WO2025080355A1 - Substitut de gluten vegan à faible teneur en glucide et compositions alimentaires et produits les contenant - Google Patents

Substitut de gluten vegan à faible teneur en glucide et compositions alimentaires et produits les contenant Download PDF

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WO2025080355A1
WO2025080355A1 PCT/US2024/045272 US2024045272W WO2025080355A1 WO 2025080355 A1 WO2025080355 A1 WO 2025080355A1 US 2024045272 W US2024045272 W US 2024045272W WO 2025080355 A1 WO2025080355 A1 WO 2025080355A1
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composition
shred
food
shreds
gluten
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David Z. Ovadia
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Moat Consultancy
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Moat Consultancy
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    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D2/00—Treatment of flour or dough by adding materials thereto before or during baking
    • A21D2/08—Treatment of flour or dough by adding materials thereto before or during baking by adding organic substances
    • A21D2/36—Vegetable material
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/04—Products made from materials other than rye or wheat flour
    • A21D13/045—Products made from materials other than rye or wheat flour from leguminous plants
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/06—Products with modified nutritive value, e.g. with modified starch content
    • A21D13/064—Products with modified nutritive value, e.g. with modified starch content with modified protein content
    • A21D13/066—Gluten-free products
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/40—Products characterised by the type, form or use
    • A21D13/41—Pizzas
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/40—Products characterised by the type, form or use
    • A21D13/42—Tortillas
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/40—Products characterised by the type, form or use
    • A21D13/43—Flatbreads, e.g. naan
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D2/00—Treatment of flour or dough by adding materials thereto before or during baking
    • A21D2/08—Treatment of flour or dough by adding materials thereto before or during baking by adding organic substances
    • A21D2/36—Vegetable material
    • A21D2/362—Leguminous plants
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2200/00—Function of food ingredients
    • A23V2200/12—Replacer
    • A23V2200/13—Protein replacer
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2200/00—Function of food ingredients
    • A23V2200/26—Food, ingredients or supplements targeted to meet non-medical requirements, e.g. environmental, religious
    • A23V2200/264—All vegan ingredients, i.e. all animal product free

Definitions

  • raw dough such as pirozhki, pierogi, kolach, egg rolls, spring rolls, strudel, Danish pastry, empanadas, samosas, Cornish pasties, and dumplings that are subsequently baked, fried, or steamed.
  • Gluten is a storage-protein in the endosperm of grains of wheat, designed by nature to help the grain sprout and grow before it has put out roots to draw nutrients from the soil and leaves for photosynthesis to create glucose from water and carbon dioxide. Its initial growth is also helped by energy-providing starch and other nutrients located in the wheat berry.
  • Gluten possesses nutritional value as a protein consumed by millions of people around the world in bread, pizza, pita, pasta, and wheat-based Asian foods, such as egg rolls, spring rolls, lumpia, samosas, noodles, gyoza, wontons, and dumplings. Gluten is sometimes added to special diets of athletes and the elderly to help increase muscle mass.
  • gluten also plays a key functional role in making bread and other foods. Dough making involves what bakery scientists call, “gluten development,” which makes the dough stronger when mixed and sheeted. Therefore, gluten provides tensile strength and flexibility when wheat flour is mixed into a dough, kneaded, sheeted, and folded, sometimes re-sheeted and re-folded several times. In dough for both yeast-leavened bread and unleavened dough, such as egg rolls casings (skins), gluten helps create a microscopic three-dimensional network that possesses this tensile strength and flexibility. It is usually absent or of much poorer quality in gluten free (GF), lo-carb, and vegan dough-based foods.
  • GF gluten free
  • lo-carb lo-carb
  • the gluten network wraps itself around and contains microscopic wheat starch granules, as well as microscopic bubbles of air, introduced into the dough when it is mixed.
  • carbon dioxide from yeast fermentation expands the gas cells.
  • Gluten forms the continuous phase of these thin gas cell walls as they expand like tiny balloons.
  • Flexible gas cell walls in bread can be compared to bricks and mortar of a residential building.
  • Continuous gluten sheets (“mortar”) surround and encase within them spherical wheat starch granules (“bricks”). Therefore, these “bricks” are surrounded by a continuous phase of “mortar”.
  • Bricks and mortar of residential buildings are very rigid, and gas cell walls in bread are flexible.
  • Bread types include hearth bread, sandwich bread, artisan bread, sourdough bread, whole grain, and multi grain bread.
  • Breads with a filling that are facilitated by the functional role of gluten include pirozhki, pierogi and kolach.
  • Today’s flat breads around the globe include: Italian pizza; Middle Eastern pita and khubz tannour; North American maize-based and wheat flour tortilla; Indian naan and tandoori roti; Egyptian aish baladi and tanoor; and Egyptian sangak, barbari, taftoon, and lavash.
  • Some of these flat breads are used to wrap around encased fillings, such as calzones and stromboli made from pizza crust dough, wraps made from lavash, and burritos made from tortillas.
  • Pita is sometimes cut open like a purse or a pocket and filled with food, such as shawarma roasted meat or falafel fried vegetable balls and chopped vegetables, sometimes called “pocket bread” and popular in the Middle East.
  • Cornish pasties, Indian samosas, Mexican empanadas, Chinese egg rolls, spring rolls, wontons, and dumplings are made by wrapping sometimes thinly sheeted dough around a filling before baking, frying, or steaming. Many of these serve as convenient, portable, handheld meals.
  • a similar dough sheeting process is also applied to make thin (0.7-1.0 mm) outer casings (skins) for filled Asian products, such as egg rolls, spring rolls, dumplings, potstickers, and crab Rangoon.
  • Their folding, filling, and ability to contain dense, often high-moisture fillings is enabled in large part by gluten.
  • the flexibility and tensile strength of such thinly sheeted dough is provided by the gluten network. This enables sheeted dough pieces to have a filling placed in them and then be sealed.
