U.S. patent application number 10/890947 was filed with the patent office on 2005-01-20 for laminated cook-in food package.
Invention is credited to Mitchell, Cynthia G., Mitchell, Melvin G..
Application Number | 20050013951 10/890947 |
Document ID | / |
Family ID | 34068267 |
Filed Date | 2005-01-20 |
United States Patent
Application |
20050013951 |
Kind Code |
A1 |
Mitchell, Cynthia G. ; et
al. |
January 20, 2005 |
Laminated cook-in food package
Abstract
A packaging material for forming a cook-in food package formed
from an aluminum foil sheet for providing uniform heat distribution
and moldable conformity of the material to a food being cooked, a
paper sheet for directly contacting the food and providing a
non-stick, releasable food contacting surface and a barrier between
the food and the aluminum foil sheet, and a food grade adhesive
applied between the aluminum foil sheet and the paper sheet and
bonding the aluminum foil sheet and paper sheet together to form a
lamination thereof.
Inventors: |
Mitchell, Cynthia G.;
(Penrose, NC) ; Mitchell, Melvin G.; (Penrose,
NC) |
Correspondence
Address: |
Adams Evans P.A.
2180 Two Wachovia Center
301 S. Tryon Street
Charlotte
NC
28282
US
|
Family ID: |
34068267 |
Appl. No.: |
10/890947 |
Filed: |
July 14, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60486976 |
Jul 14, 2003 |
|
|
|
Current U.S.
Class: |
428/34.2 |
Current CPC
Class: |
B32B 2439/70 20130101;
A47J 36/022 20130101; Y10T 428/1303 20150115; B32B 2255/12
20130101; B65D 81/34 20130101; B32B 2037/1276 20130101; B32B
2255/20 20130101; B32B 29/06 20130101; B32B 7/12 20130101; B32B
15/12 20130101; B65D 31/02 20130101 |
Class at
Publication: |
428/034.2 |
International
Class: |
D21J 001/00 |
Claims
We claim:
1. A packaging material for forming a cook-in food package,
comprising: (a) an aluminum foil sheet for providing uniform heat
distribution and moldable conformity of the material to a food
being cooked; (b) a paper sheet for directly contacting the food
and providing a non-stick, releasable food contacting surface and a
barrier between the food and the aluminum foil sheet; and (c) a
food grade adhesive applied between the aluminum foil sheet and the
paper sheet and bonding the aluminum foil sheet and paper sheet
together to form a lamination thereof.
2. A packaging material according to claim 1, wherein the adhesive
comprises a water-based acrylic with low vapor emission.
3. A packaging material according to claim 1, and including an
edible film applied to the paper for contacting the food during
cooking, and a modifier carried by the film for modifying the food
during cooking, the modifer selected from the group consisting of
colorants, odorants, flavorants, antioxidants, antimicrobial
agents, enzymes, odor absorbents, and blends of the foregoing
modifiers.
4. A packaging material according to claim 3, wherein the edible
film comprises a film formed from a material selected from the
group consisting of cellulose ether, starch, hydroxypropylated
starch, corn zein, wheat gluten, soy protein, milk proteins, or
pureed fruits and vegetables.
5. A packaging material according to claim 1, wherein the paper
comprises parchment.
6. A packaging material according to claim 1, wherein the paper
comprises a silicone-coated, grease-proof paper.
7. A packaging material according to claim 1, wherein the packaging
material is formed into a structure selected from the group
consisting of pouches, trays, pan liners, tents, wraps, and
lids.
8. A cook-in food package, comprising: (a) an aluminum foil sheet
for providing uniform heat distribution and moldable conformity of
the material to a food product being cooked; (b) a paper sheet for
directly contacting the food and providing a non-stick, releasable
food contacting surface and a barrier between the food and the
aluminum foil sheet; and (c) a food grade adhesive applied between
the aluminum foil sheet and the paper sheet and bonding the
aluminum foil sheet and paper sheet together to form a lamination
thereof that is manually-moldable into a shape conforming to the
shape of the food product to be cooked.
