time sufficient for the starch to retrograde to attain essentially maximum viscosity and/or gel strength. The retrograded starch paste can be dried to give a crystalline, retrograded texturizing agent. Alternatively, the filtered starch solution can be dried at a temperature sufficient to maintain the solubility of the starch to produce a non-crystalline, non-retrograded texturizing agent. A third alternative is to cool the filtered starch solution to a sufficient temperature for a sufficient period of time to partially precipitate the starch before drying, thereby giving a partially retrograded texturizing agent. Retrograded, partially retrograded and non-retrograded texturizing agents can be later rehydrated and used in food formulations. The structural and functional properties of the texturizing agent can be tailored to the specific end use by varying the process parameters such as the concentration of the starting materials, the conditions of time, temperature, pressure, pH and shear at the various stages of the process.

Depending upon the final processing of the pregelatinized starch, the resultant texturizing agent will be retrograded (in the case of cooling the starch prior to drying), non-retrograded (in the case where the solution is dried at a temperature sufficient to maintain the solubility of the starch) or partially retrograded (in the case where the starch is partially precipitated prior to drying). Whether a starch is retrograded can be ascertained by Differential Scanning Calorimetry (DSC) (see, for example, Slade and Levine in Recent Developments in Industrial Polysaccharides eds. S. S. Stivala, V. Crescenzi and F. C. M. Deq), Gordon and Breach Science: New York, 1987, 387-430). The crystallinity can be determined by its X-ray defraction pattern. The retrograded texturizing agent is insoluble in water, exhibits both microparticulate- and gel-like structural and functional properties, is white in color and is bland in flavor, i.e., does not exhibit flavors typical of starch products which have been exposed to high temperature processing or chemical modification. A rehydrated form of the retrograded texturizing agent also has a high degree of stability, i.e., minimal syneresis was observed during refrigerated storage for two months in the absence of microbial contamination. The stability of the texturizing agent regarding syneresis is novel in that most food starches are chemically-modified in order to prevent exclusion of water from the starch polymer upon retrogradation over time, a phenomenon which reduces the shelf-life of starch-containing products.

The texturizing agent produced by allowing the starch to partially precipitate before drying, i.e. a partially retrograded starch is partially crystalline and non-degraded. It still retains the favorable properties of retrograded texturizing agents.

The texturizing agents of the present invention provide a safe and cost effective product for use in foods and, alternatively, in drug and cosmetic applications. The functionality of the texturizing agent as a fat replacer and stabilizer is achieved without chemical modification of the starch polymer, does not necessitate the use of numerous adjunct ingredients, and is stable for use in a variety of food processing schemes such as high temperature cooking, baking, freezing, whipping, extrusion, pasteurization, HTST (high temperature, short time) processing, UHT (ultra-high temperature cooking) retorting, etc. In full fat products, the texturizing agents provide improved mouthfeel, body and stability. Food formulations containing the texturizing agents of the present invention exhibit excellent freeze/thaw and frozen storage stability, shelf stability and resistance to shear and thermal abuse.

Among the major issues facing food producers that employ currently available texturizers/fat replacers are the negative effects on taste due to off-flavors, the masking of the foods inherent flavor and flavor delivery in the mouth by the texturizers/fat replacer. Key differences between the texturizing agents of the present invention and others are their lack of off-flavor, minimal masking of flavors, and minimal effects on flavor profile.

The versatile texturizing agents of this invention function to fully or partially replace fat in a variety of food products which typically contain fat in their formulation. The texturizing agents function to provide structure, opacity, viscosity, stability and acceptable organoleptic attributes with performance approximating the qualities of the corresponding full fat versions. The texturizing agents of the present invention have been shown to function well in both laboratory and commercial plant processing schemes and equipment.

FIG. 1 is a schematic representation of one embodiment for making the retrograded, crystalline texturizing agent of this invention.

FIG. 2 is a schematic representation of one embodiment for making the non-retrograded, non-crystalline texturizing agent of this invention.

The invention relates to methods for producing pregelatinized, starch-based texturizing agents, to the novel texturizing agents themselves, and to stabilized, full-fat food formulations or food formulations in which the fat content has been fully or substantially replaced by the starch-based texturizing agents. For purposes of the present invention, the term "texturizing agents" will be used to describe products derived from high amylose (>30% amylose as determined by iodine binding) starch which has been processed under specific conditions of temperature, pressure and shear, as described herein, and have a DE of less than about 5 with about 1.5 being preferred.

According to the method of this invention, texturizing agents are prepared from a high amylose starch which contains greater than about 30% amylose, and preferably about 70% amylose as determined by the iodine binding method. The high amylose starch can be obtained from a variety of plant sources, including but not limited to peas, oats, corn and barley. In addition, the high amylose starch can be chemically modified, for example by phosphorylation, oxidation, succinylation or crosslinking using known techniques. The starting material may be a product of the milling of whole grains in which the non-starch components of the grain have been removed. The milled starch product may be obtained in a wet or dry form. A number of commercial sources of high amylose starch include AMYLOMAIZE.RTM. VII (approx. 70% amylose; American Maize Products Co., Hammond, Ind.) and HYLON.RTM. VII (National Starch and Chemical Corp., Bridgewater, N.J.). Filtering by treatment with diatomaceous earth and activated charcoal, as described below, results in removal of the fat and protein with greater efficiency, thereby yielding texturizing agents with improved sensory properties.

The method for producing the novel texturizing agents generally involves: cooking the slurry under conditions of time, temperature, pressure, pH, ionic strength and shear sufficient to solubilize the starch by fully disrupting the starch granules while minimizing generation of objectionable side products which contribute off-flavor and off-color; filtering the solubilized starch to remove a substantial portion of non-starch components such as lipid and protein, preferably by treatment with diatomaceous earth and activated charcoal; and cooling of the fully solubilized starch under controlled conditions of time, temperature and shear to yield a thixotropic gel. The retrograded texturizing agent can be dried to reduce the moisture content of the gel to provide a free-flowing powder. Alternatively, the filtered starch solution can be dried at a temperature sufficient to maintain the solubility of the starch to yield a powdered non-crystalline, non-retrograded, amorphous texturizing agent that is more readily hydrated in water than retrograded starches. A third alternative is to cool the filtered starch solution to a temperature and for a period of time sufficient to allow partial precipitation of the starch, thereby resulting in a partially retrograded texturizing agent. In any of these three cases, the texturizing agents can be used directly in food formulations. The dry powder may be used directly or can be rehydrated prior to use. Each of these steps are discussed in detail below, and additionally shown schematically in FIGS. 1 and 2.

Specifically, the method involves preparing a starch slurry in an aqueous acidic medium with a total high amylose starch content of from about 1 to about 30% (w/w) solids, preferably from about 5 to about 15% (w/w). For purposes of the present invention, "aqueous medium" is defined as water or a solution which is substantially water such as buffer, acid, base, salt, antioxidant, reducing agent, and/or chelating agent solutions or a blend of water with a miscible organic solvent, in an amount sufficient to inhibit oxidation of lipids present in the starch starting materials. It is preferred that the aqueous medium, such as water, be pretreated to remove dissolved minerals. The starch may be dispersed in an aqueous medium at ambient temperature or after the aqueous medium has been heated.

Regulation of pH is also important to the texturizing properties of the product. The acidity of the slurry is controlled using appropriate food grade acidulants and alkali. The method of cooking dictates the pH at which the starch is cooked. If a jet cooker is used, the pH should be lower than that required for batch cooking. The typical pH of the slurry before and after cooking is in the range of from about 3 to about 6, preferably about 4.3 to about 4.7 when cooked in a reactor and about 3.6 to about 4.0 using a jet cooker.

The resulting slurry is transferred to a reactor vessel equipped with appropriate stirring device for agitation during the cooking of the starch slurry. The slurry is subjected to controlled conditions of time, temperature, pressure, pH, ionic strength and shear, to fully disrupt the starch granules and solubilize the starch via caramelization, hydrolysis, etc. For the purposes of the present invention, the term "solubilize" refers to the absence of any detectable particulate matter, especially partially disrupted starch granules, when viewed under 200 to 400-fold magnification using a standard light microscope. The rate of heating, time duration at the final cook temperature (i.e., the temperature above the gelatinization temperature of starch), and shear rate in the reactor vessel affect the properties of the final product.

