U.S. patent application number 10/475284 was filed with the patent office on 2006-09-14 for sweet microwave popcorn product and method for production thereof.
Invention is credited to AmarjitS Bakshi, Caroline Ponting, Lis K. Renini.
Application Number | 20060204622 10/475284 |
Document ID | / |
Family ID | 25280465 |
Filed Date | 2006-09-14 |
United States Patent
Application |
20060204622 |
Kind Code |
A1 |
Renini; Lis K. ; et
al. |
September 14, 2006 |
Sweet microwave popcorn product and method for production
thereof
Abstract
A sweet microwave popcorn product is provided that can be
prepared by the consumer in a single step. The product comprises a
microwaveable container; a plurality of unpopped corn kernels in
the container; and a plurality of sugar pellets in the container.
Each sugar pellet comprises sugar in an amount of at least about
15% by weight, based on the total weight of the sugar pellet. The
sugar pellets are substantially free of an emulsifying agent.
Inventors: |
Renini; Lis K.; (Anaheim
Hills, CA) ; Bakshi; AmarjitS; (Yorba Linda, CA)
; Ponting; Caroline; (Yorka Linda, CA) |
Correspondence
Address: |
Gary D Lueck;Bingham McCutchen
18th Floor
Three Embarcadero Center
San Francisco
CA
94111-4067
US
|
Family ID: |
25280465 |
Appl. No.: |
10/475284 |
Filed: |
March 29, 2002 |
PCT Filed: |
March 29, 2002 |
PCT NO: |
PCT/US02/10100 |
371 Date: |
April 29, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09839715 |
Apr 20, 2001 |
|
|
|
10475284 |
Apr 29, 2004 |
|
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Current U.S.
Class: |
426/107 |
Current CPC
Class: |
B65D 2581/3494 20130101;
B65D 2581/3421 20130101; B65D 2581/3429 20130101; B65D 2581/3466
20130101; B65D 2581/3472 20130101; A23L 7/183 20160801; B65D
81/3469 20130101 |
Class at
Publication: |
426/107 |
International
Class: |
B65D 81/34 20060101
B65D081/34 |
Claims
1. A sweet popcorn product suitable for popping in a microwave
oven, comprising: a microwaveable container having a bottom region,
a middle region adjacent the bottom region, a top region adjacent
the middle region; a plurality of unpopped corn kernels in the
container; and a plurality of sugar pellets in the container,
wherein each sugar pellet comprises sugar and corn syrup, each
sugar pellet having sugar in an amount of at least about 15% by
weight, based on the total weight of the sugar pellet, the sugar
pellets are free of an emulsifying agent and not homogeneously
mixed with the unpopped kernels, and a majority of the sugar
pellets is contained within a portion of the middle region nearest
one of the bottom region or the top region, and a majority of the
unpopped corn kernels is contained within a portion of the middle
region nearest the other of the regions.
2. (canceled)
3. (canceled)
4. (canceled)
5. A microwave popcorn product according to claim 4, wherein the
ratio of sugar to corn syrup in each sugar pellet ranges from about
1:1 to about 5:1.
6. A microwave popcorn product according to claim 1, wherein the
unpopped corn kernels are present in a total amount ranging from
about 15% to about 95% by weight based on the total weight of the
product excluding the container.
7. A microwave popcorn product according to claim 1, wherein the
sugar pellets are present in a total amount ranging from about 1%
to about 70% by weight based on the total weight of the product
excluding the container.
8. A microwave popcorn product according to claim 1, wherein each
sugar pellet has a moisture content no greater than about 3.5%.
9. A microwave popcorn product according to claim 1, wherein each
sugar pellet has a moisture content no greater than about 2.5%.
10. A microwave popcorn product according to claim 1, wherein the
sugar pellets are prepared according to the process comprising:
admixing sugar and corn syrup to produce an admixture; reducing the
moisture content of the admixture by heating the admixture to a
temperature ranging from about 110.degree. C. to about 170.degree.
C.; and forming the heated admixture into the sugar pellets.
11. A microwave popcorn product according to claim 10, wherein the
process further comprises subjecting the heated admixture to a
vacuum to further reduce the moisture content of the admixture.
12. A microwave popcorn product according to claim 1, wherein the
product further comprises an oil component in the container,
wherein the oil component is not homogeneously mixed with the sugar
pellets.
13. A microwave popcorn product according to claim 12, wherein the
oil component comprises partially hydrogenated soybean oil, salt,
color, butter flavor and sucralose.
14. A microwave popcorn product according to claim 1, wherein the
product further comprises salt in the container.
15. A microwave popcorn product according to claim 14, wherein the
salt is present in a total amount up to about 10% by weight based
on the total weight of the product excluding the container.
16. A microwave popcorn product according to claim 1, wherein the
microwaveable container does not include a susceptor.
17. A microwave popcorn product according to claim 16, wherein the
sugar pellets are present in a total amount ranging from about 10%
to about 70% by weight based on the total weight of the product
excluding the container.
18. A microwave popcorn product according to claim 1, wherein the
microwaveable container includes a susceptor.
19. A microwave popcorn product according to claim 18, wherein the
microwaveable container comprises a bag having a top surface and a
bottom surface, and further wherein the susceptor is generally flat
and attached to the bottom surface of the bag.