9. A cook-in food package according to claim 8, wherein the paper
sheet comprises a non-stick silicone-coated sheet.
10. A cook-in food container, comprising: (a) an aluminum foil
sheet for providing uniform heat distribution and moldable
conformity of the material to a food product being cooked; (b) a
paper sheet for directly contacting the food and providing a
non-stick, releasable food contacting surface and a barrier between
the food and the aluminum foil sheet; (c) a food grade adhesive
applied between the aluminum foil sheet and the paper sheet and
bonding the aluminum foil sheet and paper sheet together to form a
lamination thereof; and (d) the resulting laminate being formed
into a container adapted for containing a food product during
cooking.
11. A cook-in food package according to claim 10, wherein the paper
sheet comprises a non-stick silicone-coated sheet for providing a
non-stick surface in direct contact with the food.
Description
[0001] This application claims the benefit of Provisional
Application No. 60/486,976, filed on Jul. 14, 2003.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0002] This invention relates to a laminated wrapper for use in
cook-in food preparation. The hand-molded integral packaging
wrapper when placed around food items or cooking containers prior
to cooking provides uniform heat distribution, minimizes or
prevents cook-out, can be peeled from the food product after
cooking without tearing away portions of the surface of the food
product, provides a strong tear resistant wrapper, reduces the risk
of aluminum toxicity, and which may facilitate the transfer of a
modifier to the food product during the cooking process and will
provide a barrier between the food and cooking container. According
to one preferred embodiment of the invention, the wrapper comprises
a lightweight parchment or similar type of paper laminated to
aluminum foil with a food grade adhesive system. The aluminum foil
provides uniform heat distribution, minimizes or prevents cook-out
and provides the ability to mold the wrapper onto the food surface
or cooking container. The parchment paper provides ready release
from the food surface, overall strength to the wrapper and provides
barrier from the aluminum foil. The subject wrapper can also be
prepared with a modifier absorbed into the paper to impart
colorants, odors or flavors to the food product. The modifier is
transferable from the paper to the receiving surface of the food
product by fluid contact.
[0003] Numerous prior art patents disclose multilayer or coated
films which heat shrink to fit the food. Typically these food
products are prepared utilizing manually molded packaging which
includes individual sheets of parchment paper overwrapped with
aluminum foil. Wrappers for packaging must be structurally capable
of withstanding exposure to heat during cooking time and
temperature conditions while containing the food product. Cooking
time and temperature conditions may vary dramatically. Parchment
paper used by itself should not touch open flame, be used under a
broiler, in toaster ovens or halogen light ovens. Parchment paper
generally withstands temperatures up to 420 F. (215 C.) Aluminum
foil has heat resistance properties sufficient for most commercial
or home ovens <550 F. (<288 C.) Aluminum foil used in
conjunction with parchment paper as an overwrap allows the wrapper
package to withstand most time and temperature conditions.
[0004] Prior to the cooking process, the wrapper package should be
substantially conformed to the shape of the contained food product.
The wrapper should also possess sufficient product adherence to
restrict or prevent "cook-out," i.e., loss of juices from between
the surface of the contained food product and the
food-contact-surface of the packaging material during cooking,
thereby increasing product yield and providing a better-tasting
moist food.
[0005] Conventional pan liners typically consist of a parchment
paper, with excellent release capabilities, placed in the bottom of
a tray, pan or dish where the food ingredient contents are then
baked or broiled. Unfortunately paper pan liners cannot be
conformed to the shape of the tray, pan or dish, thereby allowing
cooking liquids to migrate under the liner and contaminate the
cooking container. Aluminum foil laminated to parchment paper as a
pan liner allows the wrapper to conform to shape of the tray, pan
or dish, preventing contamination of the cooking container.