  • the dough is not leavened, except when fried. Gas cells are formed by the expansion of trapped steam created inside the dough.
  • the gluten network is, once again, developed during dough mixing and sheeting.
  • cut dough pieces of thinly sheeted GF dough often split, crack, or fall apart when folded. They may be cut into circles (approximately 7” (18 mm) - 14” [36 mm]) or squares (approximately of side 7” [18 mm] - 14” [36 mm]) to make products with fillings such as egg rolls or burritos.
  • this splitting, cracking, or falling apart occurs, for example, either before frying in the case of egg rolls, or after baking in the case of tortillas for burritos. This renders them useless or poor quality for the reasonable containment of fillings and their commercial sale as acceptable quality foods.
  • An additional or alternative dietary concern for many consumers is the caloric content, meaning, the digestible carbohydrate content of foods that is converted into energy in the body or stored as fatty tissue.
  • the human body must generate energy to keep warm, walk, and work.
  • Starchy foods such as bread, rice, millet, potatoes, and tortillas made from corn or wheat flour have provided the energy needs of the whole human race for thousands of years.
  • Such foods, rich in high levels of starch, are usually called “high carbohydrate,” or, “hi-carb.”
  • people do not have enough of this essential nourishment.
  • industrialized countries of North America, Europe, and Australasia for example, there is a reverse problem. People eat too much food and become obese. In turn, obesity can lead to illnesses, such as heart attack, diabetes, and bone spurs from excessive body weight on feet and ankles.
  • Lo-carb foods include vegetables low in carbohydrates and high in fiber such as cabbage, broccoli, and cauliflower, carbonated beverages without sugar, and high fiber breads and breakfast cereals. The body cannot digest fiber. Therefore, a feeling of satiety can be provided by a lo-carb diet: it makes the stomach feel full, satisfying the appetite, the craving for food. Most fruits and vegetables contain pectin, a “soluble fiber,” which is lo-carb and generally regarded as good for digestion. Grains contain pectin-like soluble fiber, known as beta-glucan, pentosans, xylans, or arabinoxlyans. A grain with a high level of beta-glucan is oats. It is one of several reasons why oatmeal is popular as a health-promoting food.
  • Hi-carb starchy foods are usually derived from: (1) grains, such as wheat, rice, corn, millet, rye and barley; also, (2) legumes, such as soybeans, chickpeas, lentils, kidney beans, Lima beans, Fava beans, navy beans and Pinto beans; also, (3) tubers such as potatoes, yam, oca, cassava; and (4) others, such as sago palm. These are regarded as hi-carb ingredients.
  • a numerical measure of the digestible carbohydrate (net carbs) content of foods is often represented as “calories” of energy. This energy provides (1) heat for body warmth; and (2) the mechanical energy needed to walk, climb, swim, chop wood, or lift and move heavy objects. These calories are the energy provided when carbohydrates are digested, converted to glucose in our blood stream, and metabolized to provide energy.
  • a food might contain 20% fiber and 80% net carbs.
  • fiber can either be soluble (e.g., pectin and beta glucan) or insoluble (e.g., bran from wheat and other grains).
  • soluble e.g., pectin and beta glucan
  • insoluble e.g., bran from wheat and other grains.
  • net carbs is defined more thoroughly in the following two paragraphs.
  • cabbage and other members of the cruciferous botanical family are low in digestible carbohydrates. They are lo-carb.
  • cabbage contains 23 kCal per 100 g, only 8.5% that of white bread and 6.3% that of white wheat flour. This lo-carb% is caused, in part, by the high moisture content of these vegetables.
  • cauliflower contains 92%, cabbage 93%, and broccoli 95% moisture.
  • the energy available also depends on which type of carbohydrate is digested.
  • Simple carbohydrates such as sugars (fructose, sucrose, glucose, etc.), are sometimes single monomer units, like glucose, or dimers, two monomer units joined together, like sucrose and fructose. They differ from complex carbohydrates such as starch, when converted to energy by digestion and absorption into our bodies. All digestible carbohydrates are converted into the simple monomeric sugar, glucose, which enters the blood stream. Common granular sugar, sucrose, yields 390 kCal per 100 g, and starch 340 kCal per 100 g. Simple sugars release energy into our bodies more quickly than starches. Their chemical makeup is simpler, making them easier to digest and metabolize. They can also contribute greatly to obesity from foods and drinks.
  • Starches are polymeric in structure, comprised of about 300 - 1000 glucose monomers. There are many different types of starch, such as potato starch, wheat starch, rice starch, starches in legumes and tubers, etc. Multiple starch polymers aggregate together in nature in grains and legumes, for example, to form small, semi-crystalline starch granules, about 1 - 20 pm (micrometers, or, millionths of a meter) in diameter. The human body cannot digest them unless they are cooked, which is one reason humans cook rice, potatoes, and bake bread. These are “complex carbohydrates,” being more chemically complex than simple sugars.
  • a key attribute in lo-carb food product formulation can often be high levels of water content.
  • the net carb content of a food item can be reduced by increasing water content. If water content increases and other factors remain the same, the net carb content decreases. This can be accomplished in doughs by adding water-absorbing ingredients.
  • One example is an Oat Fiber product, VITACEL® HF 200 (J Rettenmaier USA LP, Schoolcraft, MI 49087). It absorbs above 600% of its own weight in water. This has been used in lo-carb doughs of bread and related products.
  • lo-carb products that contain gluten. Even if they are not GF, there is still significant consumer demand for lo-carb gluten-containing products. Many consumers are neither allergic to gluten nor suffer from Celiac’s disease. Therefore, for the vast majority, gluten is a nutritious protein that facilitates making many of the world’s most popular foods, such as bread, pizza, pasta, hamburger buns, hotdog rolls, egg rolls, noodles, tortillas, burritos, and so forth. When more water is incorporated into such products by using VITACEL® HF 200, for example, its starch (net carbs) and its gluten will be diluted to help make lo-carb foods.
