Process for preparing an aerated food product comprising protein and fiber

1. A process for preparing an aerated food product that maintains good taste, texture and density, the process comprising the steps of:

a) preparing a liquid carbohydrate blend comprising saccharide and fiber, the preparing comprising mixing and heating liquid and solid carbohydrates in a mixer at a temperature that dissolves the solid carbohydrate but does not boil the mixture and does not concentrate the liquid carbohydrate blend;

b) preparing a hydrocolloid blend comprising hydrating hydrocolloid and a carbohydrate in a separated high shear mixer;

c) mixing the carbohydrate blend of a) with the heated hydrated hydrocolloid blend of b) in a mixer to form a homogenous blend;

d) adding to the homogenous blend of c), a dry food product comprising fiber, about 4-45% protein that has not been treated with fat and about 1-5% of a whipping agent and mixing, in a double arm mixer, the homogenous blend and dry food product for about 1 minute at about 60 RPM to form a dough that has a density of 1.00 g/cc to 1.1 g/cc;

e) aerating the dough in double arm mixer for about 5 to 15 minutes at about 120 RPM to obtain a semi-moist, non-sticky aerated food product having a density of 0.4 g/cc to 0.9 g/cc, wherein no gas or chemical for gassing is added during the aeration process; and wherein optionally fiber is added after aeration;

f) optionally, adding flavors and fat to the aerated food product; and

g) shaping the aerated food product without the need for further cooling, drying or setting;

wherein the aerated food product comprises from about 50 to 80% carbohydrate of which about 4% to 70% of the carbohydrate is fiber.

2. The process of claim 1 , wherein in step a), the liquid blend is heated to a temperature of about 75° to 105° C.

3. The process of claim 1 , wherein the carbohydrate of step a) is selected from the group consisting of sugar, fructose, dextrose, polydextrose, honey, maple syrup, hickory syrup, sugar beet syrup, cane syrup, molasses, brown rice syrup, agave syrup, yacon syrup, stevia syrup or powder, high fructose corn syrups, high maltose corn syrups, corn syrup 42 DE, corn syrup 62 DE, Inverted Syrups, Glycerin, Sorbitol Syrup, Crystal Maltitol, Maltitol Syrup, Isomalt, Xylitol, lactitol, erythritol, manitol, fructo-oligosacharide, oligofructose, maltodextrin, cellulose gel, fruit fiber, corn dextrin, wheat dextrin, sugar beet fiber, psyllium, citrus fiber, vegetable fiber, apple pectin, xanthan gum fiber, arabic gum fiber and combinations thereof.

4. The process of claim 1 , wherein the hydrocolloid is selected from the group consisting of arabic, tragacanth, karaya, ghatti, agar, alginate, carrageenan, locust bean gum, psyllium, quince, tamarind, corn hull gum, pectin, arabinogalactan, dexran, xanthan, curdlan and mixtures thereof.

5. The process of claim 1 , wherein protein of the dry food product of step d) is selected from the group consisting of whey, gelatin, soy, milk protein, egg, vegetable protein and combinations thereof.

6. The process of claim 1 , wherein the whipping agent in the dry food product of step d) further comprises a whipping aid.

7. The process of claim 1 , wherein the whipping agent is selected from the group consisting of egg albumen, soy protein enzyme modified and mixtures thereof.

8. The process of claim 6 wherein the whipping aid is a lactate of sodium, potassium or calcium.

9. The process of claim 1 , wherein in step f) flavor is mixed with the aerated dough for 15-30 seconds at 15 to 60 RPM.

10. The process of claim 1 , wherein in step f) fat is mixed with the aerated dough for 15-75 seconds at 15-60 RPM.

11. The process of claim 1 , wherein in step a) a mixture of glycerin and corn syrup 62 DE are mixed with salt, maltodextrin 150, inulin, fructose and sugar at about 80 to 82 degrees centigrade; wherein in step b) pectin, water, sodium citrate and sugar are mixed together and heated to about 100 degrees centigrade and then cooled to about 85 degrees centigrade; wherein in step d) whey protein isolate hydrolyzed, whey protein concentrate, soy protein isolate, soy protein enzyme modified and inulin are added and mixed with the blend of step c) for about 50 seconds at 60 RPM; and wherein in step e) color is added to the dough and then the dough and color are whipped for about 8 to 12 minutes at 120 RPM and wherein in step f) inulin, peanut flour and flavors are added to the whipped dough.

12. The process of claim 1 , wherein in step a) a mixture of glycerin, water, potassium lactate, invert syrup and corn syrup 62 DE are mixed with fructose at about 75 to 80 degrees centigrade; wherein in step b) pectin, fructose and water are mixed together and heated to about 100 degrees centigrade and then cooled to about 85 degrees centigrade; wherein in step d), whey protein isolate, calcium caseinate, tartaric acid, salt and cocoa are added and mixed with the blend of step c) for about 50 seconds at 60 RPM; and wherein in step e), the dough is whipped for about 8 to 12 minutes at 120 RPM; and wherein in step f) flavors are added to the whipped dough.

13. The process of claim 1 , wherein in step a) a mixture of glycerin, water, potassium lactate, invert syrup and corn syrup 62 DE are mixed with fructose at about 75 to 80 degrees centigrade; wherein in step b) fructose, carrageenan and water are mixed together and heated and maintained at 85 degrees centigrade; wherein in step d), soy protein enzyme modified, oat fiber, inulin, cellulose gel, maltodextrin fiber, salt and titanium dioxide are added and mixed with the blend of step c) for about 50 seconds at 60 RPM; and wherein in step e) the dough is whipped for about 8 to 12 minutes at 120 RPM; and wherein in step f) melted fractionated palm oil mixed into the whipped dough for 10 to 15 seconds at about 15 to 60 RPM; and wherein in step g) the dough is immediately slabbed into a layer.

14. The process of claim 1 , wherein in step a) hydrated fructooligosaccharide, crystalline fructose and glycerine are blended; wherein in step b) water, alginate and crystalline fructose are blended; wherein in step d) a homogenous blend of a) and b) is mixed with whey protein, casein calcium, dried egg albumin, gelatin, corn dextrin, crystalline sorbitol powder, salt, chocolate flavor, instant coffee gold cup tartaric acid, ethyl vanillin flavor, a vitamin blend and encapsulated magnesium oxide 40% to form a dough; and wherein in step e) the dough of d) is whipped.