20. A microwave popcorn product according to claim 19, wherein the
susceptor extends over at least about 40% of the length of the
bag.
21. A microwave popcorn product according to claim 19, wherein the
susceptor extends over at least about 50% of the length of the
bag.
22. A microwave popcorn product according to claim 21, wherein the
unpopped corn kernels are present in a total amount ranging from
about 40% to about 95% by weight based on the total weight of the
product excluding the container.
23. A microwave popcorn product according to claim 21, wherein the
unpopped corn kernels are present in a total amount ranging from
about 45% to about 75% by weight based on the total weight of the
product excluding the container.
24. A microwave popcorn product according to claim 21, wherein the
sugar pellets are present in a total amount ranging from about 1%
to about 10% by weight based on the total weight of the product
excluding the container.
25. A microwave popcorn product according to claim 21, wherein the
sugar pellets are present in a total amount ranging from about 2%
to about 4% by weight based on the total weight of the product
excluding the container.
26. A microwave popcorn product according to claim 21, wherein the
product further comprises an oil component present in a total
amount ranging from about 10% to about 45% by weight based on the
total weight of the product excluding the container.
27. A microwave popcorn product according to claim 21, wherein the
product further comprises an oil component present in a total
amount ranging from about 20% to about 40% by weight based on the
total weight of the product excluding the container.
28. A microwave popcorn product according to claim 21, wherein: the
unpopped corn kernels are present in a total amount ranging from
about 40% to about 95% by weight based on the total weight of the
product excluding the container; the sugar pellets are present in a
total amount ranging from about 1% to about 10% by weight based on
the total weight of the product excluding the container; and the
product further comprises an oil component present in a total
amount ranging from about 10% to about 45% by weight based on the
total weight of the product excluding the container.
29. A microwave popcorn product according to claim 21, wherein: the
unpopped corn kernels are present in a total amount ranging from
about 45% to about 75% by weight based on the total weight of the
product excluding the container; the sugar pellets are present in a
total amount ranging from about 2% to about 4% by weight based on
the total weight of the product excluding the container; and the
product further comprises an oil component present in a total
amount ranging from about 20% to about 40% by weight based on the
total weight of the product excluding the container.
30. A microwave popcorn product according to claim 19, wherein the
susceptor covers at least about 90% of the width of the bag.
31. A microwave popcorn product according to claim 19, wherein the
susceptor covers from about 25% to about 50% of the length of the
bag.
32. A microwave popcorn product according to claim 19, wherein the
susceptor covers from about 30% to about 40% of the length of the
bag.
33. A microwave popcorn product according to claim 19, wherein the
susceptor covers from about 75% to about 85% of the width of the
bag.
34. A microwave popcorn product according to claim 19, wherein the
unpopped corn kernels are present in a total amount ranging from
about 20% to about 80% by weight based on the total weight of the
product excluding the container.
35. A microwave popcorn product according to claim 19, wherein the
unpopped corn kernels are present in a total amount ranging from
about 25% to about 55% by weight based on the total weight of the
product excluding the container.
36. A microwave popcorn product according to claim 19, wherein the
sugar pellets are present in a total amount ranging from about 5%
to about 35% by weight based on the total weight of the product
excluding the container.
37. A microwave popcorn product according to claim 19, wherein the
sugar pellets are present in a total amount ranging from about 15%
to about 25% by weight based on the total weight of the product
excluding the container.
38. A microwave popcorn product according to claim 19, wherein the
product further comprises an oil component present in a total
amount ranging from about 20% to about 50% by weight based on the
total weight of the product excluding the container.
39. A microwave popcorn product according to claim 19, wherein the
product further comprises an oil component present in a total
amount ranging from about 30% to about 50% by weight based on the
total weight of the product excluding the container.
40. A microwave popcorn product according to claim 19, wherein: the
unpopped corn kernels are present in a total amount ranging from
about 25% to about 55% by weight based on the total weight of the
product excluding the container; the sugar pellets are present in a
total amount ranging from about 15% to about 25% by weight based on
the total weight of the product excluding the container; and the
product further comprises an oil component present in a total
amount ranging from about 30% to about 50% by weight based on the
total weight of the product excluding the container.
41. A microwave popcorn product according to claim 19, wherein the
bag includes an opening in contact with the top region, wherein the
bottom region, middle region and top region are approximately equal
in length; and further wherein the bag is folded so that the bottom
region and top region overlay the middle region.
42. A microwave popcorn product according to claim 41, further
comprising an oil component wherein the unpopped corn kernels and
sugar pellets, along with the oil component are contained
substantially within the middle region.
43. A microwave popcorn product according to claim 42, wherein the
majority of the sugar pellets is contained within a portion of the
middle region nearest the bottom region or the top region, and
further wherein the majority of the unpopped corn kernels and the
majority of the oil component are contained within a portion of the
middle region nearest the other of the bottom region or the top
region.
44. A microwave popcorn product according to claim 43, wherein the
susceptor covers substantially the entire length of the middle
region.