The slurry is typically heated from room temperature (approximately 22.degree. C.) to from about 125.degree. C. to about 150.degree. C., with about 138.degree. C. being preferred, under stirring over a time period which ranges from 40 to 120 minutes, preferably 60 minutes until starch granules are solubilized.

The concentration of the high amylose starch solids in the reactor can be varied to yield products with different functional properties. For instance, texturizing agents produced at 5% starch on a dry solids basis (dsb) in the reactor yield final products of higher viscosity but lower opacity when compared to a texturizing agent produced at 10% dsb under identical processing conditions. The differences in opacity and viscosity are apparent in both the gel per se and in final formulated food products, such as cheesecake and mayonnaise. In essence, the properties of the final texturizing agent are sensitive to relatively minor changes in any of the process parameters. This sensitivity to conditions in the reactor enables one to produce a variety of texturizing agents from a single starting material.

The final temperature of 138.degree. C. for cooking of the starch is preferred to produce texturizing agents that possess smooth mouthfeel, high opacity, and acceptable organoleptic properties. The complete disruption and solubilization of the starch is monitored by periodic sampling of small aliquots from the reactor over time and examination of the slurry under magnification (e.g., 200 to 400.times. fold) for presence or absence of starch granules. The slurry is heated at about 125.degree. to about 150.degree. C. (about 138.degree. C. being preferred) for a time period which ranges typically from about 40 to about 120 minutes, preferably about 60 minutes. The heating step is considered complete when essentially all the starch granules have dissolved. The importance of the final temperature used in the present invention is illustrated by the following comparison. High amylose starch was heated to a maximum temperature in the reactor of 121.degree. C. for 8 hours in the absence of shear. Even though the cooking process is carried out for a much longer time period than that of the present invention, this lower temperature does not allow for complete solubilization and disruption of the starch granules resulting in a product that contains relatively large particulates that exhibit grittiness and poor mouthfeel when tasted directly. In contrast, the higher temperature used in the present process insures full disruption of the starch granules and solubilization of the high amylose starch which yield a much smoother product.

An alternative method of heating is to directly inject steam into the slurry, such as can be accomplished in a rapid heat-up device commonly known in the art, such as a jet cooker. Using a jet cooker or other rapid heat-up device, temperatures above the preferred range can be tolerated without affecting product properties if the contact time is sufficiently short. Generally, the temperature is raised up to about 160.degree. C. and maintained at the elevated temperature for up to about ten minutes, with one to two minutes being preferred. Higher temperatures can be used for shorter time periods.

Upon complete disruption of the starch granules and solubilization of the starch, the starch solution is filtered. It is cooled to a temperature below boiling and above about 85.degree. C. Temperatures lower than about 85.degree. C. result in inefficient filtration as the starch retrogrades. Cooling can be accomplished by any suitable means such as heat exchanger, flash cooling or by running cooling medium through the reactor jacket. The cooled starch solution is transferred from the,reactor vessel by expulsion under pressure, pumping, or other suitable method.

The starch solution (at approximately 90.degree. C.) is filtered to remove undissolved impurities, such as protein, fats and other compounds. Any filtration device having metal sieves, filter papers/cloths, filter pads or other filter media can be used. For example plate and frame filter presses, cartridge, bag and pressure leaf filters can be used. It is desirable to preheat the filters and filtering device to the temperature of the slurry being filtered prior to filtration. This prevents premature retrogradation of the starch on the filter media and consequent blinding of the filter.

In a preferred embodiment, a filter aid such as diatomaceous earth is typically added to the starch solution and stirred for about 10 to about 120 minutes, with 60 minutes being preferred. The amount of diatomaceous earth used is generally from about 5% to about 20% by weight of the starch being purified, and is preferably about 10% by weight. The starch solution is then passed through a primary filter to remove the diatomaceous earth and then through the secondary filter containing the activated charcoal. For a pad filter, suitable carbon impregnated pads are available, for example, from Alsop Engineering Co., Kingston, N.Y. (S-51, grade 872).

Alternatively, the filtration step is performed by treating the starch solution with activated charcoal after the solution is cooled to about 90.degree. C. Activated charcoal is added to the reactor vessel for approximately from about 10 to about 120 minutes, with 60 minutes being preferred. Typically, the solution is simultaneously treated with a filtering aid such as diatomaceous earth, e.g. CELITE.RTM. (CELITE.RTM. Corp., Lompoc, Cailf.). The amount of diatomaceous earth generally used is as described above. The starch solution containing suspended activated charcoal and diatomaceous earth is then filtered, as described above, to remove the charcoal and diatomaceous earth.

Starch based texturizing agents which have been treated with activated charcoal and diatomaceous earth have reduced protein and fat contents compared with starch based texturizing agents which have not undergone this treatment. By removing impurities from the starch solution which inhibit crystallization, filtration facilitates the crystallization of the starch. In addition, treatment with diatomaceous earth and activated charcoal gives the resulting texturizing agent improved sensory properties such as flavor (see Example 1).

The filtered starch solution is collected in a receiving vessel. A retrograded, non-retrograded or partially retrograded starch can be produced from the filtered starch solution, depending on how the solution is processed. Drying the filtered starch solution before the starch precipitates produces a non-retrograded starch. Allowing the solution to cool so that the starch precipitates yields a retrograded starch. Adjusting the temperature and time of precipitation so that the starch only partially precipitates results in a partially retrograded starch.

A retrograded starch is produced by cooling the filtered or treated starch solution to a temperature sufficient to allow the starch to precipitate, typically from about 1.degree. C. to 7.degree. C., preferably to about 4.degree. C. Optionally, salts suitable for use in food such as sodium chloride can be added to increase the rate of crystallization. Cooling should be carried out with a minimum of shear for maximum gel strength in the resultant precipitated texturizing agent; however, application of shear during the cooling step can be used to produce texturizing agents with varied functional properties, i.e., lower viscosity. For example, the filtrate can be stored in a temperature controlled cooler overnight. Alternatively, any efficient method of cooling can be used, such as, but not limited to, jacketed kettles, tube-n-tube heat exchangers, conventional heat exchangers, belt chillers and shell-n-tube heat exchangers. After completion of the cooling process, the resultant precipitate can be stored in the temperature range of from about 4.degree. C. to about 50.degree. C., preferably about 4.degree. C. to about 22.degree. C.

Starch solutions can be combined with one or more enzymes that hydrolyze starch into other products useful in food applications. For example, conversion of starch solutions into a food grade, non-digestible insoluble bulking agent is described in U.S. Pat. No. 5,051,271, the teachings of which are hereby incorporated in their entirety into this application. Starch solutions of the present invention which have been treated with diatomaceous earth and activated charcoal, as described above, results in products with different properties when converted enzymatically into a non-digestible, insoluble bulking agent, compared with starch solutions that have not been so treated. For example, when reacted with pullanase, starch solutions treated with activated charcoal and diatomaceous earth yielded starches which contain 40% more dietary fiber compared with starch solutions in which the treatment was omitted (see Example 2).

Optionally, the treated, filtered starch solution can be subjected to shear before being allowed to retrograde in order to change the sensory properties of the product. Shear may be provided by piston, probe, jet, or valve homogenization (e.g., one and two stage), colloid milling, or similar technique. Conditions of shear will vary with the specific technique employed.

Excipients such as sugars, gums, other starches etc. that aid in rehydration or improve functionality in specific food applications can be optionally added at any point in the cooking, filtration and homogenization steps. Preferred excipients are any hydrolyzed starch-based carbohydrate, with low DE maltodextrin being most preferred. Excipients that aid in the rehydration are not necessary if the resulting starch product is used in wet form without prior drying and rehydration or if the dry powder is rehydrated under conditions of sufficient heat and shear to insure complete rehydration.

The texturizing agent can then be used directly in food formulations or dried by an appropriate method to a white, free-flowing powder. If the texturizing agent is dried, the preferred method is to use a spray dryer to achieve rapid drying. This preserves the functional characteristics and facilitates rehydration. For example centrifugal atomizers, pressure nozzles and two fluid nozzles can be used to atomize the starch gel. Alternative drying methods can be used and include drum drying and freeze drying.

