Process for the controlled introduction of oil into food products
A process for the application of a predetermined amount of oil to food pieces comprises: (a) providing or receiving a plurality of cut or shaped food pieces; (b) applying an oil-water emulsion to the food pieces for a time sufficient to provide a predetermined amount of oil to the food pieces and so that the food pieces have an initial moisture level after applying the oil-water emulsion; and (c) reducing the initial moisture level, in the absence of frying in oil, to a moisture level of from about 0.2 to about 80% by weight to provide a cooked food product, comprising said predetermined amount of oil, wherein step (c) does not comprises frying the food pieces in hot oil.
1. A method of making a snack food product comprising,
(a) providing a plurality of cut or shaped food pieces comprising a fruit or a vegetable;
(b) exposing the food pieces to a solution comprising about 0.1-5 wt % of one or more starch-reducing enzymes and about 0.1 to about 5 wt % CaCl 2 ;
(c) thereafter blanching the food pieces for a time sufficient to inactivate the enzymes and rinsing the food pieces with water, wherein the food pieces have an initial moisture level after the blanching step:
(d) applying an emulsion consisting essentially of oil and water, said emulsion comprising salt (NaCl), for a tune sufficient to provide a predetermined amount of oil to the food pieces and so that the food pieces have an initial moisture level after applying the emulsion;
(e) reducing the initial moisture level of the food pieces by cooking the food pieces in bulk in at least one oven or drier set at a first temperature of about 325-450° F. for a first time period of about 0.5-40 min. to reduce the initial moisture level to an intermediate moisture level; and
(f) cooking a bulk quantity of the intermediate moisture food pieces in the one or more driers or ovens set at a second temperature of about 225-325° F. for a second time period of about 4-35 minutes, wherein the second temperature is lower than the first temperature, wherein the food pieces are not cooked or fried in hot oil, to yield a snack food product having moisture level of about 0.2-20 wt-%; and a fat content of up to about 35 wt-%, wherein the snack food product exhibits one or more characteristics of a snack food product produced by frying a food piece in oil wherein the characteristics are selected from the group consisting of texture, flavor, crispness, crunchiness, color and appearance.
2. The method of claim 1 , wherein in step (f), the food pieces are cooked at about 300-325° F.
3. The method of claim 2 , wherein the food pieces are cooked in a dryer/oven providing an air velocity of about 500-10,000 feet per minute.
4. The method of claim 1 , wherein in step (e) the food pieces are cooked for a time of about 0.5 to about 14 minutes.
5. The method of claim 1 wherein the food pieces are cooked at about 350-400° F. in step (e).
6. The method of claim 1 , wherein step (f) comprises cooking the food pieces at a temperature of about 275-300° F. for a time of about 6 to about 12 minutes.
7. The method of claim 1 , wherein the food pieces are cooled and stored at ambient, refrigeration or freezer conditions after the food pieces are brought to the first temperature for the first time period, and before the food pieces are brought to the second temperature for the second time period.
8. The method of claim 1 wherein the food pieces are exposed to a solution comprising one or more of amylase or amyloglucosidase.
9. The method of claim 8 wherein in step (b) the food pieces are exposed to the solution for time of about 1 to about 3 minutes.
10. The method of claim 1 , wherein the food pieces are cooked in at least one rotary drier or oven, at least one fluidized bed drier or oven or at least one microwave drier or oven.
11. The method of claim 1 , wherein said food is selected from the group consisting of beets, zucchini, carrots, eggplant, apples, pears, bananas, rutabaga, plantain, taro, okra, onions, parsnips, yams, sweet potatoes, yucca , and potatoes.
12. The method of claim 1 , wherein said cut food pieces are slices, strips or sticks.
13. The method of claim 1 , wherein said blanching comprises a wet blanch.
14. The method of claim 13 , wherein said wet blanch comprises treating said cut food pieces in an aqueous solution at a temperature of about 140° F.-248° F. and for about 15 seconds to about 10 minutes.
15. The method of claim 1 , wherein the emulsion is sprayed onto the food pieces.
16. The method of claim 15 wherein the emulsion comprises about 5-85 wt-% oil.
17. The method of claim 1 further comprises rinsing the food pieces with water and drying the food pieces prior to applying the emulsion to the food pieces.
18. The method of claim 1 , wherein the fat content of the snack food product is up to about 15 wt-%.
19. The method of claim 1 wherein the final moisture level is about 2-5 wt-%.
20. The method of claim 1 wherein the pieces are fluidized in air by said at least one drier or oven in steps (e) or (f).
21. The method of claim 1 wherein the snack food product has a fat content of less than about 0.5 wt-%.
22. The method of claim 1 wherein the intermediate moisture level is about 40-70%.
23. A food product produced by the process of claim 1 .
24. The method of claim 1 wherein the emulsion does not contain an exogenous emulsifier or surfactant.