45. A microwave popcorn product according to claim 44, wherein: the
unpopped corn kernels are present in a total amount ranging from
about 40% to about 95% by weight based on the total weight of the
product excluding the container; the sugar pellets are present in a
total amount ranging from about 1% to about 10% by weight based on
the total weight of the product excluding the container; and the
oil component is present in a total amount ranging from about 10%
to about 45% by weight based on the total weight of the product
excluding the container.
46. A microwave popcorn product according to claim 44, wherein: the
unpopped corn kernels are present in a total amount ranging from
about 45% to about 75% by weight based on the total weight of the
product excluding the container; the sugar pellets are present in a
total amount ranging from about 2% to about 4% by weight based on
the total weight of the product excluding the container; and the
product further comprises an oil component present in a total
amount ranging from about 20% to about 40% by weight based on the
total weight of the product excluding the container.
47. A microwave popcorn product according to claim 43, wherein the
susceptor covers less than 90% of the length of the middle region,
thereby creating a portion of the middle region not covered by the
susceptor that corresponds to the portion of the middle region in
which the majority of the sugar pellets is contained.
48. A microwave popcorn product according to claim 47, wherein: the
unpopped corn kernels are present in a total amount ranging from
about 25% to about 55% by weight based on the total weight of the
product excluding the container; the sugar pellets are present in a
total amount ranging from about 15% to about 25% by weight based on
the total weight of the product excluding the container; and the
oil component is present in a total amount ranging from about 30%
to about 50% by weight based on the total weight of the product
excluding the container.
49. A microwave popcorn product according to claim 1, wherein each
sugar pellet comprises sugar in an amount ranging from about 30% to
about 75% by weight, based on the weight of the sugar pellet.
50. A microwave popcorn product according to claim 1, wherein the
sugar pellets each further comprise a polishing material.
51. A method for producing a microwave popcorn product comprising:
providing a microwaveable container having a top region, a middle
region, a bottom region, and an opening at the top of the
container; introducing into the container sugar pellets and
unpopped corn kernels, wherein each sugar pellet comprises sugar
and corn syrup, wherein the sugar pellets are free of an
emulsifying agent, and wherein the sugar pellets are not
homogeneously mixed with the unpopped corn kernels; introducing
into the container an oil component, wherein more of the oil
component is maintained in the container with the unpopped corn
kernels than is maintained with the sugar pellets, a majority of
the sugar pellets is contained within the middle of the
microwaveable container nearest one of the bottom or the top, and a
majority of the unpopped corn kernels and a majority of the oil
component are contained within a portion of the middle nearest the
other of the regions, so that the corn kernels act as a buffer
between the sugar pellets and the oil component.
52. A method according to claim 51, wherein the sugar pellets are
introduced into the container before the unpopped kernels are
introduced into the container.
53. A method according to 51, wherein the sugar pellets are
introduced into the container before the oil component is
introduced into the container.
54. A method according to 51, wherein the container includes a
susceptor over at least a portion of the length of the
container.
55. A method according to 51, wherein the microwaveable container
comprises a bag having a top surface, a bottom surface, and a
generally-flat susceptor attached to the bottom surface of the
bag.
56. A method according to claim 55, wherein the susceptor extends
over at least about 50% of the length of the bag.
57. A method according to claim 56, wherein the unpopped corn
kernels are introduced in a total amount ranging from about 40% to
about 95% by weight based on the total weight of the product
excluding the container; the sugar pellets are introduced in a
total amount ranging from about 1% to about 10% by weight based on
the total weight of the product excluding the container; and the
oil component is introduced in a total amount ranging from about
10% to about 45% by weight based on the total weight of the product
excluding the container.
58. A method according to claim 55, wherein the susceptor covers at
least about 90% of the width of the bag.
59. A method according to claim 58, wherein: the unpopped corn
kernels are introduced in a total amount ranging from about 25% to
about 55% by weight based on the total weight of the product
excluding the container; the sugar pellets are introduced in a
total amount ranging from about 15% to about 25% by weight based on
the total weight of the product excluding the container; and the
oil component is introduced in a total amount ranging from about
30% to about 50% by weight based on the total weight of the product
excluding the container.
60. A method according to claim 54, wherein the bottom region,
middle region and top region are approximately equal in length; and
further wherein the bag is folded so that the bottom region and top
region overlay the middle region.
61. (canceled)
62. (canceled)
63. A method according to claim 60, wherein the susceptor covers
substantially the entire length of the middle region.
64. A method according to claim 63, wherein: the unpopped corn
kernels are introduced in a total amount ranging from about 40% to
about 95% by weight based on the total weight of the product
excluding the container; the sugar pellets are introduced in a
total amount ranging from about 1% to about 10% by weight based on
the total weight of the product excluding the container; and the
oil component is introduced in a total amount ranging from about
10% to about 45% by weight based on the total weight of the product
excluding the container.
65. A method according to claim 63, wherein: the unpopped corn
kernels are introduced in a total amount ranging from about 45% to
about 75% by weight based on the total weight of the product
excluding the container; the sugar pellets are introduced in a
total amount ranging from about 2% to about 4% by weight based on
the total weight of the product excluding the container; and the
oil component is introduced in a total amount ranging from about
20% to about 40% by weight based on the total weight of the product
excluding the container.