[0006] Conventional wrappers possess a number of undesirable
drawbacks. Parchment paper alone does not provide sufficient
adherence to the surface of the food product or cooking container
to prevent cook-out or container contamination. In other words it
is not moldable. This results in reduced product yield, non-uniform
heat distribution and poor taste or cooking container
contamination. Aluminum foil successfully prevents cook-out and
cooking container contamination, but typically may adhere to the
surface of the food product with such adhesive strength that
portions of the food product are torn away from the remainder of
the food product when the foil is peeled from the food product
after cooking. That is, the cohesive force within the food product
is overcome by the adhesive force between the foil and the surface
of the food product. As a result, product yield is reduced and the
food product has an unsightly (pitted) surface-appearance. Aluminum
foil is also susceptible to tearing. A tear may result in the loss
of barrier for the food during cooking or may result in a piece of
aluminum foil being adhered to the food which then may be ingested
if not removed.
[0007] Aluminum from aluminum foil is generally known to migrate
into food surfaces imparting a metallic taste and increased risk of
aluminum toxicity. Aluminum is not a heavy metal, but it can be
toxic if present in excessive amounts--even in small amounts, if
deposited in the brain. Many of the symptoms of aluminum toxicity
are similar to those of Alzheimer's disease and osteoporosis.
Aluminum toxicity can lead to colic, rickets, gastrointestinal
disturbances, poor calcium metabolism, extreme nervousness, anemia,
headaches, decreased liver and kidney function, forgetfulness,
speech disturbances, memory loss, softening of the bones, and weak,
aching muscles.
[0008] Research indicates that the longer that you cook food in
aluminum, the more it corrodes, and the more aluminum compounds
migrate into food and are absorbed by the body. Aluminum is more
readily dissolved by acid-forming foods, such as cheeses, meats,
cabbage, cucumbers, tomatoes, turnips, spinach, and radishes.
[0009] It is often desirable to apply a modifier to the outer
surface of the processed food product. For example, if the food
product is poultry, beef or ham, it may be desirable to impart
smoke color, flavor, and odor to the outer surface of the food
product. This is often accomplished by applying "liquid smoke" to
the outer surface of the food product during or after cooking. It
would be desirable for the wrapper to allow smoke color, flavor,
and odor to be transferred to the poultry, beef or ham during the
process. In general, a wrapper can apply a modifier which imparts
colorants, odors or flavors to the food product would be
desired.
[0010] Accordingly, a need exists in the art for a food packaging
which incorporates both parchment paper and aluminum foil by
lamination into an integral packaging wrapper. The integral
packaging wrapper is hand-molded when placed around food items or
cooking containers prior to cooking, and provides uniform heat
distribution, minimizes or prevents cook-out, can be peeled from
the food product after cooking without tearing away portions of the
surface of the food product, provides a strong tear resistant
wrapper, reduces the risk of aluminum toxicity, and which may
facilitate the transfer of a modifier to the food product during
the cooking process.
SUMMARY OF THE INVENTION
[0011] Therefore, it is an object of the invention to provide a
laminated wrapper within which food items may be contained and
cooked.
[0012] It is another object of the invention to provide a laminated
wrapper within which food items may be contained and cooked, and
having both a paper and metallic foil component, each of which
provide enhanced cooking features.
[0013] It is another object of the invention to provide a laminated
wrapper within which food items may be contained and cooked,
wherein a metallic component is separated from the food by a paper
component.
[0014] It is another object of the invention to provide a laminated
wrapper within which food items may be contained and cooked, and
which includes an edible film layer containing substances that
impart flavor, odor and/or color to the food being cooked.
[0015] Paper, in the form of "boxboard" or "paperboard," has been
widely used for such disposable items as dining cups and containers
for liquids, such as milk and fruit juices. For these applications,
paper has the advantages of low toxicity, low cost, printability,
biodegradability, and the ease with which it may be formed into the
required shapes. However, untreated paper is not suitable for the
aforementioned applications, because it is permeable to water and
other aqueous and non-aqueous fluids.
[0016] It is well known in the art to coat materials and substrates
with a fluorochemical coating, in order to impart oil and grease
resistance to the materials and substrates. For example, Schwartz,
"Oil Resistance Utilizing Fluorochemicals," TAPPI, Seminar Notes,
74, 71-75 (1987) discloses the use of commercially available
FDA-cleared fluorochemicals to impart resistance to low surface
tension fluids on various substrates.