  • Some aspects of the present disclosure are directed to functional replacements for gluten, providing at least the following seven commercial advantages, (1) - (7). They are (1) gluten free (GF), (2) low in digestible carbohydrates (lo-carb), and (3) vegan. They are also (4) higher in gastronomic quality and (5) less expensive than current GF, lo-carb, and vegan products. They are derived, in some examples, from fruit and vegetable parts discarded as trash, in contrast to current more expensive GF alternatives. Certain usually discarded fruit and vegetable parts, such as the hard, fibrous inner cores and lower stems and leaves of broccoli, Brussel sprouts, pineapple, and cauliflower, are shredded to form Julienne shreds.
  • Shred diameter is approximately 0.2 mm - 2.0 mm and length approximately 1.0 mm - 5.0 mm in some embodiments.
  • Some processes of the present disclosure provide a dough that incorporates approximately 10% - 50% of these shreds (with their original moisture included) to make a broad variety of breads. Examples include tinned breads, hearth breads, and flatbreads, such as pita, pizza, naan, tortilla, lavash, taftan (taftoon), sangak, barbari, aish baladi, tanoor, tandoori roti, and paratha.
  • aspects of the present disclosure are directed to vegan, lo-carb shred compositions useful as a replacement for gluten, or as a gluten enhancer, in doughs (and the like) and corresponding food products.
  • Other aspects of the present disclosure are directed to doughs and food products incorporating the shred compositions.
  • Some non-limiting examples of doughs and corresponding food products of the present disclosure include any known dough composition and resultant food product that conventionally includes wheat flour (or other source of gluten) as an ingredient, including bread, bread-like products, other baked products, etc., where the wheat flour (or other source of gluten, such as vital wheat gluten (VWG) extracted from low-grade wheat flour milling streams that are otherwise worthless for making bread and like products) is replaced by the shred compositions of the present disclosure.
  • VWG vital wheat gluten
  • Food, lo-carb shred compositions of the present disclosure generally include shreds of one or more types of plant-based items (e.g., portions or an entirety of one or more vegetables and/or fruits in shredded form).
  • the shreds are low in digestible carbohydrate content (lo-carb), sometimes also described as, “low in net carbs,” desired by those seeking to lose weight. They are vegan, facilitating the manufacture of vegan GF baked items such as calzones and burritos that could not, hitherto, be made to a high level of gastronomical quality.
  • the shred compositions of the present disclosure consist of shreds of one or more types of plant-based items.
  • the shred compositions of the present disclosure are or include a mixture of shreds of one or more types of plant-based items (i.e., one or more shredded components) and a separator material selected to separate the shreds from one another (e.g., a dry powder such as gluten-free flour) as described below.
  • a separator material selected to separate the shreds from one another (e.g., a dry powder such as gluten-free flour) as described below.
  • a dry powder e.g., a dry powder such as gluten-free flour
  • An analogy used previously of "bricks and mortar” describes microscopic wheat starch granules ("bricks") embedded in the continuous "mortar" of microscopic gluten sheets. The gas cell walls of leavened bread and like products are "constructed” of this allegorical "bricks and mortar” combination. Therefore, the gluten-replacing "mortar” of the present disclosure is the network of shreds, described in greater detail below.
  • raw materials for the shred compositions of the present disclosure include members of the Brassica family, in particular broccoli, cauliflower, cabbage, and Brussel sprouts, also fruits, such as pineapple.
  • a desirable part for gluten replacement, for the purposes of the present disclosure is that which is discarded, such as: the core of cabbage and pineapple, and the outer “skin” zones of the pineapple usually discarded; the outer lower leaves, particularly the thick lower stems of leaves, and the core of the cauliflower; and the stems of broccoli that are often discarded.
  • Brussel sprouts the plant looks like a miniature tree or shrub 24” (60 cm) - 47” (120 cm) tall, about 0.5” (13 mm) - 1.0” (25 mm) in diameter.
  • the Brussel sprouts grow in a helical pattern up and down the long stalk. They are harvested off this miniature “tree trunk,” its long stalk. The stalk is then discarded. However, this long stalk can be used as a raw material for some of the shred compositions or gluten replacements of the present disclosure.
  • Some of the raw materials useful with or as the shred compositions of the present disclosure may be regarded, usually, as too tough or fibrous.
  • they are often not even noticed. They also contribute desirably to the fiber content of the dough (or other food composition) and products made from it, enhancing yet further its nutritional benefit and reducing their net carb content.
  • the firmness of these fibers is greatly softened by cooking or baking. This is well known, for example, when cabbage, broccoli, cauliflower, and Brussel sprouts are cooked in water, steamed, or fried. They become extremely soft, moist, and palatable.
  • Additional vegetables in shredded form, can also be used to apply the benefits of the present disclosure, provided they can form at least a proportion of about 10%-90% of the shred composition.
  • They can include, for example, carrots, turnips, bok choy, radishes, tomatoes, green and red peppers, celery stalks and roots, beetroot, parsley, cilantro, greens (a popular vegetable emanating from the southern United States), sugar beet, sugar cane, asparagus, green beans, aubergines (egg plant), Zucchini (summer squash, courgette), pumpkin, French beans, pea pods, runner beans (butter beans, lima beans), jicama, potatoes, the bran of grains such as wheat (if GF is not required), corn (maize), barley, rye, rice, sorghum, millet, sweet potatoes, yam, and corn.
  • additional types of fruit, in shredded form can be used as or with the shred compositions of the present disclosure such as mangoes, apples, pears, peaches, nectarines, apricots, and citrus fruit such as oranges, tangerines, and grapefruit.
  • An advantage of incorporating these various fruits and vegetables can occur when there is a glut, an excess, supplied by growers. Supply may exceed consumer demand for fresh produce, as well as the demand for industrial production of various items, such as frozen or canned products. Therefore, growers may seek alternative outlets. This may be concurrent with lowering the prices of such fruits and vegetables, making it a significant economic opportunity.