66. A method according to claim 55, wherein the susceptor covers
less than 90% of the length of the middle region, thereby creating
a portion of the middle region not covered by the susceptor that
corresponds to the portion of the middle region in which the
majority of the sugar pellets is contained.
67. A method according to claim 66, wherein: the unpopped corn
kernels are introduced in a total amount ranging from about 25% to
about 55% by weight based on the total weight of the product
excluding the container; the sugar pellets are introduced in a
total amount ranging from about 15% to about 25% by weight based on
the total weight of the product excluding the container; and the
oil component is introduced in a total amount ranging from about
30% to about 50% by weight based on the total weight of the product
excluding the container.
68. A method for producing a microwave popcorn product comprising:
providing a microwaveable container having a top, a middle, a
bottom, and an opening at the top of the container; preparing sugar
pellets having sugar and corn syrup, wherein each sugar pellet
comprises sugar in an amount of at least about 15% by weight based
on the total weight of the sugar pellet, and wherein the sugar
pellets are free of an emulsifying agent; and introducing into the
container the sugar pellets and unpopped corn kernels so that the
sugar pellets and unpopped corn kernels are not homogeneously
mixed, wherein a majority of the sugar pellets is contained within
a portion of the middle of the microwaveable container nearest one
of the bottom or the top, and a majority of the unpopped corn
kernels is contained within a portion of the middle nearest the
other of the regions.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a sweet microwave popcorn
product that can be prepared by the consumer in a single-step and a
method for its production.
BACKGROUND OF THE INVENTION
[0002] Microwaveable popcorn is one of the most popular snack foods
on the market today. Currently, there are several commercially
available microwaveable popcorn products containing a sugar-based
glaze or coating. In these products, the sugar-based glaze or
coating is added separately to the popcorn after it has been
popped. Manufacturers have experienced difficulties producing a
product where the sugar-based coating is formed on the popcorn
during popping (i.e., in a single step) due to technical
difficulties in popping popcorn and heating a sugar-based
composition simultaneously in a microwave oven. Specifically, at
elevated temperatures and in the presence of moisture, simple
sugars darken and polymerize in a process known as carmelization.
Carmelization occurs at virtually the same temperature at which
popcorn pops. Carmelization is enhanced by the presence of oil in
the product. As a result, when a sugar-based glaze is heated in a
microwave along with the popcorn, a food product is obtained that
is not only visually undesirable, but also effectively inedible due
to its burnt odor and flavor. Accordingly, a need exists for a
single-step sweet microwave popcorn product that avoids these
drawbacks.
SUMMARY OF THE INVENTION
[0003] The present invention concerns a sweet microwave popcorn
product that can be prepared by the consumer in a single step, as
well as a method for its production. In one embodiment, the
invention is directed to a sweet microwave popcorn product
comprising a microwaveable container; a plurality of unpopped corn
kernels in the container; and a plurality of sugar pellets in the
container. Each sugar pellet comprises sugar in an amount of at
least about 15% by weight, based on the total weight of the sugar
pellet. The sugar pellets are substantially free of an emulsifying
agent.
[0004] In another embodiment, the invention is directed to a method
for producing a microwave popcorn product. The method comprises
providing a microwaveable container having a top, a bottom, and an
opening at the top of the container. The method further comprises
introducing into the container sugar pellets and unpopped corn
kernels, wherein the sugar pellets and unpopped corn kernels are
not homogeneously mixed; and introducing into the container an oil
component, wherein more of the oil component is maintained in the
container with the unpopped corn kernels than is maintained with
the sugar pellets.
[0005] In another embodiment, the invention is directed to a method
for producing a microwave popcorn product. The method comprises
providing a microwaveable container having a top, a bottom, and an
opening at the top of the container. Sugar pellets and unpopped
corn kernels are introduced into the container so that the sugar
pellets and unpopped corn kernels are not homogeneously mixed. Each
sugar pellet comprises sugar in an amount of at least about 15% by
weight, based on the total weight of the sugar pellet, and is
substantially free of an emulsifying agent.
DESCRIPTION OF THE DRAWINGS
[0006] These and other features of the advantages of the present
invention will be better understood by reference to the following
detailed description when considered in conjunction with the
accompanying drawings wherein:
[0007] FIG. 1 is a top cut-away view of a microwave popcorn product
according to the invention with the susceptor shown in phantom.
[0008] FIG. 2 is a top cut-away view of an alternative microwave
popcorn product according to the invention with the susceptor shown
in phantom.
DETAILED DESCRIPTION
[0009] The invention concerns a sweet microwaveable popcorn
composition comprising unpopped corn kernels, sugar pellets, and
optionally an oil component. In accordance with the invention, the
unpopped corn kernels can be any hulled or dehulled popcorn kernel
capable of use as a microwave popcorn. The kernels may be large,
medium, small, white, yellow, flavored or any other suitable type
of kernel. A particularly preferred type of popcorn is "mushroom"
or "butterfly" popcorn.
[0010] The sugar pellets comprise sugar and preferably corn syrup.