[0017] U.S. Pat. No. 4,426,466 discloses treatment compositions
containing fluorochemical carboxylic acid and epoxidic cationic
resin to impart oil and water repellency to cellulosic materials.
U.S. Pat. No. 4,529,658 discloses fluorochemical copolymers useful
for imparting oil and water repellency to cellulosic and textile
materials. U.S. Pat. No. 5,370,919 discloses fluorochemical
compositions for imparting oil and water repellency to various
substrates.
[0018] U.S. Pat. No. 5,603,996, to Overcash et al. discloses a
coated sheet material that includes a porous cellulose substrate
sheet material, having a barrier coating thereon which is a blend
of a cross-linkable polymer that is resistant to penetration by
water moisture when cured and a water-dispersible, film-forming
polymer that is resistant to penetration by grease and oil when
cured. Disposed on the barrier layer is a release coating, which
consists of a fatty acid complex of a metal ion, which is
cross-linked to the film-forming polymer in the barrier layer.
[0019] Another approach has been to coat a mixture of polyvinyl
alcohol and a chrome-fatty acid complex, such as Quilon.RTM., onto
a paper substrate. Quilon.RTM., manufactured by the DuPont Company,
is a dark, blue-green, chemically reactive, Werner complex in which
a C14-C18 fatty acid is coordinated with trivalent chromium in
isopropanol solution.
[0020] Another approach is to utilize silicone to impart easy and
clean release to paper is applied on a gravure coater off line to a
typical fourdrinier wet laid paper machine. The base paper used for
silicone treatment requires a high level of cellulose fiber
refining and calendering in order to achieve a very tight sheet
pore structure (as measured by air porosity). The subject base
paper is typically a supercalendered kraft paper or glassine type
product.
[0021] These and other objects of the present invention are
achieved in the preferred embodiments disclosed below by providing
a packaging material for forming a cook-in food package, comprising
an aluminum foil sheet for providing uniform heat distribution and
moldable conformity of the material to a food being cooked or
cooking container, a paper sheet for directly contacting the food
and providing a non-stick, releasable food contacting surface and a
barrier between the food and the aluminum foil sheet, and a food
grade adhesive applied between the aluminum foil sheet and the
paper sheet and bonding the aluminum foil sheet and paper sheet
together to form a lamination thereof. The adhesive used to
laminate the aluminum foil sheet and paper sheet together should be
food grade having adequate ductility and elasticity for desired
lamination properties.
[0022] According to one preferred embodiment of the invention, the
adhesive comprises a water-based high temperature acrylic with low
vapor emission.
[0023] According to another preferred embodiment of the invention,
the adhesive comprises a solvent-based high temperature acrylic
with low vapor emission.
[0024] According to another preferred embodiment of the invention,
the adhesive comprises a 100% solids-based high temperature acrylic
with low vapor emission.
[0025] According to another preferred embodiment of the invention,
the adhesive comprises an extruded high temperature acrylic or
polyolefin with low vapor emission.
[0026] According to another preferred emobdiment of the invention,
the adhesive comprises a water-based, solvent-based, 100%
solids-based high temperature casein with low vapor emission.
[0027] According to another preferred embodiment of the invention,
the packaging material includes an edible coating or film applied
to the paper for contacting the food during cooking, and a modifier
carried by the film for modifying the food during cooking, the
modifier selected from the group consisting of colorants, odorants,
flavorants, antioxidants, antimicrobial agents, enzymes, odor
absorbents, and blends of the foregoing modifiers.
[0028] According to another embodiment of the invention, the edible
coating or film is a film formed from a material selected from the
group consisting of cellulose ether, starch, hydroxypropylated
starch, corn zein, wheat gluten, soy protein, milk proteins, or
pureed fruits and vegetables.
[0029] According to yet another preferred embodiment of the
invention, the paper comprises parchment.
[0030] According to yet another preferred embodiment of the
invention, the paper comprises a silicone-coated, grease-proof
paper.
[0031] According to yet another preferred embodiment of the
invention, the packaging material is formed into a structure
selected from the group consisting of pouches, trays, pan liners,
tents, wraps, and lids.