  • a broad selection of grains and legumes can be harvested earlier and then shredded for use with or as the shred compositions of the present disclosure.
  • the grains or legumes can still be green and immature. Being green and relatively tender, they are then shredded with relative ease in accordance with the descriptions below.
  • soy or chickpea flour from normally harvested soy beans or chickpeas can be mixed with shreds of early-harvested green soy (edamame) beans or chickpeas, still in their immature green hulls for use with or as the shred compositions of the present disclosure. With their green hulls, they are then shredded into vitamin-C-containing shreds.
  • any one of the plant-based items described above can serve as the sole shredded component of a shred composition of the present disclosure.
  • two (or more) of the items described above can be shredded and combined for use as, or with, a shred composition of the present disclosure.
  • the selected raw material is shredded into shreds that can assume various forms or formats (e.g., size and/or shape).
  • the shreds are a well-known thin type of shred called, “Julienne.” It is well known to cooks, chefs, food technologists, and many who prepare food at home. Regardless of an exact format, in some embodiments dimensions of the shreds of the present disclosure (e.g., Julienne shreds) are approximately 0.5-2.0 mm in diameter and approximately 1.0 - 5.0 mm long.
  • the shreds of the shred composition have a diameter of in the range of 0.5-2.0 mm and a length of 1.0 - 5.0 mm; alternatively at least 80%; alternatively at least 95%.
  • the shreds and the shred compositions of the present disclosure are distinguishable or different from a puree format. With a puree form, a raw material item is grinded, milled and/or mashed into fine particles or bits that are not visually distinguishable from one another; in contrast, the shreds of the present disclosure are substantively larger than puree particles orbits, and individually ones of the shreds are visually perceptible.
  • a Julienne-type shredder can be employed.
  • Julienne shredders can be manual or mechanical.
  • One example of a manual shredder is the Oneida USA Stainless Steel Box Style Grater Shredder Slicer Cheese Citrus Zester, Oneida Limited, Sherrill, New York. It is 10” (25.4 cm) tall, 4-sided, 4” (10.2 cm) long, 3” (7.6 cm) wide, with four grating/slicing/shredding sides.
  • the Oneida Julienne shredding side is comprised of multiple slanted orifices, 2 mm in diameter, 6 mm long, slanted at approximately 30° to the perpendicular.
  • Julienne shredders can be used that make larger quantities of shred more quickly than the Oneida manual shredder. These use “shredder discs,” rotated by an electrical motor, are available in residential food processors marketed by Sharkninja Operating LLC, Needham, MA 02494, and Hamilton Beech Brands Holding Company, Glen Allen, VA 23059. However, some do not offer Julienne shredders, usually only larger-sized shreds. Julienne shredders can sometimes be ordered separately, e.g., from Hamilton Beach ih. ⁇ b.:b)#U35100).
  • a larger disc shredder for institutional kitchens is Robot Coupe’s R101P Plus Combination Processor w Julienne Disk (Robot Coupe USA, Ridgeland, MS 391 7), that also offers a Julienne shredding disc #27610. Larger scale Julienne shredders are also offered Robot Coupe and by Hobart, Troy, Ohio 45373. Suitable industrial scale equipment is available from John Bean Technologies Corporation (JBT) Lakeland, Florida 33801.
  • Firm shreds provide structure to the dough that replaces the structure provided by gluten. [48] Furthermore, it may be more difficult, but not impossible in some cases, to create firm Julienne shreds, for example, from soft, ripe, tomatoes, peaches, pears, mangoes, tomatoes, and apricots, etc. Shredding these can be enabled when they are frozen and tempered, as for meat that is frozen at, for example, 30°F (-1°C), but not deep frozen at, for example at 10°F (-12°C). Tempering of meat in this way can allow it to be cut more easily than when completely thawed.
  • tempering This process is well known to those versed in the art of meat processing as, “tempering.” Similar tempering might, in some cases, be applied to shred certain ripe fruits and vegetables, if it would provide sufficient commercial advantage. For example, a very large excess of ripe fruits or vegetables may be available that must otherwise be discarded for lack of an alternative commercial outlet for profitable sale or processing.
  • the Julienne shreds of fruits and vegetables can be an important ingredient of the shred compositions of the present disclosure. They can be used, for example, to replace gluten in wheat flour dough for bread and other related products, such as tortillas, pizza, and the outer casings of fried egg rolls or steamed and filled dumplings.
  • the fruit and vegetable shreds, directly after shredding may not be sufficient by themselves to make such products.
  • the first step is separation of shreds. Therefore, with some shred compositions of the present disclosure, a powdered dry material, for example, GF flour, can be employed.
  • the separator material serves to separate the shreds. Then, when water is added, this flour is mixed with the separated shreds to form a desirable dough or other food composition.
  • Other separator materials are also envisioned.
  • a powered dry material exhibiting a high water-holding capacity for example an Oat Fiber product, VITACEL® HF 200 (J Rettenmaier USA LP, Schoolcraft, MI 49087), can be used to replace some or all of the GF flour, providing a shred composition useful in preparing lo-carb food compositions and food products.
  • This separation of shreds on a small scale can be accomplished manually by rubbing the shreds in the GF or other flour (or other separator material) between the fingers until the shreds are separated and surrounded by flour and are no longer adhering to other shreds, as best can be accomplished.
  • separation can be enabled by thorough mixing in a ribbon blender for example, well known to those versed in the art of preparing dry blends for the food industry. If moisture needs to be removed from the resultant shred composition before packing, storing, and shipping, this may be accomplished by one of several drying technologies practiced in the food industry.
  • the shred composition e.g., mixture of GF or other flour and the moist shreds
  • the shred composition could be packaged, frozen, stored, sold and transported as a frozen ingredient. This increases the weight and cost of shipping, compared to dried shreds, but promises to retain the valuable vitamin C of many types of shred, noted above.