Each sugar pellet preferably comprises at least about 15%, more
preferably from about 30% to about 75%, by weight sugar, based on
the total weight of the sugar pellet. As used herein, the term
"sugar" includes mono-, di-, tri-, and polysaccharides, including
polydextrose, as well as sugar substitutes, such as sugar alcohols,
including sorbitol, xylitol, and mannitol. The preferred sugar for
use in the sugar pellets of the invention is sucrose. The sugar
pellets are substantially free of an emulsifying agent, and
preferably contain less than 0.1 wt % of an emulsifying agent, and
more preferably contain no emulsifying agent.
[0011] The corn syrup component of the sugar pellet comprises a
partial hydrolysate of starch or a hydrogenated starch hydrolysate.
The term "corn syrup" is further intended to embrace not only those
syrups that are generally called in the trade glucose syrups, but
also all other partial hydrolysates of starch including high
fructose corn syrups. The term is also intended to include solid
corn syrup. The sugar to corn syrup ratio in the sugar pellets
preferably ranges from about 1:1 to about 5:1.
[0012] The term "pellet" as used herein is not limited to
pellet-shaped or -sized pieces, but is intended to encompass all
three dimensional shapes. Suitable pellet shapes include regular
and irregular shapes, such as spheres, ellipses, cubes, rods,
chips, flakes and the like. Suitable sugar pellets for use in
connection with the invention are commercially available from
Primrose Candy Company (Chicago, Ill.) and Ferrera Pan Candy
Company (Forest Park, Ill.).
[0013] Regardless of the sugar used, the sugar pellets should
possess a sweet taste. Therefore, if in preparing the sugar
pellets, a sugar is used that does not possess a sweet taste, such
as certain polysaccharides, then an additional sugar should be used
that, either alone or in combination with the non-sweet sugar,
possesses a sweet taste. Artificial sweeteners such as sucralose,
acesulfame potassium, and aspartame can also be used to provide a
sweet taste if the sugar used in preparing the pellets does not
itself do so.
[0014] The sugar pellets can further comprise a polishing material,
such as paraffin wax, microcrystalline wax, beeswax, candelilla
wax, carnauba wax, polyethylene wax, animal fat, vegetable oil,
hydrogenated vegetable oil, partially hydrogenated vegetable oil,
cocoa butter, corn zein, whey protein, hydroxymethylcellulose,
methylcellulose, or ethylcellulose.
[0015] To minimize burning of the sugar during microwaving, the
sugar pellets have a relatively low moisture content. Preferably
the moisture content of the sugar pellets ranges from about 0.5% to
about 6%, more preferably from about 1% to about 5%, still more
preferably from about 1.5% to about 3.5%.
[0016] A particularly preferred method for preparing the sugar
pellets in accordance with the invention comprises admixing sugar
and corn syrup. The admixture is heated to a temperature ranging
from about 110.degree. C. to about 170.degree. C., more preferably
from about 130.degree. C. to about 150.degree. C., to remove
moisture. The heated admixture is then formed into pellets.
Preferably following heating and prior to forming pellets, the
admixture is subjected to a vacuum, which helps reduce the moisture
content of the pellets. The sugar pellets prepared according to
this process can be, following the forming step, substantially the
same size and density as the unpopped kernels.
[0017] If the sugar pellets are to comprise a polishing material,
preferably following the forming step the pellets are coated with a
coating material and then polished with the polishing material.
Preferably the coating material (e.g., sugar syrup) is poured over
the sugar pellets using traditional panning procedures as such as
that described by Minifi, B. in Chocolate Manufacture, Chocolate,
Cocoa and Confectionary, AVI Publishing Co., Inc., Westport, Conn.
(1982), although other coating procedures known in the art may be
used as well. For hot panning, the coating material is preferably a
crystallizing syrup containing sucrose. Successive layers of syrup
are applied to the sugar pellets with excess sugar moisture removed
through the application of heat to the pan. For cold panning, the
coating material is preferably a non-crystallizing syrup containing
sucrose or other sugars, and one or more corn syrups. Successive
layers of syrup are applied to the sugar pellets with excess syrup
moisture absorbed by dry sugar or starch, which is applied directly
to the syrup-coated sugar pellets. Regardless of whether a
crystallizing or non-crystallizing syrup is used, the syrup can
also contain minor amounts of gums, flavoring agents, and/or
coloring agents. A suitable coating machine is the Thomas
Engineering Accela Cota Tablet Coating System from Thomas
Engineering, Inc. Other coating devices include the Driacoater,
Hi-Coater, and Volvo or tulip pans. Thereafter, the pellets are
coated with wax, which is then polished using a panning process, as
is known in the art. Suitable waxes for use in connection with the
invention include paraffin wax, microcrystalline wax, beeswax,
candelilla wax, carnauba wax, and polyethylene wax.
[0018] The oil component is preferably present in the form of a
slurry at elevated temperatures, e.g., around 120.degree. C., and
in generally solid form at room temperature. Oils suitable for use
in the present invention include partially hydrogenated oils, such
vegetable oil, sunflower oil, safflower oil, rapeseed oil,
cottonseed oil, maize oil, linseed oil, high oleic acid residue
containing varieties thereof, groundnut oil, and mixtures thereof.
The oil enhances the flavor of the microwaved product. If desired,
the oil component can include an artificial sweetener, such as
those listed above. A particularly preferred composition for the
oil component comprises partially hydrogenated soybean oil, salt,
color, butter flavor and sucralose.
