Phytosterol esterification product and method of make same

Abstract

An ingredient suitable for use in the manufacture of specialty margarines and bakery shortenings with nutritional and functional benefits is the reaction product of a phytosterol material esterified with a saturated fatty acid material. The reaction product is substantially solid at ambient temperature, and thus is suitable for use as an ingredient in solid shortening products, yet without the adverse health effects believed to be associated with saturated fatty acids. In the method of making the product, the esterification reaction is carried out at elevated temperatures, under vacuum, and for a relatively longer duration than prior art procedures. The esterification reaction may be carried out in the presence of a catalyst and optionally, high oleic canola oil. The reaction product is neutralized, then filtered at least once and preferably twice to remove any residual catalyst.

1 . A composition suitable for use as an ingredient for a food product comprising the esterification product of a phytosterol material and at least one saturated fatty acid, the esterification product being substantially solid at ambient temperature.  
   
   
       2 . The composition of  claim 1  wherein said saturated fatty acid has between 2 and 24 carbon atoms.  
   
   
       3 . The composition of  claim 1  wherein the esterification is conducted in the absence of a catalyst, such that the composition is catalyst-free.  
   
   
       4 . The composition of  claim 1  wherein said esterification is conducted with a catalyst, and the amount residual catalyst remaining in the ingredient is less than 10 ppm.  
   
   
       5 . The composition of  claim 4  wherein the amount of residual catalyst remaining in the ingredient is less than 5 ppm.  
   
   
       6 . The composition of  claim 4  wherein the amount of residual catalyst remaining in the ingredient is less than 1 ppm.  
   
   
       7 . The composition of  claim 1  wherein the moisture content is less than 3000 ppm.  
   
   
       8 . The composition of  claim 7  wherein the moisture content is less than 2000 ppm.  
   
   
       9 . The composition of  claim 1  wherein said phytosterol material is derived from a wood product.  
   
   
       10 . The composition of  claim 1  wherein said phytosterol is derived from a vegetable oil product.  
   
   
       11 . The composition of  claim 1  wherein said at least one saturated fatty acid is present as one or more of the group consisting of palm oil, palm kernel oil, cottonseed oil, soybean oil, coconut oil, corn oil, canola oil, high oleic canola oil, low linoleic soy oil, medium chain triglycerides, and edible animal source oil.  
   
   
       12 . The composition of  claim 1  having a melting point in the range of about 115-135° C.  
   
   
       13 . A shortening product for use as a food ingredient, the shortening product comprising the composition of  claim 1 .  
   
   
       14 . A method of making a composition for use as an ingredient in a food product, the method comprising 
 A. providing a quantity of a phytosterol material, a quantity of at least one saturated fatty acid, and glycerin, and forming a mixture thereof,    B. heating the mixture to a temperature of about 230-250° C.,    C. maintaining the temperature of the mixture for a time sufficient for esterification to take place,    D. neutralizing the mixture,    E. filtering the mixture, and    F. cooling the mixture to ambient, such that the composition becomes substantially solid.    
   
   
       15 . The method of  claim 14  wherein said esterification step takes place at a reduced pressure sufficient to remove at least some moisture that evolves during the esterification step.  
   
   
       16 . The method of  claim 14  wherein said esterification occurs in the presence of a catalyst.  
   
   
       17 . The method of  claim 14  wherein said esterification step is carried out for a duration of at least about three hours.  
   
   
       18 . The method of  claim 14  wherein said saturated fatty acid has between two and twenty four carbon atoms.  
   
   
       19 . The method of  claim 14  wherein the extent of esterification is greater than about 55%.  
   
   
       20 . The method of  claim 14  further including a second filtration step.  
   
   
       21 . The method of  claim 14  wherein said phytosterol material is in the range of about 60-75% of the reaction mixture and said saturated fatty acid mixture is in the range of about 20-30% of the reaction mixture.  
   
   
       22 . The method of  claim 13  wherein said phytosterol material is in the range of about 50-60% of the mixture and said saturated fatty acid is in the range of about 40-50% of the reaction mixture.  
   
   
       23 . The method of  claim 13  wherein said esterification step is conducted in the presence of a high oleic canola oil.