  • a “food composition” in in reference to a mixture or recipe of various ingredients that can be converted into a “food product” with further processing (e.g., sheeting, cutting, baking, drying, etc.).
  • Food compositions of the present disclosure are doughs that include the shred composition as described above, and one or more additional ingredients such as water and other conventional ingredients implicated by the particular food composition/food product desired.
  • the doughs, and resultant food products are gluten free.
  • the food compositions and food products of the present disclosure are of a known format and conventionally include wheat flour (or other source of gluten), except that the wheat flour (or other source of gluten) is replaced by a shred composition as described above.
  • Gluten-free food products according to embodiments of the present disclosure contain less than 20 ppm gluten, preferably less than 10 ppm gluten and, more particularly, 0% by weight of gluten.
  • gluten content can be determined by the gliadin content.
  • food compositions and food products of the present disclosure are gluten free, vegan, and lo-carb. In other embodiments, food compositions and food products of the present disclosure need not necessarily be gluten free, but exhibit one or more attributes including vegan, lo-carb, gluten enhanced, and/or vitamin C enhanced. Regardless, the food compositions and food products of the present disclosure contain 10%-50% by weight of the plant-based shreds as described above, with the original moisture of the fruit or vegetable included.
  • Some food compositions and food products incorporate the functional gluten replacements of the present disclosure include baked products like bread, pizza, pita, and tortilla, and fried Asian products, such as egg rolls. They are based on shredded components of fruits and vegetables. They are gluten free (GF) and therefore suitable for those suffering from gluten allergy and Celiac’s disease. These shreds are low in digestible carbohydrate content (lo-carb), sometimes also described as, “low in net carbs,” desired by those seeking to lose weight. They are vegan, facilitating the manufacture of vegan GF baked items such as calzones and burritos, which could not, hitherto, be made to a high level of gastronomical quality.
  • This higher level of gastronomic quality refers particularly to the tensile strength, and the springy, flexible texture of such flat breads as pita, naan, tortillas and pizza crusts, and thin sheets (skins) of egg roll casing dough.
  • Many current GF alternatives of such doughs and their end products are usually brittle and cannot be folded conveniently without cracking, breaking, falling apart, or failing in some such fashion. This can prevent the manufacture, for example, of acceptable GF calzones, burritos, and egg rolls.
  • superior elasticity and tensile strength of dough and food products made from it are accomplished by inclusion of the fruit and vegetable shreds in dough at levels of approximately 10% - 50%.
  • Such dough can be used to make bread, pizza, naan, lavash, tortillas, egg rolls, dumplings, strudel, Danish pastry, wontons, spring rolls, calzones, burritos, Cornish pasties, and many other like products.
  • the shreds serve as a functional replacement for gluten that is (1) gluten free (GF), (2) low in digestible carbohydrates (lo-carb), (3) vegan, and (4) relatively inexpensive, compared to alternative ingredients currently used to make such products.
  • the food composition includes the shreds as described above mixed with a separator material (e.g., gluten free flour), when water is added, this flour is mixed with the separated shreds to form a desirable dough.
  • a separator material e.g., gluten free flour
  • this flour is mixed with the separated shreds to form a desirable dough.
  • high quality products can be made, for example, bread, tortillas, pita, Calzones, Cornish pasties, kolach, burritos, taquitos, dumplings, wontons, egg rolls, spring rolls, and many others.
  • sheeting can be an important step. Sheeting provides additional structure to dough because it stretches and aligns the dough in a structural fashion. It creates a tension within the sheeted dough that allows it to rise in tinned sandwich bread, for example, but also in hearth bread, where there are no baking tins and loaves are baked on a completely flat baking surface in the oven. If a proofed dough piece for hearth bread is roughly hemispherical in shape, then, after proofing, the baked loaf of bread will also be roughly hemispherical in shape.
  • Hearth bread can and often does rise to a loaf height of about 3” (8 mm) - 5” (13 mm), depending on the size and type of the dough.
  • the dough development mechanism may be similar in principle to the process of structural alignment within the dough during the sheeting of wheat flour dough that contains gluten.
  • Other examples of food compositions and food products of the present disclosure include food products intended to be wrapped onto themselves and/or filled food products. With these and similar products, the inventor of the present disclosure has surmised that the shredded fibers become aligned, a little like fibers of cloth material, and create a tensile strength and an elastic flexibility that, for example, allow encased, filled products, such as calzones, burritos, egg rolls, strudel, Danish pastries, empanadas, samosas, and dumplings to be made. These products are made by thinly sheeting dough to about 1 mm thickness that must possess tensile strength so as not to fall apart.
  • tortillas Another category of food compositions and food products of the present disclosure include tortillas.
  • wheat flour and com (maize) tortillas often abbreviated as, “flour tortillas” and, “corn tortillas”.
  • corn (maize) base There are two main types of commonly available tortilla made from: (1) wheat flour, popular in the United States, Europe, and around the world; and (2) corn (maize) base called nixtamal, popular in Mexico and Latin America.
  • Com tortillas are made from a base called nixtamal, made from cooking corn in an alkali solution.
  • Masa or, masa di maiz
  • corn masa flour or, “masa harina,” in many stores in the United States.
  • Corn tortillas are readily available in the United States, Europe, and worldwide, but are generally less popular than wheat flour tortillas. By contrast, in Mexico and Central America, 98% of the tortillas are made from corn.
  • the term “corn” today usually means “maize,” but in old English and in the Bible, “com” is a general term meaning, “grain,” such as wheat and barley. Maize was unknown to the Middle East in Biblical times. Therefore, reference to “corn” as meaning, “maize,” needs to be emphasized in the context of the present disclosure. In towns in the UK today, cities still have buildings called, “the com exchange,” meaning, “the grain exchange” for exchanging grains in years past that did not include maize. In the following, “corn tortillas” will be used to mean tortillas made from maize.