The properties of the texturizing agent may be further modified at this point in the process by co-drying with added constituents such as sugars, colorants, flavors, gums, maltodextrin, other starches, proteins, lipids, etc. The powder can be used directly in food formulations or rehydrated prior to use by addition of water and subjecting to suitable conditions of time, shear, temperature, etc.

The retrograded product of the invention is crystalline, insoluble in cold water and can be rehydrated at elevated temperatures. The retrograded product exhibits both microparticulate- and gel-like structural and functional properties, is white in color and exhibits essentially no off-flavors typical of starch products. The microstructure of the product as characterized by SEM can be described as a semi-continuous, macroporous gel network composed of filaments of a uniform diameter. The gel network is devoid of starch granules or granule fragments and its discontinuous portions appear as roughly spheroidal microparticles. The protein content is less than 0.3%, with 0.15% preferred. The total organic solvent (e.g., petroleum ether, diethyl ether, hexane, chloroform,) extractable material is less than 2% but is typically 1.2%. The hydrated product exhibits a high degree of stability and no syneresis during refrigerated storage in the absence of microbial contamination. The stability of the texturizing agent regarding syneresis is novel in that most starches must be chemically-modified in order to prevent exclusion of water from the starch polymer upon retrogradation over time.

In another aspect of the present invention, the starch solution after filtration is processed such that a non-retrograded starch is produced. A non-retrograded starch is trapped in a glassy state which is characterized by the absence of crystalline regions within the starch polymer, i.e. the glass is amorphous and non-crystalline. Consequently, starch in the glassy state can be more readily hydrated in water. In addition, the glassy state preserves the desirable functional characteristics of the starch, for example reduction in off-flavors, stability, no syneresis during refrigerated storage, and suitability for use as fat replacements in food.

The glassy state is created by removing water from the solution sufficiently fast at a sufficiently elevated temperature to immobilize the starch molecules before they have a chance to order into the retrograded state. This is accomplished, for example, by drum drying, belt drying, flash drying or spray drying. Spray drying is preferred and is carried out by maintaining the filtered starch solution at an elevated temperature sufficient to prevent crystallization of the starch, for example at about 85.degree. C. to about 95.degree. C. The filtered starch solution is then fed to a commercially available spray dryer (e.g. Crepaco Compact Spray Dryer, APV Crepaco Inc., Tonawanda, N.Y.) at a suitable inlet temperature. The treated starch solution is then atomized through the nozzle of the spray dryer. A variety of nozzles can be used, for example a two fluid nozzle from Spraying Systems Co., Wheaton, Ill. (Set Up 22B). The atomized mist of the treated starch solution is dried by subjecting the atomized mist to elevated temperatures (referred to as the outlet temperature) in the spray dryer chamber. The resulting product is a free flowing white powder with a lower bulk density and is more readily hydrated in water compared with the retrograded starch counterpart. The inlet and outlet temperatures used depend on the type of spray dryer, the scale of the process, the feed rate and how much moisture is desired in the final product. The skilled artisan will be able to determine the appropriate outlet temperature, based on the conditions used and the desired properties of the final product. In one example using a two fluid nozzle from Spraying Systems Co., Wheaton, Ill. (Set Up 22B), the outlet air temperature is about 93.degree. C. and the inlet temperature is about 216.degree. C. (See Example 3).

In another aspect of the present invention, a partially retrograded product is obtained by cooling the filtered starch solution to a temperature at which the starch partially retrogrades, e.g., from about 50.degree. C. to about 60.degree. C. After the partial retrogradation is complete, the slurry is dried, as described above, for example by spray drying, to yield a partially retrograded texturizing agent. The degree of retrogradation can be controlled by varying the time and temperature at which the filtered solution is allowed to retrograde.

The product of the invention which is spray dried at a temperature sufficient to prevent precipitation of the starch is substantially non-degraded, amorphous, non-crystalline and more readily soluble in water than the retrograded product. It retains the desirable characteristics of the retrograded product, discussed above, such as essentially no off-flavors typical of the starch products, stability, no syneresis during refrigeration, and suitability for use as a fat substitute in food. The non-retrograded powder, once rehydrated, will retrograde.

The texturizing agents of the present invention provide a safe and cost effective product for use in foods and, alternatively, in drug and cosmetic applications. The functionality of the texturizing agent as a fat replacer is achieved without chemical modification of the starch polymer, does not necessitate the use of numerous adjunct ingredients, and is stable for use in a variety of food processing schemes including high temperature cooking, baking, freezing, whipping, extrusion, pasteurization, high temperature short time (HTST) processing, UHT (ultra-high temperature processing), retorting, etc.

The versatile texturizing agents of this invention function in full-fat foods or can fully or partially replace fat in a variety of food products which typically contain a high percentage of fat in their formulation. Generally, the texturizing agent can be incorporated into food formulations at levels between about 0.5 and about 10%, preferably between about 1.0 and about 6% (w/w). Applications of the texturizing agents include viscous systems such as mayonnaise and spoonable and pourable salad dressings; confections such as cake frostings and fudge toppings; baked applications such as cheesecake; cold processed foods such as a no-bake cheesecake; processed cheese; cream- and cheese-based sauces such as Hollandaise and Alfredo sauces; savory sauces; cultured and non-cultured dairy products such as sour cream, cream cheese, yogurt, cottage cheese dressing, ice cream; whipped applications such as chocolate mousse, toppings and cream fillings; meat products; frozen desserts and retorted formulations such as canned soups, among others. The fat-like attributes and stability are achieved without chemical modification of the starch. As a result of these fat-like attributes, food formulations normally containing fat can now be made having reduced levels of fat approaching 100% reduction in certain formulations.

The texturizing agents work particularly well in cultured and processed dairy products to stabilize the food product. Non-fat and reduced fat containing dairy products with excellent organoleptic properties can be formulated. Dairy products, such as cultured sour cream and processed cream cheese spread, containing the texturizing agent, when stored refrigerated over a period of time, exhibit excellent stability.

The texturizing agents function to provide structure, opacity, viscosity, stability, and acceptable organoleptic attributes with performance approximating the qualities of the full fat versions when used in reduced fat foods. The texturizing agents lack off-flavors, do not mask the flavors of the foods' inherent flavors when added to a food formulation and have minimal effects on flavor profile. The food formulations containing the texturizing agents of the present invention exhibit excellent freeze/thaw and frozen storage stability, shelf stability and resistance to shear and thermal abuse. The texturizing agents of the present invention have been shown to function well with both laboratory and commercial plant processing schemes and equipment.

The invention is further illustrated by the following examples which are not to be construed as limiting in any way:

A stainless steel reactor was charged with 80 gallons (302.8 liters) of reverse osmosis water. Under moderate agitation, 84 lb (38.1 kg) of 70% amylose starch (AMYLOMAIZE VII.RTM., American Maize Products Co., Hammond, Ind.) was added. The pH of the slurry was adjusted to 4.5 using phosphoric acid (80%, w/w). The reactor was sealed. Oxygen was purged from the reactor and starch slurry by eight repeated evacuations of the head space and sparging the liquid phase with nitrogen. Vacuum was pulled to a minimum of 25 inches (635 mm) of mercury. Nitrogen was sparged into the vessel through a dip tube into the liquid phase. The nitrogen was applied until the vessel pressure reached 2 inches (50.8 mm) Hg vacuum. At the end of this sparging process, the oxygen content in the liquid phase was less then 1.0 ppm. Under agitation, the vessel contents were heated to 280.degree. F. (138.degree. C.) in approximately 90 minutes. After the batch temperature was held at 280.degree. F. (138.degree. C.) for 30 minutes a sample was removed from the reactor. The sample was examined for the presence of remaining starch granules or granule fragments with a microscope (Olympus Corporation, Lake Success, N.Y., Model BHS) under 250-fold magnification. Starch dissolution typically occurred approximately 45 minutes after the slurry reached 280.degree. F. (138.degree. C.). When the starch granules were essentially dissolved, the slurry was cooled to about 204.degree. F. (95.6.degree. C.) by passing cooling water through the reactor jacket. Twenty four pounds (10.8 kg) of DE 5 maltodextrin (Maltrin M040, Grain Processing Co., Muscatine, Iowa) was added and agitation continued until the maltodextrin was completely dispersed. A sample was removed for sensory evaluation. 7.5 pounds (3.4 kg) filter aid (CELITE.RTM., CELITE.RTM. Corporation, Lompoc, Calif.) was added and the batch was held for 60 minutes before filtration through two filter presses in series. The first press (Model BT-240, Alsop Engineering Co., Kingston, N.Y.) was dressed with four 24 square inch (155 cm.sup.2) (filter pads (A-10 filter media, Alsop Engineering Co., Kingston, N.Y.). The filter press consisted of two 2-inch (5.1 cm) wide frames and one half-inch (1.3 cm) wide plate. The second press (Alsop Engineering Co., Kingston, N.Y.) was dressed with four 113 square inch (729 cm.sup.2) carbon filter pads (S-51, grade 872 pads, Alsop Engineering Co., Kingston, N.Y.). A sample was removed for sensory evaluation after removal of the diatomaceous earth and after the filtration through the carbon pads. The hot starch slurry was stored in 2 ounce (60 cm.sup.2) containers at 4.degree. C. overnight. The following day the samples were evaluated by a panel of trained experts. The samples were scored on a scale of 1 to 10, where 10 was the score for a sample with extreme off-flavor. The sensory results are shown in Table 1. The retrograded starch was spray dried and the proximate analysis are shown in Table 2.