[0032] According to yet another preferred embodiment of the
invention, a cook-in food package is provided, comprising an
aluminum foil sheet for providing uniform heat distribution and
moldable conformity of the material to a food product being cooked,
a paper sheet for directly contacting the food and providing a
non-stick, releasable food contacting surface and a barrier between
the food and the aluminum foil sheet, and a food grade adhesive
applied between the aluminum foil sheet and the paper sheet and
bonding the aluminum foil sheet and paper sheet together to form a
lamination thereof that is manually-moldable into a shape
conforming to the shape of the food product or cooking container to
be cooked.
[0033] According to yet another preferred embodiment of the
invention, the paper sheet comprises a non-stick silicone-coated
sheet.
[0034] According to yet another preferred embodiment of the
invention, a cook-in food container is provided, comprising an
aluminum foil sheet for providing uniform heat distribution and
moldable conformity of the material to a food product being cooked,
a paper sheet for directly contacting the food and providing a
non-stick, releasable food contacting surface and a barrier between
the food and the aluminum foil sheet, a food grade adhesive applied
between the aluminum foil sheet and the paper sheet and bonding the
aluminum foil sheet and paper sheet together to form a lamination
thereof. The resulting laminate is formed into a container adapted
for containing a food product during cooking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Some of the objects of the invention have been set forth
above. Other objects and advantages of the invention will appear as
the invention proceeds when taken in conjunction with the following
drawings, in which:
[0036] FIG. 1 is a perspective view of a laminated food package in
sheet form according to one embodiment of the invention;
[0037] FIG. 2 is a perspective view of a laminated food package in
sheet form according to one embodiment of the invention;
[0038] FIG. 3 is a perspective view of a laminated food package in
pouch form according to one embodiment of the invention;
[0039] FIG. 4 is a perspective view showing the pouch of FIG. 3
manually-molded around a food item prior to cooking;
[0040] FIG. 5 is a perspective view of a laminated food package in
roll form according to one embodiment of the invention; and
[0041] FIG. 6 is a perspective view of a laminated food package in
the form of a molded cooking container and lid according to one
embodiment of the invention.
[0042] FIG. 7 is a perspective view of a laminated food package in
sheet form according to one embodiment of the invention; and
[0043] FIG. 8 is a perspective view of a laminated food package in
the form of a cooking container lidding molded to fit a cooking
container to one embodiment of the invention.
[0044] FIG. 9 is a perspective view of a laminated food package in
the form of a cooking container pan liner molded to fit a cooking
container to one embodiment of the invention.
[0045] FIG. 10 is a perspective view of a laminated food package in
the form of a cooking container pan liner and lidding molded to fit
a cooking container to one embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE
[0046] Referring now specifically to the drawings, a laminated
paper and aluminum foil food product wrapper according to the
present invention is illustrated in FIG. 1 and shown generally at
reference numeral 10. In preferred embodiment shown in FIG. 1, the
wrapper 10 is formed of a sheet of aluminum foil 11 laminated to a
sheet of paper 12 using an adhesive 13, applied either to the paper
12 or to the aluminum foil 11, as shown in FIG. 1, which holds the
paper 11 and aluminum foil 12 together. In both embodiments, the
adhesive 13 has a high melting point that resists separation of the
cooking wrapper 10 during high-heat cooking.
[0047] A preferred embodiment of the adhesive 13 useful in this
application is a water-based acrylic, casein or a plastics material
such as polyester or other temperature-resistant polymer with low
vapor emission (EVA). The adhesive used to laminate the aluminum
foil sheet and paper sheet together should be food grade having
adequate ductility and elasticity for desired lamination
properties. These adhesives may be applied as water-based,
solvent-based or 100% solids-based systems. The plastics material
may be applied by extrusion coating. While the laminate
construction is proposed by standard lamination manufacturing
procedures, it should be understood that the present invention can
be constructed using any known technique, including heat seal,
thermal bonding and sonic sealing.