[0019] The oil component can further include a flavoring agent
and/or coloring agent. Suitable flavoring agents include natural
and artificial flavors, such as synthetic flavor oils and flavoring
aromatics and/or oils, oleoresins and extracts derived from plants,
leaves, flowers, fruits, and so forth, and combinations thereof.
Particularly useful flavorings include artificial, natural and
synthetic fruit flavors such as vanilla, and citrus oils including
lemon, orange, lime, grapefruit, and fruit essences including
apple, pear, peach, grape, strawberry, raspberry, cherry, plum,
pineapple, and apricot. The flavoring agents may be in liquid or
solid form. Commonly used flavors include mints such as peppermint,
menthol, artificial vanilla, cinnamon derivatives, and various
fruit favors. Other flavorings that can be used include aldehyde
flavorings, such as acetaldehyde (apple), benzaldehyde (cherry,
almond), anisic aldehyde (licorice, anise), cinnamic aldehyde
(cinnamon), citral, i.e., alpha-citral (lemon, lime), neral, i.e.,
beta-citral (lemon, lime), decanal (orange, lemon), ethyl vanillin
(vanilla, cream), heliotrope, i.e., piperonal (vanilla, cream),
vanillin (vanilla, cream), alpha-amyl cinnamaldehyde (spicy fruity
flavors), butyraldehyde (butter, cheese), valeraldehyde (butter,
cheese), citronellal (modifies, many types), decanal (citrus
fruits), aldehyde C-8 (citrus fruits), aldehyde C-9 (citrus
fruits), aldehyde C-12 (citrus fruits), 2-ethylbutyeraldehyde
(berry fruits), hexenel, i.e., trans-2 (berry fruits), tolyl
aldehyde (cherry, almond), veratraldehyde (vanilla),
2,6-dimethyl-5-heptanal, i.e., melonal (melon), 2,6-dimethyloctanal
(green fruit), and 2-dodecenal (citrus, mandarin), cherry, grape,
strawberry shortcake, and the like. Preferred flavoring agents
include butter, brown sugar, caramel, cooked milk, maple, vanilla,
cream, pastry, marshmallow, cheese, cinnamon, and honey. Other
examples of suitable flavoring agents are described in S.
Arctander, Perfume and Flavor Chemicals (1969) and Allure
Publishing Corporation's Flavor and Fragrance Materials (1993), the
disclosures of which are incorporated herein by reference. In
general, the amount of flavoring agent used should be in an amount
effective to provide the desired or acceptable taste to the
consumer.
[0020] Coloring agents may be included in an amount up to about 10%
by weight, preferably no more than about 6% by weight, of the
microwaveable popcorn composition. Suitable coloring agents include
natural food colors and dyes suitable for food, drug and cosmetic
applications, which are preferably oil-dispersible, including the
indigoid dye known as F.D. & C. Blue No. 2, the disodium salt
of 5,5-indigotindisulfonic acid), and the dye known as F.D. &
C. Green No. 1, the monosodium salt of
4-[4-(N-ethyl-p-sulfoniumbenzylamino)
diphenylmethylene]-[1-(N-ethyl-N-p-sulfoniumbenzyl)-delta-2,5-cyclohexadi-
eneimine.
[0021] The oil component preferably also includes salt. Any
suitable type of salt can be used, including coarse, fine or extra
fine salt. The salt is preferably present in an amount up to about
10%, more preferably from about 0.5% to about 6% by weight, based
on the total weight of the composition. However, because the salt
increases the burning of the sugar, the precise amount of salt used
will depend on the presence, size and shape of the susceptor used
in the packaging, discussed further below.
[0022] If desired, the salt, flavoring agent and/or coloring agent
can be combined with the sugar pellet in addition to or instead of
with the oil component. Salt can alternatively be sprinkled or
otherwise provided in the bag with the unpopped corn kernels.
[0023] The composition is provided in a microwaveable package, for
which any conventional popcorn bag or tub arrangement may be used.
A suitable popcorn bag for use in connection with the invention
comprises a conventional 2-ply bag arrangement with a pinch-bottom
design. Such an arrangement is generally described in U.S. Pat. No.
5,044,777, the disclosure of which is incorporated herein by
reference. Generally, the bag is folded from a 2-ply panel or sheet
to form a bag having a length ranging from about 10 to about 14
inches, preferably from about 11 to about 12 inches, and a width
ranging from about 4.5 to about 7 inches, preferably from about 5
to 6.5 inches. The sheet of paper that forms the outer surface of
the bag, when folded, is preferably a 23-30 lb blended Kraft paper
(lb/ream). The sheet of paper that forms the inside of the bag is
preferably a 23-25 lb. greaseproof paper. Both papers may be
treated with a fluorochemical material for grease resistance, such
as 3M fluorocarbon FC807. The laminating adhesive between the plies
of paper could be a typical conventional adhesive used in such
arrangements, for example Duracet 12, available from Franklin
International, Inc. of Columbus, Ohio, or H. B. Fuller WO-3460ZZ,
available from H. B. Fuller, St. Paul, Minn. The folded bag has a
top surface and a bottom surface. When the bag is placed in a
microwave oven, as described further below, the bottom surface of
the bag rests on the inner surface of the microwave oven, as is
generally known in the art.