A slurry of 70% amylose corn starch (AMYLOMAIZE.RTM. VII, American Maize-Products Company, Hammond, Ind.) was prepared in an agitated pressure vessel by mixing 21.1 lb (9.5 kg) of the starch with 250 pounds (112.5 kg) water. The slurry was cooked under high agitation to a temperature of 280.degree. F. (138.degree. C.), where it was held for 70 minutes before being cooled to 202.degree. F. (94.degree. C.).

The cooked starch slurry was split into two lots. An 11 pound (5.0 kg) sample of the cooked starch was removed and placed in a 2 gallons (7.6 liters), temperature controlled, agitated vessel and held at 140.degree. F. (60.degree. C.) to serve as the unfiltered control. The remaining starch in the cook vessel was filtered. First, 2.0 pounds (0.90 kg) of diatomaceous earth (CELITE.RTM., CELITE.RTM. Corporation, Lompoc, Calif.) was slurried into the cooked starch, and then held for one hour. Next, the starch/diatomaceous earth mixture was filtered through four 4 ft.sup.2 (3700 cm.sup.2), carbon impregnated pads (type AC-30, die 154, Alsop Engineering Company, Kingston, N.Y.) in a plate-and-frame filter press. The filtration was conducted at an average pressure drop across the filter of 10 psi (0.68 atmospheres) and flow rate of 7.5-8.0 gallons/minute (28.4-30.3 liters/minute). The filtrate was collected in an agitated, temperature controlled vessel maintained at 140.degree. F. (60.degree. C.).

The two starch solutions were then processed according to the teachings of C.-W. Chiu, M. Henley and P. Altieri (European Patent Application 0,564,893/A1) to illustrate the effect of impurities removal on the yield of enzyme resistant starch. The control lot was adjusted to pH 5.02 with phosphoric acid. Then 7.0 grams of pullulanase (PROMOZYME.TM., Novo Industry A/S, Bagsvaerd, Denmark) were added. The enzyme was allowed to react for 2 hours at 140.degree. F. (60.degree. C.). The filtered lot was adjusted to pH 5.01 with phosphoric acid. Then 139.8 grams of pullulanase were added, and allowed to react at 140.degree. F. (60.degree. C.) for 2 hours. Resistant starch was allowed to form in both lots by holding at 167.degree. F. (75.degree. C.) for 18 hours. This also serves the function of inactivating the enzyme. The two lots of resistant starch were spray dried using 330.degree. F. (166.degree. C.) inlet air and 215.degree. F. (102.degree. C.) outlet air conditions.

The two lots of resistant starch were assayed for apparent total dietary fiber (AACC Method 32-07), Approved Methods of the American Association of Cereal Chemists, eighth edition, 1990, AACC, St. Paul, Minn.). The unfiltered, control lot yielded 16.7% total dietary fiber. The filtered lot contained 23.4% total dietary fiber, representing a 40% yield increase in resistant starch due to the purification by filtration.

Six hundred seventy pounds (304.5 kg) of reverse osmosis, de-ionized (RODI) water was metered into a 100 gallon (378 liter) reactor (Lee Kettles, Phillipsburg, N.J.) and heated to 43.degree. C. Eighty-four pounds (38.2 kg) 70% amylose corn starch (AMYLOMAIZE.RTM. VII, American Maize Products Co., Hammond, Ind.) was weighed into the reactor with agitation. The final starch solids concentration was 10% (w/w). The reactor contents were agitated using a LIGHTNIN.TM. mixer (Model V5S18, Lightnin Mixers, Rochester, N.Y.) with an A-100 propeller at 340 rpm. The pH of the suspension was adjusted to 4.56 using 15% phosphoric acid. The batch was heated from 43.degree. C. to 105.degree. C. in 14 minutes. The heating began with the vessel open to atmospheric pressure. The vessel was sealed by closing a vent valve when the product temperature reached 95.degree. C. The temperature was then raised from 105.degree. C. to 138.degree. C. in 61 minutes. The product was held at 138.degree. C. for 60 minutes. The product was then cooled from 138.degree. C. to 95.degree. C. in 11 minutes by circulating 7.degree. C. chilled water through the reactor jacket. The product was maintained at 95.degree. C. by again adding steam to the jacket and the reactor was opened. 8.4 pounds (3.8 kg) of diatomaceous earth (Hyflo Supercel CELITE.RTM., CELITE.RTM. Corporation, Lompoc, Calif.) and 25 pounds (11.4 kg) of maltodextrin (MALTRIN.RTM. M040, Grain Processing Corporation, Muscatine, Iowa) were added. The slurry was held for 60 minutes before filtering through two filter presses in series. The first press (Model BT-240, Alsop Engineering Co., Kingston, N.Y.) was dressed with six 24".times.24" (61 cm.times.61 cm) square filter pads (Grade A-10 filter media, Alsop Engineering Co., Kingston, N.Y.). The press had two 2-inch (5.08 cm) wide frames and one-half inch (1.27 cm) wide frame installed between one-half inch (1.27 cm) wide filter plates. The second press (Alsop Engineering Co., Kingston, N.Y.) was dressed with five 13 inch (33.0 cm) square carbon filter pads (1640 HC pads, Cellulo Corporation, Fresno, Calif. 93721). The presses had been preheated by circulating 95.degree. C. RODI water through them. The batch was pumped at 31.0 lb/min (14.1 kg/min) through the filter presses and into a holding kettle. The filtered starch solution was maintained at 91.degree. C. by applying steam to the holding kettle jacket. The starch solution was fed directly to a spray dryer (Crepaco Compact Spray Dryer, APV Crepaco Inc., Tonawanda, N.Y.) using a progressive cavity pump (Netzch, Corp., Model #3NE10, Lionville, Pa.). The starch solution was atomized with a two fluid nozzle (Set Up 22B, Spraying Systems, Co., Wheaton, Ill.). Inlet and outlet air temperatures were 420.degree. F. (216.degree. C.) and 200.degree. F. (93.degree. C.), respectively. Product was a free-flowing white powder.