[0048] Referring to FIG. 2, another preferred embodiment of the
food product wrapper 20 is formed of a sheet of aluminum foil 21
laminated to a sheet of paper 22 using an adhesive 23, as described
above and applied either to the paper or to the aluminum foil, as
shown in FIG. 2, which holds the two layers 21 and 22 together.
[0049] While the application of the adhesive formulation has been
discussed above in the context of a lamination, it should be
understood that the methodology for adhering the paper 12, 22 to
the foil 11, 21 as disclosed in the present invention can be
applied to either one of the materials using any known technique,
including application by paper mills at a size press or calender
stack. It may also be applied by converters via rotogravure,
flexographic, blade, air knife, spray and other like coating
equipment.
[0050] The cooking sheet 20 also includes an edible film 24
laminated to the surface of the paper 22 opposite the surface
bonded to the aluminum foil sheet 21, and which contains a material
to be transferred by contact to the food during cooking. The edible
film 24 may be formulated from, for example, cellulose ether,
starch, hydroxypropylated starch, corn zein, wheat gluten, soy
protein, milk proteins, or pureed fruits and vegetables. Examples
of modifiers which can be transferred to the food product via the
edible film 24 during cooking include colorants, odorants,
flavorants, antioxidants, antimicrobial agents, enzymes, odor
absorbents, or blends of the foregoing materials.
[0051] The variety of food product wrappers with which the
construction of the present invention can be used to provide an
enhanced enclosure is substantial. For example, the present
invention can be used to provide food product wrappers which are
hand or commercially molded into lidding, pouches, trays, tents and
wraps which may incorporate the use of metal glass or plastic pots,
pans, trays or dishes.
[0052] As is shown in FIG. 3, a pouch 30, formed from a food
cooking wrapper such as wrapper 10 or 20, is used to enclose a food
item to be cooked. The pouch 30 may be made in numerous sizes and
shapes to accommodate a variety of food items. The pouch 30 has
opposed major panels 31, 32 defining an open mouth 33 on one end.
The pouch is preferably fabricated from the wrapper 10 or 20 shown
in FIGS. 1 and 2, respectively.
[0053] As is shown in FIG. 4, pouch 30 is conformable to the
general shape of the food, and the mouth 33 is closed by folding
the open end of the pouch 30 over itself to form a sealed end 35.
The aluminum foil provides sufficient strength and rigidity to hold
the sealed end 35 closed during cooking. Typically, the pouch 30
will be supported in a baking dish or other container during
cooking.
[0054] As is shown in FIG. 5, a predetermined length of the
wrapper, for example, wrapper 10, is positioned in a rolled
configuration in a dispenser box 40 from which a desired length of
the wrapper 10 may be dispensed in a manner similar to conventional
foil, plastic wrap and parchment waxed paper.
[0055] Referring to FIG. 6, a laminated wrapper according to the
invention can be molded into a shape, such as a bowl or dish, in
which food can be cooked. As shown, a dish 50 formed of the wrapper
10 is provided, and may include a lid 60, also formed of the
wrapper 10. For larger dishes or those intended for heavy food
products, the dish 10 and lid 60 may be fabricated from thicker
materials, or multiple layers of the wrapper 10, overlaid and then
molded in a suitable mold.
[0056] As is shown in FIG. 7, a predetermined length and width of
the wrapper, for example, wrapper 10, is positioned in a stacked
sheet configuration in a dispenser box 70 from which a desired
sized sheet of the wrapper 10 may be dispensed in a manner similar
to conventional foil and parchment waxed paper sheets which are
hand or commercially molded into lidding, pouches, trays, pan
liners, tents and wraps which may incorporate the use of metal
glass or plastic pots, pans, trays or dishes.
[0057] Referring to FIG. 8, a laminated wrapper 10 according to the
invention can be molded into the shape of a fitted lidding for a
bowl or dish 80, in which food can be cooked. The dish 80 may be
used with a lid 90.
[0058] Referring to FIG. 9, a laminated wrapper according to the
invention can be molded into the shape of a fitted pan liner for a
tray 100 in which food can be cooked.