  • Wheat flour tortillas are flexible, can be folded and made into many filled products, such as burritos,zihangas, taquitos, enchiladas, and other foods of this general type. However, such foods are not GF.
  • corn tortillas are indeed GF, but they tend to be fragile, brittle, and fall apart easily when handled. They are often used to make tacos, after being folded into a “U” shape, often baked into that shape as a dry, crispy form, like a large simple “U” shaped tortilla chip, into which fillings are placed.
  • the shred compositions of the present disclosure can be used as an inexpensive GF gluten replacer, providing the tensile strength and flexibility of wheat flour tortillas. With these and similar food composition and food product of the present disclosure, the commercial potential of making corn-based burritos and like products would be great.
  • compositions and food products of the present disclosure include corn tortillas.
  • Com tortillas are GF, but they usually fall apart when folded to make burritos and other similar products with a moist filling.
  • Wheat flour tortillas are not GF, but they are flexible and possess tensile strength. They can be used to make burritos and such products without splitting, cracking, or falling apart.
  • the masa dough formula can include a certain percentage, approximately 10% - 50%, of the shreds of the present disclosure, made from health-promoting cauliflower or other health-promoting shreds of the present disclosure; or (2) additional shreds of the present disclosure can be made from corn itself and included in the formula, the advantage of the second approach being that the important label declaration of ingredients on the packaging of commercially available products. It is important in the eyes of customers. It does not need to be changed, because “corn” is being replaced by “corn”, even if it is a slightly different form of corn.
  • these corn shreds can be included in the tortilla dough formula at levels approximately between 10% - 50%.
  • this dough could be used to make egg rolls, samosas, calzones, and other such products.
  • burritos made from com masa with its unique flavors and colors.
  • creating com shreds can enable the making of flexible GF corn tortillas and GF burritos, for example, without splitting, cracking, and falling apart. It can be accomplished, for example, in at least two methods, in both instances starting from whole kernels of corn that have not been nixtamalized, based on two commonly available forms of corn kernel.
  • the first method uses dried corn kernels, readily available for animal feed and many other purposes, and it is relatively inexpensive.
  • the kernels can first be hydrated to swell with water, perhaps by soaking in water overnight or another method, such as steaming.
  • the second method takes corn that is ripe but not yet dried, as used to make corn on the cob at home by cooking, baking or grilling on the BBQ, or in the food industry for making cans of whole kernel corn or frozen corn kernels.
  • the com kernels can be passed through a Julienne-type shredder or other suitable device to produce the dough-enhancing shreds of this invention.
  • the second method can shred com from: directly from the cob; kernels freshly separated from the cob, as for cans of whole kernel corn; as corn kernels that have been frozen and thawed or partially thawed; from canned corn kernels; or by other means yet to be developed to yield the shreds of the present disclosure.
  • Food compositions and food products of the present disclosure are not gluten free in some embodiments. With these and related embodiments, the value of the dough (or other food compositions) of the present disclosure and its component shreds are not confined to GF products, even if these are considered promising commercially.
  • the shreds as prepared and used to make a dough provide structure, tensile strength, and flexibility to GF dough that, without the shreds of the present disclosure, lack these attributes. However, if there are gluten-containing wheat flour doughs that are partially lacking in these attributes, the shreds of the present disclosure and their application, described above, can serve to “strengthen” or enhance the gluten of an otherwise “weak” dough.
  • a weak dough may possess an insufficient degree of gluten functionality. This means it does not provide sufficient tensile strength and elastic flexibility required for the product being made from it. Therefore, the dough must be fortified in some way in practice, often by adding expensive vital wheat gluten.
  • the solution is often to add vital wheat gluten as a separate ingredient, which is expensive.
  • the fruit and vegetable shreds of the present disclosure promise to be cheaper, being made from products usually discarded as trash in some non-limiting examples. Also, as “health giving cauliflower,” for example, the inclusion of these shreds can enhance the “healthy,” “good for you” appeal of the product to the buying public.
  • Some food compositions and food products of the present disclosure are characterized by an enhanced level of vitamin C.
  • addition of broccoli or cauliflower shreds offers four more commercial advantages to wheat-based doughs and breads: (1) more fiber is added to the finished product, as desired by many health conscious consumers; (2) cauliflower and other fruits and vegetables, irrespective of fiber, are generally perceived as health promoting ingredients, with many GF, lo-carb pizza crusts advertising, for example, “contains cauliflower”; (3) broccoli, cauliflower, cabbage and other members of the Brassica botanical family are also rich in healthpromoting vitamin C.
  • Cauliflower for example, contains around 52 mg vitamin C per 100 grams, close to the same as for oranges; and (4) vitamin C is well known to those versed in the art of dough making to contribute significantly to improving yet further the development of a strong wheat-flour-based dough.
  • Vitamin C as a separate ingredient added to dough to make it stronger is costly, but it is as an integral part of the above noted inexpensive shreds of the present disclosure. They can be made from, for example, Brussel sprouts, cauliflower, cabbage, pineapple, and additional shreds types that can include mango, parsley, cilantro, citrus fruit, all of which are inherently rich in vitamin C.
  • Some food compositions and food products of the present disclosure are characterized as lo-carb that may or may not be gluten free.
  • some food compositions and food products of the present disclosure that otherwise incorporate or include some examples of the shred compositions are baked, fried, or steamed items that are GF, lo-carb, vegan, and high in fiber.
  • the shreds of the shred composition can be prepared from a raw material high in moisture content, such as fruits and/or vegetables, for example a moisture content in the range of approximately 85% - 95%.
  • the separator material used with the corresponding shred composition can be dry powdered material with a high water-holding capacity, such, but not limited to, the VITACEL® HF 200 oat fiber product mentioned above (available from J Rettenmaier USA LP, of Schoolcraft, MI) and other commercially available high-fiber, lo-carb ingredients with low to zero net carbs that absorb high levels of water and have been used to manufacture lo-carb baked products.