Two hundred fifty pounds (113.6 kg) of reverse osmosis, deionized) water was metered into a 30 gallon (115 liter) reactor (Lee Kettles, Phillipsburg, N.J.) and heated to 43.8.degree. C. Thirty pounds (13.6 kg) 70% amylose corn starch (AMYLOMAIZE.RTM. VII, American Maize Products Co., Hammond, Ind.) was weighed into the reactor with agitation. The final starch solids concentration was 10% (w/w). The reactor contents were agitated using a LIGHTNIN.TM. mixer (Model V5S18, Lightnin Mixers, Rochester, N.Y.) with an A-310 impeller at 340 rpm. The pH of the suspension was adjusted to 4.47 using 15% phosphoric acid. The batch was heated from 43.8.degree. C. to 105.degree. C. in 14 minutes. The heating began with the vessel open to atmospheric pressure. The vessel was sealed by closing a vent valve when the product temperature reached 95.degree. C. The temperature was then raised from 105.degree. C. to 138.degree. C. in 60 minutes. The product was held at 138.degree. C. for 60 minutes. The product was then cooled from 138.degree. C. to 95.degree. C. in 9 minutes by circulating 8.degree. C. chilled water through the reactor jacket. The product was maintained at 95.degree. C. by again adding steam to the jacket. The reactor was opened for the addition of three pounds (1.4 kg) of diatomaceous earth (Hyflo Supercel CELITE.RTM., CELITE.RTM. Corporation, Lompoc, Calif.) and nine pounds (4.1 kg) of maltodextrin (MALTRIN.RTM. M040, Grain Processing Corporation, Muscatine, Iowa). The slurry was held for 60 minutes before filtering through two filter presses in series. The first press (Model BP-240, Alsop Engineering Co., Kingston, N.Y.) was dressed with four 24".times.24" (61 cm.times.61 cm) square filter pads (Grade A-10 filter media, Alsop Engineering Co., Kingston, N.Y.). The press had one 2-inch (5.08 cm) wide frame and one half-inch (1.27 cm) wide frame installed between one-half inch (1.27 cm) wide filter plates. The second press (Alsop Engineering Co., Kingston, N.Y.) was dressed with three 13 inch (33.0 cm) square carbon filter pads (1640 HC pads, Cellulo Corporation, Fresno, Calif. 93721). The presses had been preheated by circulating 95.degree. C. reverse osmosis deionized water (RODI) water through them. The batch was pushed at 24 lb/min (10.9 kg/min) through the filter presses and into a holding kettle by pressurizing the feed kettle to 25 psig. The filtered starch solution was maintained at 83.degree. C. by applying steam to the holding kettle jacket. The starch solution was metered to a spray dryer (Crepaco Compact Spray Dryer, APV Crepaco Inc., Tonawanda, N.Y.) using a progressive cavity pump (Netzch Corp., Model #3NE10, Lionville, Pa.). The starch solution was atomized with a two fluid nozzle (Set Up 22B, Spraying Systems Co., Wheaton, Ill.). Air atomization pressure was 60 psig. Inlet and outlet air temperatures were 319.degree. F. (159.degree. C.) and 220.degree. C. (104.degree. C.), respectively. Product was a free-flowing white powder.

The procedure for producing the texturizing agent using a batch method is described below: 137.5 grams of 70% amylose corn starch (AMYLOMAIZE.RTM. VII starch, American Maize Products Co., Hammond, Ind.) was weighed into each of two 4 liter beakers. 2740 mL of deionized water was added to each beaker. The final starch solids concentration was 5% (w/v). The beakers were stirred using a LIGHTNIN.RTM. mixer (Lightnin Mixers, Rochester, N.Y., Model #TS1515) at approximately 250 rpm. The pH of the suspension was checked and adjusted to pH 4.5. The suspensions were then combined in a two gallon (7.6 liters) Parr reactor (Parr Instrument Co., Moline, Ill., Model No. 4552) by transferring through a funnel into the reactor vessel which was stirred at 250 rpm. The batch was then heated to 138.degree. C. After the batch temperature was 138.degree. C. for 60 minutes, a sample was taken for evaluation. Using an appropriate microscope at 250 fold magnification, the starch suspension was examined for the presence of remaining starch granules or granule fragments. If the starch granules were completely dissolved, the slurry was discharged from the reactor. If not, a sample was drawn every few minutes for evaluation until remaining starch granules were dissolved. Typical cook time at 138.degree. C. was 100 minutes. The contents of the reactor were discharged into a suitable receptacle. While monitoring the temperature, the slurry was homogenized using a Polytron homogenizer (Brinkman Instruments, Westbury, N.Y.) outfitted with a PTA20S probe until the temperature of the slurry was 50.degree. C. At this point, the slurry was opaque and white in appearance.

The product of this method was a predominately white gel-like paste which could be used directly in food formulations or could be further concentrated by centrifugation prior to use. This method yielded a product which exhibited a slight degree of mottled brown color and a pronounced rancid off-flavor.

A texturizing agent of slightly different functionality was prepared using Method 1 of Example 5 with a single change in procedure. The solids concentration of the batch was increased to 10% (w/v). Preparation of the texturizing agent under these conditions yielded a product of higher visual opacity and slightly lower viscosity than the texturizing agent produced at 5% solids in the reactor. Due to the higher concentration of starting material in the reactor vessel, the off-flavor and off-color were even more pronounced than in the batch of Method 1 produced at a lower solids concentration.

A substantially deflavored, decolored texturizing agent was produced by modification of Example 5, Method 2. The reactor vessel was evacuated prior to loading of the starch suspension. The starch suspension was then aspirated into the reactor vessel under vacuum. Prior to heating in the reactor vessel, the slurry was sparged with nitrogen for a period of ten minutes. All subsequent steps in the preparation of the texturizing agent were performed as described in Example 5, Method 1.

Method 3 yielded a texturizing agent that retained the structural and functional characteristics of the texturizing agents prepared by Example 5, Method 2; however, the off-flavor and off-color had been greatly reduced relative to the agents produced from a starch suspension that had not been deaerated, sparged and cooked under inert atmosphere.

The preparation of texturizing agent was identical to that described in Example 5, Method 1 except the pH of the starting material had been adjusted to pH 3 with hydrochloric acid. The texturizing agent produced at this lower pH was of much higher opacity and much lower viscosity than those produced at pH 4.5 at 5 or 10% starch solids.

The texturizing agent was produced as described in Example 5, Method 3, except that the starting material was changed to AMYLOMAIZE.RTM. V (American Maize Products Co., Hammond, Ind.) AMYLOMAIZE.RTM. V has an amylose content of about 50% as opposed to the 70% amylose-containing starch used in Methods 1 through 4.

Five hundred fifty grams of 70% amylose corn starch (AMYLOMAIZE.RTM. VII, American Maize Products Co., Hammond, Ind.) was weighed into two 4 liter beakers. 2602 mL of deionized water was added to each beaker. The final starch solids concentration was 11.6% (w/v). The beakers were agitated using a LIGHTNIN.RTM. mixer (Lightnin Mixers, Rochester, N.Y. Model #TS1515) at approximately 250 rpm. This was sufficient to suspend the starch uniformly. The pH of the suspension was adjusted to 4.5 with 1M phosphoric acid. The suspensions were then combined in a two gallon (7.6 liters) Parr reactor (Parr Instrument Co., Moline, Ill., Model #4552) by syphoning into the vessel. The reaction vessel was stirred at 356 rpm. The starch slurry and reactor was then purged of substantially all oxygen by bubbling nitrogen through a dip tube. The reactor was then sealed and heated to 138.degree. C. After the batch temperature was held at 138.degree. C. for 30 minutes, a sample was taken to check the progress of the starch granule dissolution. A few milliliters of the sample were withdrawn through a liquid sampling valve. Using a microscope at 250 fold magnification, the starch suspension was examined for the presence of remaining starch granules or granule fragments. The starch granules were essentially dissolved and the slurry was cooled to less than 100.degree. C. by passing cooling water through an internal coil.

The starch slurry cooled to 95.degree. C. was passed through a 10 micron filter (Grade A10, Alsop Engineers, Kingston, N.Y.) to remove undissolved impurities. The filter holder and media were pre-heated with hot water prior to starch slurry filtration. This was done to prevent premature retrogradation of the starch on the filter media and consequent blinding of the filter. Filtered starch slurry was collected in a metal beaker.

The filtered starch slurry was processed through a two-staged homogenizer (APV-Gaulin Model #15MR-8TBA, Wilmington, Mass.). The homogenization pressure was set at 3000 psig. At this point the slurry was opaque and white in appearance. The homogenate was then allowed to cool overnight inside a cold room regulated at 4.degree. C. The product at this point is a white stiff gel which can be used directly in food formulations or can be dried to a powder using various drying techniques. In particular, spray drying of the gel produces a free-flowing powder that is readily hydrated in water.

The starch paste was too stiff for direct feeding to a spray dryer. It had to be sheared into a more flowable form. It was diluted to approximately 7% (w/w) solids using deionized water. This was fed to a spray dryer (Niro Model #1291, Columbia, Md.) which was fitted with a centrifugal atomizer. Inlet air temperature was regulated to maintain outlet air temperature at 100.degree. C.