[0059] Referring to FIG. 10, a laminated wrapper 10 according to
the invention can be molded into the shape of a fitted lidding 90
for a bowl or dish 80 and molded into the shape of a fitted pan
liner for a tray, bowl or dish, in which food can be cooked.
[0060] The laminated wrapper within which food may be cooked is
further explained with reference to the following examples:
EXAMPLE A
[0061] 24# Silicone Grease Proof (GP) paper w/wet strength was
patterned and laminated to a 0.00285 mil, 12.0# Aluminum Foil
(#/3000 ft2) Aluminum Foil Laminate. A high temperature (+450 F,
+232 C) acrylic adhesive was applied to the GP paper utilizing a
commercial gravure coater. The adhesive coating pattern was applied
in the shape of a hexagon with 1.0 centimeter per side. The
laminate thus prepared was used to prepare potatoes, asparagus and
chuck roast. Samples were tested as follows:
[0062] 1. Prepared: Baked Potato.
[0063] Ingredients: One potato, olive oil, salt & black
pepper.
[0064] Packaging: Potato and ingredients placed on 15 inch square
laminate cut to fit. Laminate tightly wrapped around potato,
crimped and rolled at top. Cooking pouch placed in oven.
[0065] Time/Temperature: 50 minutes at 400F (204C) in natural gas
fired oven.
[0066] Observations: No cook out. No discoloration of food. No off
taste. Complete potato release from GP paper. No significant GP
paper discoloration. Only pinhole tears in foil portion of
laminate.
[0067] 2. Prepared: Baked Potato.
[0068] Ingredients: Second potato, plain.
[0069] Packaging: Potato and ingredients placed on 15 inch square
laminate cut to fit. Laminate tightly wrapped around potato,
crimped and rolled at top. Cooking pouch placed in oven.
[0070] Time/Temperature: 50 minutes at 400F (204C) in natural gas
fired oven.
[0071] Observations: No cook out. No discoloration of food. No off
taste. Complete potato release from GP paper. No significant GP
paper discoloration. Only pinhole tears in foil portion of
laminate.
[0072] 3. Prepared: Oven Roasted Asparagus.
[0073] Ingredients: Asparagus, butter, salt, pepper.
[0074] Packaging: Shallow lip pan hand formed from 20 inch square
laminate. Laminate pan placed on oven cooking stone. 20 asparagus
shoots and ingredients placed on laminate. Open cooking tray placed
in oven.
[0075] Time/Temperature: 15 minutes at 400F (204C) in natural gas
fired oven.
[0076] Observations: No bottom leakage. No discoloration of food.
No off taste. Complete asparagus and ingredient release from GP
paper. No significant GP paper discoloration. No tears in foil
portion of laminate.
[0077] 4. Prepared: Chuck Roast.
[0078] Ingredients: Chuck roast, garlic, onions, salt, pepper, red
wine vinegar.
[0079] Packaging: Laminate 20 inch square placed in baking dish.
Roast and ingredients placed on laminate. Laminate tightly wrapped
around roast and ingredients, crimped and rolled at top. Cooking
dish filled with 2 inches of water for even heat dispersion.
Cooking pouch placed in oven.
[0080] Time/Temperature: 150 minutes at 400F (204C) in natural gas
fired oven.
[0081] Observations: No bottom leakage. No discoloration of food
(except small piece of garlic on roast top light green.). No off
taste. Complete roast and ingredient release from GP paper. Top
portion of laminate showed small areas with significant GP paper
discoloration, but GP paper did not become brittle like parchment
paper. Foil portion of pouch delaminated at bottom and tore open.
GP paper remained intact and did not leak. Pouch was opened to
check cooking progress twice. First and second reseals not as good
as initial seal. This is typical even with straight aluminum foil.
The use of either a heavier gauge 0.00030 mil (12.7#) or 0.00035
mil (14.7#) foil, is suggested to improve hand and strength.
[0082] The GP paper was much easier to work with than parchment
paper, i.e.; more flexible and the cooking liquid & butter
grease did not burn onto the paper as it would with a parchment
grade. Under no condition did the GP paper tear or leak.