[0024] In a preferred embodiment, the folded bag is folded into
three approximately evenly sized regions, as shown in FIGS. 1 and
2, namely, a top region 10, a middle region 12, and a bottom region
14, with the top region 10 nearest the bag opening 16. However,
when the product is exposed to microwave energy, thereby expanding
the bag, the resulting volume in each of the top and bottom regions
is less than the volume of the middle region.
[0025] Preferably the microwave package includes a susceptor for
enhancing the popping of the kernels. Once placed under microwave
energy, the packaging containing the susceptor reaches temperatures
in excess of 300.degree. F. almost instantaneously.
[0026] In a preferred embodiment, the microwave susceptor is
positioned between the two plies of the bag described above on the
bag's bottom surface. The susceptor is preferably provided in a
location over which the unpopped corn kernels rest when the bag
arrangement is unfolded and placed in a microwave oven for cooking,
as described in more detail below. The susceptor can comprise any
of a variety of microwave interactive materials, such as a thin
layer of metal, e.g., vapor deposited metal, metal oxide, carbon
and the like. The susceptor can be applied directly to the interior
of the bag, preferably between the two plies, or can be supported
on a sheet of paper or plastic that is subsequently bonded to the
packaging. The susceptor preferably comprises a metallized
polymeric film, such as Hoechst Celanise polyester film (typically
48-92 gauge) vacuum metallized with aluminum to give a density of
0.2-0.3 (as measured by a Tobias densitometer). In the embodiment
depicted in FIG. 1, the susceptor 18 is provided in primary part in
the middle region 12 of the folded bag nearest the unpopped
kernels, as described further below.
[0027] To make the microwave product of the invention, the
components are introduced into the microwaveable package.
Preferably the sugar pellets are introduced into the package
separately from the oil component, if included, to minimize burning
of the sugar pellets. In a particularly preferred method, the bag
is provided in a generally upright position, i.e., with the opening
16 at the top of the bag, as the components are introduced into the
bag. However, before the components are introduced into the bag,
the bottom region 14 of the bag is folded under so that the
components cannot enter the bottom region, but instead remain in
the middle region 12. In one method according to the invention, the
sugar pellets are introduced first. Thereafter, the unpopped
kernels are introduced into the bag, with the oil component
introduced over the kernels. The oil component, particularly when
in the form of a slurry, generally remains with the unpopped
kernels. With this arrangement, the corn acts generally as a buffer
between the sugar pellets and the oil component, thereby reducing
burning of the sugar pellets.
[0028] In an alternative method, the sugar pellets are deposited
into a cup, and thereafter the unpopped kernels are introduced into
the cup on top of the sugar pellets. The contents of the cup are
then released into the microwaveable bag so that the sugar pellets
and unpopped kernels are generally arranged as described above.
Thereafter, the oil component is introduced directly into the
microwaveable bag so that it mixes generally with the unpopped
kernels, similar to the method described above.
[0029] The precise order that the components are introduced into
the microwaveable package is not critical to invention, but can be
selected to reduce burning of the sugar to the extent that the
sugar pellets are maintained as separate from the oil component as
possible. Thus, it is preferred that the majority of the sugar
pellets 20 is contained with a portion of the middle region 12
nearest the bottom region 14 or the top region 12, and the majority
of the unpopped corn kernels 22 and the majority of the oil
component are contained within a portion of the middle region
nearest the other of the bottom region or the top region, as shown
in FIG. 1.
[0030] After the components are introduced, the bag is sealed
closed, and the bag is folded up so that the top region 10 and the
bottom region 14 overlay the middle region 12, as is generally
known in the art. Preferably after the microwave bag is filled with
the inventive composition and folded, it is covered with a
cellophane overwrap, such as 140-160 gauge biaxially oriented
polypropylene, or the like. Heavier gauges (or wraps with improved
moisture barrier characteristics) are preferred for improved
moisture retention.
[0031] The amounts of the components in the composition will vary
depending on the presence, size and shape of the susceptor.
Generally, the composition preferably comprises the unpopped
kernels in an amount ranging from about 15% to about 95% by weight,
based on the weight of the composition. The sugar pellets are
preferably present in an amount ranging from about 1% to about 70%
by weight, based on the weight of the composition. The oil
component, when included, is preferably present in an amount up to
about 50% by weight, based on the weight of the composition. If a
susceptor is included in the bag, preferably the relative amount of
sugar pellets is reduced because the susceptor, while enhancing the
popping of the kernels, also increases the likelihood that the
sugar will burn.
[0032] When the bag does not contain a susceptor, the amount of
sugar pellets preferably ranges from about 10% to about 70%, more
preferably from about 20% to about 70%, by weight based on the
total weight of the composition.