A 700 gallons (2650 liters) stainless steel tank was charged with 624 gallons (2360 liters) of softened water heated to 110.degree. F. (43.degree. C.). Under moderate agitation, 700 pounds (315 kg) of 70% amylose starch (AMYLOMAIZE.RTM. VII, American Maize Products Co., Hammond, Ind.) was carefully added to the water. The final starch solids concentration was 10.7% (w/v). The pH of the starch slurry was adjusted to 4.5 with 75% (w/w) phosphoric acid. The starch slurry was transferred to an 800 gallon (3630 liters) pressure reactor (Northland Stainless) which was mixed with a dual impeller agitator (Lightnin Mixers, Model #XJC65, Rochester N.Y.). The reactor was sealed. Oxygen was purged from the reactor and starch slurry by repeated evacuations of the head space and sparging the liquid phase with nitrogen. Vacuum was pulled to a minimum of 25 inches (636 mm) Hg. Nitrogen was sparged into the vessel through a dip tube into the liquid phase. The nitrogen was sparged until the vessel pressure reached 2 inches (50.8 mm) Hg vacuum. This process was repeated until oxygen content in the liquid phase was less than 0.8 ppm. The vessel was then evacuated an additional time. The reactor temperature was raised to 138.degree. C. as quickly as possible. Starch dissolution typically occurred 30 minutes after reaching 138.degree. C. When the starch granules were essentially dissolved, the slurry was cooled to about 88.degree. C. by passing cooling water through the reactor heating jacket. A 24-inch (61 cm) square plate and frame filter press was fitted with 10 micron filter pads (Grade A10, Alsop Engineering, Kingston, N.Y.). Eleven or twelve frames were used to filter a batch. The press and filter media were pre-heated with softened water until the outlet temperature was greater than 77.degree. C. The starch slurry was then pumped through the press. The filtered starch slurry was collected in a 700 gallon (2650 liters) jacketed agitated vessel (Cherry Burrell, Louisville, Ky.). The filtrate was maintained at about 82.degree. C.

An excipient was added to the starch slurry at this point. To the starch slurry, 210 pounds (94.5 kg) of 5 DE maltodextrin (LoDex 5, American Maize Products Co., Hammond, Ind.) was added and stirred until dissolved. The starch slurry was processed through a single stage homogenizer operating at 3000 psig (APV-Gaulin, Model #250-M6-STBS, Wilmington, Mass.). Homogenate was collected in drums which were stored in a cold room at 4.degree. C. to complete the retrogradation process.

The product at this point was a stiff white gel-like paste. It was diluted with 1 part water to 3 parts paste and mixed in a 300 gallon (1140 liters) jacketed mixer (Groen Model #DV/TA-400, Elk Grove Village, Ill). The additional water and mixing transformed the paste into a flowable, pumpable fluid that was fed to a spray dryer. The spray dryer was operated at an outlet temperature of about 104.degree. C. High pressure nozzles (Nozzle #58, Core #21; Spraying Systems Co., Wheaton, Ill.) were used to atomize the product. The product was a free-flowing white powder.

A stainless steel reactor was charged with 75 gallons (284 liters) of reverse osmosis water. Under moderate agitation, 34.1 kg of 70% amylose starch (AMYLOMAIZE.RTM. VII, American Maize Products Co., Hammond, Ind.) was added. The pH of the starch slurry was adjusted to 4.5 using 0.6N phosphoric acid. The reactor was sealed. Oxygen was purged from the reactor and starch slurry by eight repeated evacuations of the head space and sparging the liquid phase with nitrogen. Vacuum was pulled to a minimum of 25 inches (635 mm) Hg. Nitrogen was sparged into the vessel through a dip tube into the liquid phase. The nitrogen was sparged until the vessel pressure reached 2 inches (50.8 mm) Hg vacuum. At the end of this program, the oxygen content in the liquid phase was less than 1.0 ppm. Under agitation, the vessel contents were heated to 138.degree. C. After the batch temperature was held at 138.degree. C. for 30 minutes, a sample was taken to check the progress of the starch granule dissolution as described in Method 1. Starch dissolution typically occurred 45 minutes after reaching 138.degree. C. When the starch granules were essentially dissolved, the slurry was cooled to about 95.degree. C. by passing cooling water through the reactor jacket. The reactor was then depressurized and unsealed. A filter aid (CELITE.RTM. Hyflo, CELITE.RTM. Corp., Lompoc, Calif.) was added to the hot starch slurry. As much as 9.6 kg of CELITE.RTM. was added to ensure smooth filtration. A 1 foot (30.5 cm) square plate and frame press was prepared with coarse papers and cloths. Ten frames were used to process one batch. The press was preheated with hot water to minimize starch retrogradation on the filter media. The starch slurry was recirculated through the press and returned to the reaction vessel until the filtrate was clear of filter aid. At that point, the filtrate was collected in an agitated, jacketed vessel. To the filtrate, 10.2 kg of 5 DE maltodextrin (Maltrin M040, Grain Processing Co., Muscatine, Iowa) was added and agitated until completely dispersed. The starch solution was processed through a two-staged homogenizer (APV-Gaulin, Model #15NR-8TBA, Wilmington, Mass.). The homogenizer was operated at 3000 psig. The homogenate was collected in pails. The retrogradation process was continued overnight in a cold room which was maintained at 4.degree. C.

A-homogenized starch slurry was prepared as described in Method 3. The output from the homogenizer was fed to a belt flaker (Sandrik, Tolowa, N.J.). The belt 20 inch by 12 foot (50.8 cm by 30.5 cm) flaker was cooled with water sprays of 10.degree. C. The residence time (ca. 2 minutes) on the belt was adjusted to produce a set gel on the discharge end. The product temperature leaving the belt flaker was about 12.degree. C. This material was collected into pails and stored in a cold room to complete the retrogradation process. The cold room was regulated at 4.degree. C.

Due to the likelihood that the off-flavors and off-colors observed in the texturizing agent prepared in Example 5, Methods 1 and 2 were produced via lipid oxidation or degradation, the starting material, AMYLOMAIZE.RTM. VII (American Maize Products Co., Hammond, Ind.) was analyzed for lipid content in the following manner: 50 grams of AMYLOMAIZE.RTM. VII were dispersed in 200 mL of 2% sulfuric acid (w/v). The suspension was heated 70.degree. C. for 7 hours with stirring followed by slow cooling to room temperature and overnight incubation. A white slurry was observed at this point due to unhydrolyzed starch, therefore, the slurry was transferred to a 500 mL round bottom flask and the slurry was heated and refluxed for 4 to 5 hours. At this point a brown solution was obtained. The solution was allowed to cool and stand at room temperature overnight and was then neutralized with 2N NaOH (approximately 77 mL). The solution was transferred quantitatively into a 1 L separatory funnel and extracted with 300 mL of hexane. The extraction was repeated 3 more times and the hexane extracts were combined and dried by passing over sodium sulfate. The hexane extract was evaporated to dryness leaving a fat-like residue. The residue was further air-dried overnight. The weight of the hexane extract was 0.35 grams indicating a lipid content of at least 0.7% (w/v) in the AMYLOMAIZE starting material.

The purpose of this experiment was to determine the resistance to enzyme digestion of the texturizing agent prepared according to the method of Example 5, Method 2. The resistance to enzyme digestion is an indication of the degree of retrogradation (crystallinity) within the starch polymer.

The content of reducing sugars of each sample was determined using the Somogyi-Nelson Colorimetric Assay. [Somogyi-Nelson, M. (1945) J. Biol Chem. Vol. 160:61-68] For each sample to be analyzed, 25 mg of starch solids was weighed into a tared test tube to which 1.88 mL of sodium acetate buffer (pH 4.7) was added. The samples were then centrifuged at 3,000 rpm for 5 minutes in a benchtop centrifuge (Damon, Needham Heights, Mass. Model IEC-7R). Immediately following centrifugation, a 10 mL aliquot of each sample was removed and diluted to 0.5 mL with distilled water and assayed for the determination of reducing sugars prior to enzyme digestion.