[0083] The next step was to prepare the full surface laminate.
EXAMPLE B
[0084] 24# Silicone Grease Proof (GP) paper w/wet strength was full
side laminated to a 0.00285 mil, 12.0# Aluminum Foil (#/3000 ft2)
Aluminum Foil Laminate. A high temperature (+450 F, +232 C) acrylic
adhesive was applied to the GP paper utilizing a commercial gravure
coater. The adhesive coating was a full side application. The
laminate thus prepared was used to prepare sirloin roast. Samples
were tested as follows:
[0085] 5. Prepared: Sirloin Roast.
[0086] Ingredients: Large cubes of sirloin roast, garlic, onions,
salt, pepper, red wine vinegar.
[0087] Packaging: Laminate 20 inch square placed in baking dish.
Roast and ingredients placed on laminate. Laminate tightly wrapped
around roast and ingredients, crimped and rolled at top. Cooking
dish filled with 2 inches of water for even heat dispersion.
Cooking pouch placed in oven.
[0088] Time/Temperature: 90 minutes at 400F (204 F) in natural gas
fired oven.
[0089] Observations: No bottom leakage. No discoloration of food.
No off taste. Complete roast and ingredient release from GP paper.
Foil portion of pouch cracked underwater and delaminated slightly
at bottom. Foil portion of top seal crack and delaminated slightly
where handled. GP paper remained intact and did not leak. Pouch was
opened to check cooking progress twice. First and second reseals
not as good as initial seal. (This is typical even with straight
aluminum foil.)
[0090] The Exhibit B product provided a satisfactory product. The
solid lamination is tightly bound with good aesthetics prior to
cooking. The product's clear adhesive with aluminum foil show
through to the bright GP paper represents a feel of cleanliness and
snap. The only delamination occurred where the aluminum foil was
cracked or pealed. GP paper remained intact and did not leak. The
product aluminum foil weight is adequate for pan liners and other
structures where high moldability or wrapper stressing is not
required.
[0091] The product did not "dead fold" adequately. It is more
difficult to seal a casserole dish, hand pattern a tray, or produce
a cooking pouch. A heavier aluminum foil layer with no other
changes appears desirable, for example a full surface laminate
using 0.00035 mil (14.7#) aluminum foil.
EXAMPLE C
[0092] 24# Silicone Grease Proof (GP) paper w/wet strength was full
side laminated to a 0.0035 mil, 14.7# Aluminum Foil (#/3000 ft2)
Aluminum Foil Laminate.
[0093] No bottom leakage. No discoloration of food. No off taste.
Complete food release from GP. Foil portion of pouch does not crack
or delaminate with use/handling. GP remained intact and did not
leak. The product dead folds adequately, and adequately seals a
casserole dish, hand pattern a tray, or produce a cooking
pouch.
[0094] Based on the foregoing examples, an aluminum foil layer
0.0035 mil, 14.7# Aluminum Foil (#/3000 ft2) or heavier provides
improved strength and dead fold at minimum foil weight. Layer
weights used for standard commercially available aluminum foil
0.0065 mil, 27# Aluminum Foil (#/3000 ft2) or heavier can be
laminated and will perform equally well in use testing. The
economics favor the use of a lighter weight 0.0035 mil, 14.7#
Aluminum Foil (#/3000 ft2) layer.
[0095] Numerous variations can be made on the 24#/3000 ft2 Silicone
Grease proof (GP) paper. Standard parchment papers with either
PFOS, Quilon or numerous other grease proof additives can be
utilized. Also the basis weights of the GP paper can range from 20#
to 27#/3000 ft2 with no adverse effects. Grease Proof (GP)
Discussion from applicant's United States Patent Application:
20040005341 may also be suitable.
[0096] A laminated cook-in food package is described above. Various
details of the invention may be changed without departing from its
scope. Furthermore, the foregoing description of the preferred
embodiment of the invention and the best mode for practicing the
invention are provided for the purpose of illustration only and not
for the purpose of limitation--the invention being defined by the
claims.
* * * * *