  • VITACEL® HF 200 oat fiber product available from J Rettenmaier USA LP, of Schoolcraft, MI
  • These and similar products are formulated to absorb a substantive amount of water (e.g., above 600% of its own weight in water), and have been used in lo-carb doughs of bread and related products.
  • the high water-holding capacity dry powder material can be added to replace some or all the GF flour in doughs (or other food compositions) of the present disclosure and described elsewhere except it is lo-carb.
  • the level of water in the dough formula can be adjusted as desired. This will depend on the level of absorption of water by the fiber, percent inclusion of the water-absorbing fiber, how much GF flour is replaced, and additional formula tweaks as may be necessary to make good, tasty baked products. Therefore, by using HF 200 and other high-fiber, high- water-absorbing ingredients in some doughs or other food compositions of the present disclosure, baked products can be made that are lo-carb and high fiber, and optionally GF and vegan. Moreover, vitamin C content of the baked product from shredded fiber of fruits and vegetables of some examples of the present disclosure may be significant.
  • some shred materials of the present disclosure comprise shreds formed from grains and/or legumes.
  • a broad selection of grains and legumes can be harvested earlier and then shredded according to the present disclosure.
  • the grains or legumes can still be green and immature.
  • they may also contain high levels of vitamin C. Being green and relatively tender, they are then shredded with relative ease into the Julienne shreds of the present disclosure.
  • they can be applied to dry flour made from the same crop grown to maturity and milled into flour as usual. This flour and the shreds are then mixed, as described above, separating the shreds in the shred composition.
  • the mixture can then be made into dough, sheeted, and made, for example tortillas.
  • the tortillas for example, are flexible and possess tensile strength. This being so, such tortillas can also be used to make, for example, burritos and like products.
  • This approach can be applied to a very broad spectrum of grains and legumes.
  • soy or chickpea flour from normally harvested soy beans or chickpeas can be mixed with shreds of early-harvested green soy (edamame) beans or chickpeas, still in their immature green hulls.
  • flexible tortillas and burritos could be made from flour made in the current fashion from soy, chickpeas, sorghum, millet, rye, and rice, and others, all of which cannot usually be used to make, for example, flexible tortillas and burritos.
  • Example Dough Dough #1. Shreds were prepared by processing thick bases of cauliflower leaves by a Julienne-type shredder from Oneida USA Stainless Steel Box Style Grater Shredder Slicer Cheese Citrus Zester, Oneida Limited, Sherrill, New York. Excluded were the white florets of cauliflower usually cooked and eaten as a vegetable.
  • the shredder was 10” (25.4 cm) tall, 4-sided, 4” (10.2 cm) long, 3” (7.6 cm) wide, with four grating/ slicing/ shredding sides.
  • the Oneida Julienne shredding side was comprised of multiple slanted orifices, 2 mm in diameter, 6 mm long, slanted at approximately 30° to the perpendicular.
  • the so-formed shreds were mixed with a separator material in the form of a commercially available GF flour under the trade designation Gluten Free All Purpose Flour made by Divided Sunset, Chicago, IL 60647.
  • Ingredients of the GF flour rice flour; tapioca starch; potato starch, xanthan gum, and salt.
  • the resultant shred composition was then mixed with other ingredients to form a dough (“Dough #1”) by: 41.0% of the GF flour; 30.0% water, 5.0% soybean oil, and 24.0% shredded thick bases of cauliflower leaves usually discarded, and lower central core of cauliflower usually discarded.
  • the shreds (as with other vegetables) with high moisture content (e.g., around 92% moisture), high moisture liquid, mostly water, was partially exuded from them and this makes them stick together. Therefore, the 24.0% shreds were mixed with 41.0% GF flour in a way that thoroughly separates the shreds with the help of mixing.
  • the 30.0% water was added to the shred composition and the dough subsequently mixed, the shreds were thoroughly and uniformly separated within the dough.
  • Comparative Example Dough Dough #2.
  • a comparative example dough (“Dough #2”) was prepared similar to Dough #1, except that the shreds of Dough #1 were not included.
  • cauliflower is comprised of 92% moisture and 8% dry solids. Therefore, in the formula of Dough #2, moisture of the cauliflower (22% of the formula) was replaced as 22% more water. The 8% cauliflower solids were replaced with GF flour, adding 2% more GF flour to the formula.
  • the formula for Dough #2 was, therefore: 43.0% GF flour; 52% water; and 5% soybean oil.
  • Example Food Product Burritos weighing on average 124 g (4.37 oz) were made from 26.2 cm (10.3") diameter tortillas weighing, on average, 64.0 g (2.26 oz) and filled with 60 g (2.12 oz) of RosaritaTM Traditional Refried Beans (Conagra Brands, Chicago, IL60654, USA). To make the tortillas, 150 g (5.29 oz) portions of Dough #1 were rounded manually, covered in a bowl to prevent drying and left to rest for 20 minutes. They were then sheeted in a mechanical sheeter (Model CDR 100, Somerset Industries, Lowell, MA 01852).
  • An inverted circular pan was used to cut out a circular sheeted dough piece 27.9 cm (11 .0") in diameter that weighed on average 71 g (2.50 oz).
  • the tortillas shrank on average to 26.2 cm (10.3 inch) diameter and weighed on average 64 g (2.26 oz).
  • the filling of 60 g (2.12 oz) RosaritaTM Traditional Refried Beans was placed in the center of the tortillas. Burritos were then made by folding and rolling the tortillas in traditional fashion. They were cylindrical in shape, on average 11.5 cm (4.53 inch) long. Their cross section was elliptical, on average 4.81 cm (1.99 inch) wide and 2.92 cm (1.15 inch) high.
  • the tortilla was flexible and did not crack, split or break apart when the burrito was made.
  • the shreds, shred compositions, food compositions, and food products of the present disclosure provide a marked improvement over previous designs.