To determine the reducing sugar content subsequent to enzyme treatment, an aliquot (60 .mu.L) of glucoamylase (Diazyme L-200, Solvay Enzymes, Inc., Elkhart, Ind.) and an aliquot (60 .mu.L) of .alpha.-amylase (Clarase L-40,000, Solvay Enzymes, Inc., Elkhart, Ind.) were added to the samples. The samples were then mixed on a Vortex mixer (Scientific Industries, Bohemia, N.Y.) for a few seconds. The remainder of the samples were then placed in an incubator-shaker (Lab-Line, Melrose Park, Ill., Model #3526) thermostatted to 50.degree. C. with shaking set at 200 to 250 rpm. To follow rate and/or extent of reaction, 10 .mu.L aliquots were removed and diluted to 0.5 ml with distilled water and assayed as a function of time for up to 24 hours. The samples were centrifuged as described above prior to each removal of the 10 .mu.L sample to precipitate any undigested starch that may be present in the sample. Appropriate solvent blanks were prepared according to the preceding protocol. The results are presented in Table 3 below:

The lack of reducing sugars in the texturizing agent, above background, prior to enzymatic hydrolysis indicated that little, if any, degradation of the starch polymer occurred during processing of the high amylose starch into the texturizing agent. The susceptibility of the texturizing agent to complete enzyme hydrolysis following 24 hours of incubation indicated the absence of crystalline regions within the starch matrix.

A reduced fat, reduced calorie baked cheesecake containing less than 0.8% total fat was prepared from the texturizing agent prepared in Example 6, Method 3 using the following formula:

The ingredients were processed as follows: A prehydrate blend was prepared with the xanthan gum, texturizing agent and water. Using a kitchen blender (Oster/Sunbeam Appliance Co., Memphis, Tenn., Model: OSTERIZER.TM. 10 speed) at high speed, slowly add xanthan gum and a portion of the sugar. The gum was blended for 7 minutes. The texturizing agent was added slowly to the xanthan slurry and blended at high speed for 15 minutes. The blend was then allowed to sit for at least one hour at 40.degree. F. (4.5.degree. C.).

In a separate container, the remaining dry ingredients were mixed. In another container the cheese and flavors were also combined. The cheese/flavors mixture was blended (KitchenAid, St. Joseph, Mich., Model KSM 90) slowly for 2 minutes stopping at the half way point to scrape down the sides of the bowl with a spatula. The dry blend was then added and mixed for about 2 minutes at slow speed to disperse, again stopping after about one minute to scrape the sides of the bowl. Approximately one-half of the xanthan gum/texturizing slurry was added and blended for about 30 seconds. The remainder of the xanthan gum/texturing agent mixture was then added. The combined ingredients were then mixed for an additional five minutes, scraping the sides of the bowl often with a spatula.

Aluminum pans (6.5 inch or 16.5 cm diameter) were prepared by greasing the bottoms and layering with from 8 to 10 grams of finely milled crust crumbs (A&D Ingredients, Co., East Brunswick, N.J.). The pans were filled by hand with finished batter (approx. 500 grams) and the cheesecakes were baked at 350.degree. F. (177.degree. C.) for about one hour or until lightly golden brown. The cheesecakes were then cooled to room temperature for approximately 2 hours and placed in a freezer for storage. The cheesecakes prepared by this method have a fat content of <0.8% (due to the small amount of fat introduced by the use of baker's cheese, lecithin and flavor) as compared to 23% or higher fat in the typical full-fat cheesecake for a reduction in fat content of approximately 99% and a caloric reduction of 62%. From a sensory standpoint, the cheese-cakes were of high quality and exhibited good mouthfeel and viscosity, no syneresis, good freeze/thaw stability, and flavor.

Baked cheesecake was prepared using the same formulation (on a weight percentage basis) and essentially the same procedure as presented in Example 9, Method 1, but on a large scale. Blending of ingredients was achieved using a plant scale mixer (Hobart Corp., Troy, Ohio) followed by baking in an industrial gas-fired, rotating oven. The large scale processing under plant conditions resulted in cheesecakes of improved quality relative to those produced on the small scale as described in the previous method.

A reduced fat, reduced calorie no-bake cheesecake containing less than 1.8% total fat was prepared from the texturizing agent prepared by the method of Example 6, Method 3 using the following formula:

The ingredients were processed in the following manner: the gelatin was heated with approximately 25% of the make-up water to 160.degree. F. (71.degree. C.) and allowed to cool to 140.degree. F. (60.degree. C.). In a separate container, the xanthan gum was blended with approximately 25% of the water and mixed for 10 minutes using a Virtis mixer (The Virtis Company, Inc., Gardner, N.Y., Item #176057). The remaining water was blended with the texturizing agent and mixed for 10 minutes using the Virtis mixer. The xanthan/water and texturizing agent/water blends were then combined and mixed for an additional 5 minutes.

Using a kitchen blender (KitchenAid, St. Joseph, Mich.), the cheeses were blended. The dry ingredients and vanilla were then added and mixed for 3 to 5 minutes until uniformly dispersed. The texturizing agent/xanthan gum/water blend was then added and the combined ingredients were mixed for 1 minute at speed 2. The hot gelatin (140.degree. F.; 60.degree. C.) was then mixed into the batter for 1 minute at speed 2. The batter was transferred to plastic dishes (3.75.times.3.75 inches or 9.5 cm.times.9.5 cm) which had been previously lined on the bottom with 1.5 to 2 grams of graham cracker crumbs. The cakes were then placed in a 4.degree. C. refrigerator, allowed to set, and subsequently stored in a -20.degree. C. freezer until thawed and consumed.

The resultant no-bake cheesecake had a fat content of 2.6% and exhibited good mouthfeel and flavor.

A reduced fat, reduced calorie chocolate mousse containing less than 1.1% total fat was prepared from the texturizing agent prepared in Example 6, Method 3 using the following formula:

The texturizing agent was blended with the water until well dispersed. The dry ingredients were combined and then added to the texturizing agent/water mixture in a kitchen blender. The combined ingredients were blended until uniformly dispersed. The mixture was then heated to 180.degree. F. (54.degree. C.) and held for 30 seconds at that temperature. The heated mixture was then homogenized using a Polytron Homogenizer Model PT10/35 fitted with a PT20S generator (Brinkman Instruments, Westbury, N.Y.) at 16,000 rpm for one minute. The mixture was then cooled to 100.degree. F. (38.degree. C.) on ice while continuing to homogenize at 10,000 rpm. The homogenate was further cooled to 40.degree. F. (4.degree. C.), then whipped for five minutes at high speed using a KitchenAid mixer (KitchenAid, St. Joseph, Mich.). Overrun was typically in the range of 80 to 160%.

The low amount of fat in the resultant mousse (4.1%) was contributed by that present in the cocoa powder and stabilizer mix. The fat-reduced mousse was evaluated and found to have acceptable organoleptic properties. The texturizing agent was found to contribute significantly to foam formation, foam stability, smoothness and viscosity, as compared to a negative control. No off-flavors were detectable and the mousse exhibited no unpleasant after-taste. Based on a comparison with the typical 10% fat control, the fat and caloric contents have been reduced by 90 and 46%, respectively.

Chocolate mousse was prepared using the same formulation and essentially the same procedure as presented in Example 11, Method 1 but on a larger scale. Blending of ingredients was performed using a Norman mixer followed by homogenization with a Gaulin two-stage homogenizer (APV Gaulin, Chelsea, Mass.). The homogenate was processed using a continuous whipper. By varying the product temperature and nitrogen incorporation, the degree of overrun was controlled. Specifically, overrun values of 30, 60 and 142% were achieved. The mousse produced on a large scale was of similar organoleptic quality as that produced in Example 11, Method 1.

A reduced fat, reduced calorie Alfredo sauce containing less than 13% total fat was prepared from the texturizing agent produced in Example 6, Method 3 using the following formula:

The texturizing agent and xanthan gum were mixed with the skim milk in a kitchen blender at 90.degree. C. (KitchenAid, St. Joseph, Mich.) until uniformly dispersed. The agent mixture was mixed for an additional two minutes at high speed and mixed for an additional three minutes. The butter was then blended in at high speed. The entire mixture was transferred to a heating vessel and slowly brought to a simmer (150.degree. to 160.degree. F.; 68.degree. C.). Grated Parmesan cheese was then added slowly to the blend while mixing with a whisk. The finished sauce was then pasteurized at 83.degree. C. for 30 seconds before freezing.