[0033] FIG. 1 depicts a bag having a full susceptor, i.e., a
susceptor 18 covering substantially all of the middle region 12. In
this embodiment, the susceptor has a width equal to at least about
90% of the width of the bag, preferably at least about 95% of the
width of the bag. The susceptor has a length equal to at least
about 40% of the length of the bag, more preferably at least about
50% of the length of the bag. In the depicted embodiment, the
susceptor covers the entire length of the middle region and extends
approximately equal lengths into the top and bottom regions. In
such an embodiment, the amount of unpopped corn preferably ranges
from about 40% to about 95%, more preferably from about 45% to
about 75%, the amount of sugar pellets preferably ranges from about
1% to about 10%, more preferably from about 2% to about 4%, and the
amount of oil component preferably ranges from about 10% to about
45%, more preferably from about 20% to about 40%, wherein the
percentages are by weight, based on the total weight of the
components in the bag. When the sugar pellets 20 are introduced
first, they are located in the middle region 12 nearest the bottom
region 14; the unpopped corn kernels 22, along with the oil
component, are located in the middle region nearest the top region
10. As shown in FIG. 1, the sugar pellets 20 are generally separate
from the unpopped corn kernels 22 and oil component, although some
mixing of these components naturally occurs upon their introduction
into the bag. However, it is preferred that the sugar pellets are
not homogeneously mixed with the unpopped corn kernels, and even
more preferred that the sugar pellets are not homogeneously mixed
with the oil component.
[0034] FIG. 2 depicts a bag identical to the bag of FIG. 1 in all
respects except that it has a partial (or short) susceptor, which
covers only a portion of the middle region 12. In this embodiment,
the susceptor preferably has a width ranging from about 60% to
about 90% of the width of the bag, more preferably ranging from
about 75% to about 85% of the width of the bag. The susceptor has a
length preferably ranging from about 25% to about 50%, more
preferably from about 30% to about 40%, of the length of the bag.
In the depicted embodiment, the susceptor covers approximately 80%
of the length of the middle region, does not cover the portion of
the middle region nearest the bottom region, and extends into the
top region. In this embodiment, the amount of unpopped corn kernels
preferably ranges from about 20% to about 80%, more preferably from
about 25% to about 55%, the amount of sugar pellets preferably
ranges from about 5% to about 35%, more preferably from about 15%
to about 25%, and the amount of oil component preferably ranges
from about 20% to about 50%, more preferably from about 30% to
about 50%, wherein the percentages are by weight based on the total
weight of the components in the bag. It is preferred that the
susceptor covers less than 90% of the length of the middle region,
thereby creating a portion of the middle region not covered by the
susceptor that corresponds to the portion of the middle region in
which the majority of the sugar pellets is contained. It is further
preferred that the majority of the sugar pellets 20 is provided in
the portion of the middle region nearest the bottom region, and the
majority of the corn kernels 22 and the majority of the oil
component, if included, are provided in the portion of the middle
region nearest the top region, with the susceptor not covering at
least some of portion of the middle region in which the sugar
pellets are contained.
[0035] The microwave popcorn products of the invention can be
quickly and conveniently prepared by the consumer in a single step.
The consumer removes any cellophane overwrap from the microwaveable
bag, and places the bag in the microwave oven with the bottom
surface of the bag resting on the inner surface of the microwave
oven. In the case of a tri-fold bag as described above, typically
initially only the bottom surface of the middle region is resting
on the surface of the microwave oven. As the product is exposed to
microwave energy, the bag expands, as is well known in the art.
Suitable microwaving times for the products of the invention range
from about 1.5 minutes to about 4 minutes, and can vary based on a
number of variables, including the power of the microwave being
used and the presence and size of the susceptor in the
microwaveable container.
[0036] Four microwave popcorn products were prepared, with
compositions and susceptor designs as shown in Table 1. In each
example, the bag was a two-ply bag with a pinched bottom and
single-gusset sides. The bag had a length of approximately 11.5
inches, a width of approximately 5.75 inches, and was folded to
form three substantially equally-sized regions, as generally
described above. The bottom region of the bag was folded so that,
as the components were introduced into the top of the bag, they
remained in the middle region. The bags of Examples 1 and 2 did not
include a susceptor. The bag of Example 3 contained a full
susceptor, i.e., a susceptor having a width of approximately 5.5
inches and a length of approximately 6.25 inches, with the
susceptor covering almost all of the middle region and a portion of
the top and bottom regions, as shown in FIG. 1. The bag of Example
4 contained a short susceptor, i.e., a susceptor having a width of
approximately 4.25 inches and a length of approximately 4.5 inches,
with the susceptor covering approximately 80% of the length of the
middle region and a portion of the top region. All of the microwave
popcorn products were tasty and exhibited minimal sugar burning
during popping of the kernels. TABLE-US-00001 TABLE 1 Example 1
Example 2 Example 3 Example 4 Susceptor None None Full Short Corn
Kernels 75 grams 20 grams 67 grams 35 grams Sugar Pellets 25 grams
60 grams 2 grams 20 grams Oil Component None 40 grams 31 grams 45
grams
[0037] The preceding description has been presented with reference
to presently preferred embodiments of the invention. Workers
skilled in the art and technology to which this invention pertains
will appreciate that alterations and changes in the described
structure may be practiced without meaningfully departing from the
principal, spirit and scope of this invention.
[0038] Accordingly, the foregoing description should not be read as
pertaining only to the precise structures described and illustrated
in the accompanying drawings, but rather should be read consistent
with and as support to the following claims which are to have their
fullest and fair scope.
* * * * *