  • the effective vegan gluten replacement ingredients of the present disclosure can supply the consumer demands for foods that are (1) lo-carb, (2) GF, and (3) vegan, (4) at lower cost, and (5) pertaining to a higher standard of gastronomical quality, given that the current quality of such products is often very poor. Even when dieting with lo-carb foods, or eating GF or vegan foods, people still want to enjoy eating. Therefore, better tasting lo-carb, GF, or vegan foods of the present disclosure, which often possess very poor gastronomic quality, addresses a widespread consumer need.
  • the Caulipower® company Encino, CA 91436) and Milton’s® Craft Bakers (Milton’s Baking Company, Carlsbad, CA 92008) both market GF frozen pizza containing cauliflower as the primary ingredient in the crust. Both emphasize on their packaging that these are, “Cauliflower Crusts.” In both instances, the crusts also contain xanthan gum, non-vegan egg, hi-carb rice flour, and hi-carb tapioca starch.
  • US Publication No. 2019/0008191 describes a “gluten-free cauliflower-based pizza dough” and method of making. Its ingredients include pureed cauliflower, egg whites, and several types of cheese. These can provide some limited measure of dough and crust tensile strength and flexibility, usually provided more effectively by gluten. Thickening agents include potato flour, chickpea flour, and brown rice flour, but they do not include the shredded fruits and vegetables of this invention that provide strength in place of gluten.
  • GB Publication No. 2,447,978 and US Publication No. 2016/0150798 Al both use egg whites to form a stable crust. The former creates dough and batter made from foamed egg white. The latter makes dough containing 45%-55% dried egg whites.
  • the thickness of the bread and like products of the present disclosure varies greatly from raw sheeted egg roll skins about 1 mm thick, to flatbreads about 3 - 7 mm thick, to loaves of bread about 8 cm (3 inch) to 13 cm (5 inch) thick/tall.
  • the films of the ‘763 Patent are typically used in many cases as a replacement for the seaweedbased “nori” wrap in making oriental wrapped foods such as sushi and onigiri. This replacement can serve, in some cases, those who dislike the fishy flavor and aroma of seaweed, traditionally used to wrap sushi products.
  • the wraps, the thin sheets of the ‘763 Patent, are destroyed by the heat of cooking. They are not intended for cooking. They may contain cooked and cooled rice, and other typical sushi fillings, but are not designed to be cooked themselves.
  • Flatbread or egg rolls for example, made by way of the present disclosure, are created by the heat of baking, frying, or steaming. They are often purchased as frozen items that are reheated in a regular oven, toaster oven, air fryer, or microwave oven.
  • the strength and flexibility of sheeted dough and flatbreads of some embodiments of the present disclosure are created by the inclusion of Julienne shredded fibers, approximately 0.2 mm - 2 mm in diameter and 1 mm - 5 mm long.
  • the fruit and vegetables of the ‘763 Patent are made from puree, in contrast to the shreds of the present disclosure.
  • the Gem WrapsTM sheets are usually sold like thin sheets of paper to be used for cold foods and based upon the ‘763 Patent. They comprise at least 75% - 100% fruit or vegetable puree.
  • some embodiments of the present disclosure create a bread-like dough, with typically 10% - 50% fruit or vegetable shreds in the dough formulation. Once mixed with the 50% - 90% of other ingredients, the dough is then sheeted into a multiplicity of shapes and forms. They are sometimes topped, as for pizza, or filled, as for burritos, sometimes filled and then baked, fried, or steamed to deliver finished products for consumption.

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Abstract

L'invention concerne des substituts fonctionnels pour gluten dans des produits cuits tels que le pain, la pizza, le pita et la tortilla, et des produits asiatiques frits, tels que des pâtés impériaux. Ils sont à base de composants déchiquetés de fruits et de légumes. Ils sont exempts de gluten (GF) et donc adaptés à ceux souffrant d'allergie au gluten et de la maladie cœliaque. Ces fragments sont à faible teneur en glucides digestibles (lo-carb), parfois également décrits comme "à faible teneur en glucides nets," ce qui est souhaité par les personnes cherchant à perdre du poids. Ils sont vegan, facilitant la production d'articles cuits GF vegan tels que des calzones et des burritos, qui ne pouvaient pas, jusqu'à présent, être produits à un niveau élevé de qualité gastronomique.
PCT/US2024/045272 2023-10-09 2024-09-05 Substitut de gluten vegan à faible teneur en glucide et compositions alimentaires et produits les contenant Pending WO2025080355A1 (fr)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050238780A1 (en) * 2004-04-13 2005-10-27 General Mills Marketing, Inc. Rolled dough compositions and related methods and products
US20180242620A1 (en) * 2017-02-24 2018-08-30 Ju Han Steve Song Shredded dried food products
US20190208808A1 (en) * 2012-06-05 2019-07-11 Intercontinental Great Brands Llc Production of Shredded Products With Inclusions
US20200315187A1 (en) * 2016-06-05 2020-10-08 Mondelez Europe Gmbh Baked savory food composition comprising shredded root vegetable and method of making the same
WO2023041794A1 (fr) * 2021-09-20 2023-03-23 Migros Industrie Ag Produit alimentaire végétalien tel qu'un œuf végétalien

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050238780A1 (en) * 2004-04-13 2005-10-27 General Mills Marketing, Inc. Rolled dough compositions and related methods and products
US20190208808A1 (en) * 2012-06-05 2019-07-11 Intercontinental Great Brands Llc Production of Shredded Products With Inclusions
US20200315187A1 (en) * 2016-06-05 2020-10-08 Mondelez Europe Gmbh Baked savory food composition comprising shredded root vegetable and method of making the same
US20180242620A1 (en) * 2017-02-24 2018-08-30 Ju Han Steve Song Shredded dried food products
WO2023041794A1 (fr) * 2021-09-20 2023-03-23 Migros Industrie Ag Produit alimentaire végétalien tel qu'un œuf végétalien

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