The sauce produced by this method was of very high quality, had excellent taste, mouthfeel, appearance, viscosity, and freeze/thaw stability. The fat content of the final product (15%) represented a 60% percent reduction from the fat content of a typical full-fat Alfredo sauce (38%). The caloric reduction was 48%.

A reduced-fat, reduced-calorie butter sauce containing 1% total fat was prepared from the texturizing agent prepared in Example 6, Method 3 using the following formula:

The ingredients were combined in a kitchen blender (Oster/Sunbeam Appliance Co., Memphis, Tenn.) and blended at high speed for 2 minutes. The blend was transferred to a glass container and heated in a microwave oven (General Electric Co., Louisville, Ky., Spacemaker Model set at power level 10) for 22 seconds. After heating, the sauce was stirred by hand.

The texturizing agent provided body, viscosity and opacity to the reduced-fat sauce.

A reduced fat, reduced calorie mayonnaise was prepared from the texturizing agent produced by the method described in Example 5, Method 1 using the following formula:

The .beta.-carotene, texturizing agent, and approximately half of the water was blended using a KitchenAid blender (KitchenAid, St. Joseph, Mich., Model K45SS) at speed 2 for 5 minutes. The xanthan gum, vinegar and remaining water were simultaneously blended for 5 minutes at half speed using a Virtis mixer (The Virtis Company, Inc., Gardner, N.Y., Item #176057). The two mixtures were combined in the KitchenAid blender and mixed for an additional 5 minutes at speed 2. The mixture was then passed through a colloid mill (Premier Mill Corp., Temple, Pa., Model KCD). The resultant mayonnaise is then deaerated in a Power Mixer with Vacuum (Whip Mix Corp., Louisville, Ky.).

This formulation and process yielded a mayonnaise with good opacity, acceptable mouthfeel and viscosity, and good storage stability. A 100% reduction in fat content was achieved relative to a typical 80% full fat mayonnaise with a caloric reduction of 90%.

Mayonnaise was prepared as in Example 13, Method 1 except using texturizing agent produced as described in Example 5, Method 3. The mayonnaise produced with this texturizing agent had improved flavor attributes relative to mayonnaises prepared using texturizing agents prepared as described in Example 5, Method 1.

Mayonnaise was prepared as in Example 13, Method 2 except soybean oil was added to a level of 3% by weight to the formulation. The 3% oil mayonnaise exhibited smoother mouthfeel, improved lubricity and increased opacity.

Mayonnaise was prepared as in Example 13, Method 2 except soybean oil was added to a level of 10% by weight to the formulation. The 10% oil mayonnaise exhibited further improvement in mouthfeel, lubricity, and opacity relative to the 3% oil mayonnaise prepared in the previous example.

The 0, 3 and 10% oil mayonnaises were prepared as in Example 13, Methods 2, 3 and 4, except liquid egg yolk was added to the formulation at a level of 5.8% by weight. In all cases, the overall appearance and organoleptic qualities of the reduced-fat mayos were enhanced especially regarding increased opacity and flavor.

A fat-free, reduced calorie Creamy Italian salad dressing was prepared from the texturizing agent produced by the method described in Example 6, Method 3 using the following formula:

The ingredients were processed in the following manner: The xanthan gum and water were mixed for 10 minutes using a LIGHTNIN.RTM. mixer (Lightnin Mixers, Rochester, N.Y.) at speed 3. The remaining dry ingredients, except the red pepper and oregano, were then added and mixed for an additional 5 minutes. The texturizing agent was blended in at speed 6 and the blend was mixed for 5 minutes. The mixture was then passed through a colloid mill (Premier Mill Corp., Temple, Pa., Model KCD). The resultant salad dressing was then deaerated in a Power Mixer with Vacuum (Whip Mix Corp., Louisville, Ky.). As a final step, the red pepper and oregano were mixed in by hand.

The fat-free Creamy Italian salad dressing produced by this method exhibited good opacity and viscosity, as well as acceptable flavor and mouthfeel.

A fat-free, reduced calorie Thousand Island salad dressing was prepared from the texturizing agent produced by the method described in Example 6, Method 3 using the following formula:

The milk, water, egg yolks and xanthan gum were combined and mixed for 10 minutes using a Virtis mixer at speed 5 (The Virtis Company, Inc., Gardner, N.Y., Item #176057). In a separate container, the remaining ingredients were combined and blended for 5 minutes in a kitchen blender (KitchenAid, St. Joseph, Mich., Model K45SS) at speed 2. The mixture was then passed through a colloid mill (Premier Mill Corp., Temple, Pa., Model KCD). The resultant salad dressing was then deaerated in a Power Mixer with Vacuum (Whip Mix Corp., Louisville, Ky.). As a final step, the red pepper and oregano were mixed in by hand.

The fat-free Thousand Island salad dressing produced by this method exhibited good opacity and viscosity as well as acceptable flavor and mouthfeel.

A reduced fat, reduced calorie chocolate frosting containing 2% fat was prepared from the texturizing agent using the following formula:

The texturizing agent was processed with standard kitchen equipment as follows:

1. Weigh the starch product and corn syrup solids into 2 separate containers and set aside.

2. Dry blend the remaining dry ingredients and set aside.

3. Add boiling water to a mini-food processor (Sunbeam Oskar Jr., chopper Plus). Slowly add the starch product while shearing. Once dispersed, shear for an additional 10 seconds.

4. Addcorn syrup solids and shear the 2 minutes to disperse. Scrape the sides of the mini-food processor as needed.

5. Combine the emulsifier and shortening. Heat until melted. Add to the above mixture while shearing for another 2 minutes.

6. Transfer the contents of the mini-food processor to the bowl of a KitchenAid mixer, equipped with the paddle attachment.

7. Add the dry blend. Mix on speed 1 for 1 minute. Increase to speed 10 and mix for 5 minutes. Scrape the sides of the mixer as needed.

The frosting produced by this method was of very high quality and had excellent texture, appearance and peaking characteristics. Comparison against a meltodextrin solids control verified the unique fat-like and bulking characteristics of the texturizing agent.

Oven-baked cakes were frosted and tested for slippage of the frosting during accelerated storage (24 hours at 100.degree. F. (38.degree. C.), 60% relative humidity). The frosting prepared with this ingredient showed virtually no slippage while commercially made low and full-fat frostings showed appreciable slippage from the cakes.

A no-fat sour cream was prepared from the texturizing agent using the following formulation:

The sour cream mix was prepared and processed in the following manner:

1. Weigh accurately the wet ingredients and dry ingredients separately.

2. Heat the wet ingredients in a batch pasteurizer to 110.degree. F. (43.degree. C.) and add the mixture of dry ingredients with continuous high speed mixing using LIGHTNIN.RTM. mixer.

3. Raise the temperature to 190.degree. F. (88.degree. C.) and hold for about 5 minutes, followed by homogenization at 2000 psi (1st stage) and 500 psi (2nd stage) pressures using a Gualin homogenizer.

4. The samples are heated again to 175.degree. F. (79.degree. C.) to repasteurize and immediately cooled to 78.degree. F. (26.degree. C.) before inoculation with sour cream starter culture.

5. After inoculation samples are incubated at 78.degree. F. (260.degree. C.) for 18 to 20 hours followed by cooling at 40.degree. F. (4.degree. C.) for 16 to 18 hours.

The texturizing agent processed with this method will produce an excellent quality no fat sour cream which have sensory attributes, stability, set and opacity characteristics superior to existing commercial products. The product can be made-easily with existing sour cream production equipment and the ingredient statement is clean.

A half-fat peanut butter spread was prepared from the texturizing agent using the following formulation:

The spread was prepared and processed in the following manner:

1. Heat the water to 100.degree. C. and place in a standard kitchen blender jar.

2. Slowly add the texturizing agent while mixing on high speed. Once dispersed, mix for five minutes.

3. Immediately transfer the paste into a bowl of a small mini-food processor (Sunbeam Oskar Jr., CHOPPER PLUS.RTM.); add peanut butter and mix until uniformly blended (about 3 minutes).

The texturizing agent processed with this method will produce an excellent quality half-fat peanut butter spread which has sensory and stability attributes that are similar to full-fat peanut butter. The product can be made easily with existing commercial equipment and the ingredient statement is clean.

Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims: