U.S. patent application number 11/720254 was filed with the patent office on 2008-05-15 for edible container for foodstuffs and process for producing the same.
This patent application is currently assigned to NESTEC S.A.. Invention is credited to Wolfgang Gaeng, John Green.
Application Number | 20080113069 11/720254 |
Document ID | / |
Family ID | 35543336 |
Filed Date | 2008-05-15 |
United States Patent
Application |
20080113069 |
Kind Code |
A1 |
Green; John ; et
al. |
May 15, 2008 |
Edible Container For Foodstuffs And Process For Producing The
Same
Abstract
An open-ended edible container for foodstuffs composed of
cereals and/or fruits in a sheet formed by means of a binder
wherein the inner surface of the container is very lightly
patterned while the outer surface has a smooth texture with
embedded flakes; a process for manufacturing edible containers for
foodstuffs comprising the steps of: pouring a liquid batter on
baking plates, partially cooking the batter for providing a sheet,
depositing cereals and/or fruit flakes as a layer onto the sheet,
--finally cooking the sheet, giving the desired shape to the
container, in which the inner surface of the container is very
lightly patterned while the outer surface of said container has a
rough texture with embedded flakes.
Inventors: |
Green; John; (Le Mont St.
Adrien, FR) ; Gaeng; Wolfgang; (Le Mont St. Adrien,
FR) |
Correspondence
Address: |
BELL, BOYD & LLOYD LLP
P.O. Box 1135
CHICAGO
IL
60690
US
|
Assignee: |
NESTEC S.A.
Vevey
CH
|
Family ID: |
35543336 |
Appl. No.: |
11/720254 |
Filed: |
October 11, 2005 |
PCT Filed: |
October 11, 2005 |
PCT NO: |
PCT/EP05/10911 |
371 Date: |
May 25, 2007 |
Current U.S.
Class: |
426/106 |
Current CPC
Class: |
A23G 9/48 20130101; A21D
13/48 20170101; A21D 2/36 20130101; A21D 13/24 20170101; A21D 13/33
20170101; A23G 9/506 20130101; A21D 2/364 20130101 |
Class at
Publication: |
426/106 |
International
Class: |
A23B 7/148 20060101
A23B007/148 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 26, 2004 |
EP |
04028070.3 |
Mar 23, 2005 |
EP |
05102346.3 |
Claims
1. An open-ended edible container for foodstuffs comprising cereals
and/or fruits in a sheet comprising an inner surface of the
container having a very lightly patterned surface and an outer
surface having a smooth texture with embedded flakes.
2. An edible container according to claim 1 wherein the inner
surface is coated with a chocolate.
3. An edible container according to claim 1 wherein the inner
surface is nonporous.
4. An edible container according to claim 1 comprising cereals
selected from the group consisting of wheat, barley, corn, rice,
and mixtures thereof.
5. An edible container according to claim 1 comprising fruits
selected from the group consisting of nuts, almond and mixtures
thereof.
6. An edible container according to claim 1 comprising a seed
selected from the group consisting of linseeds and flaxseeds.
7. An edible container according to claim 1 comprising a binder
that is a batter.
8. An edible container according to claim 1 in the shape of a
cone.
9. A composite frozen confection comprising an edible container for
foodstuffs comprising cereals and/or fruits in a sheet comprising
an inner surface of the container having a very lightly patterned
surface and an outer surface having a smooth texture with embedded
flakes together with an ice confectionery filling.
10. A process for manufacturing edible containers for foodstuffs
comprising the steps of: pouring a liquid batter on baking plates,
partially cooking the liquid batter for providing a sheet,
depositing cereals and/or fruit flakes as a layer onto the sheet,
finishing cooking the sheet, providing a desired shape to the
container, and wherein an inner surface of the container is very
lightly patterned while an outer surface of the container has a
smooth texture with embedded flakes.
11. A process according to claim 10 wherein the desired shape is
formed by using a rolling device.
12. A process according to claim 10 wherein the container is formed
into a cone by using a mandrel.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to edible containers for
foodstuffs and to a process for preparing them.
BACKGROUND OF THE INVENTION
[0002] Manufacturing containers is well known in the art. Usually,
edible containers are made of wafers from batter recipes. These
wafers are generally made by cooking a batter, which is a liquid
suspension, by means of an oven or by extrusion.
[0003] U.S. 2001/0043970 pertains to edible wafers, in particular
sugar wafers, and to a process for preparing them. In fact, the
invention provides a sugar wafer batter wherein part of the wheat
flour is replaced by cereal grits and/or all or part of the sucrose
is replaced by a reducing sugar. In this case, replacing part of
the wheat flour in a wafer batter by cereal grits and/or replacing
all or part of the sucrose with a reducing sugar, allows the
obtention of a sugar wafer that is sufficiently flexible over a
longer period of time compared with standard sugar wafers.
[0004] Using cereal grits allows a longer crispiness but the visual
aspect is not modified and the viscosity of the batter is quite the
same as a conventional batter.
[0005] There is a need to provide a new kind of edible containers.
It is an object of the present invention to provide a container
with nutritional features that are improved. It is an other object
of the present invention to provide a container with an innovative
fashion to be more attractive for consumers. It is an other object
of the invention to provide an edible container with a new
texture.
[0006] Furthermore, including flakes is not obvious because of
their shape. In fact, edible containers obtained by means of
cooking a batter lose their crispiness over time by absorbing
moisture which softens them. The solution is to coat the inner
surface of the container with a fat-based coating, for example
chocolate. But this step needs a smooth surface to allow a
homogeneous coating. It is an object of the present invention to
provide a container, which contains cereal and/or fruit flakes and
which can simultaneously be coated.
SUMMARY OF THE INVENTION
[0007] The invention relates to an open-ended edible container for
foodstuffs composed of cereals and/or fruits in a sheet formed by
means of a binder characterized in that the inner surface of the
container is very lightly patterned while the outer surface has a
smooth texture with embedded flakes.
[0008] Moreover, the inner surface is nonporous such that it allows
a homogeneous coating for example with a confectionery fat, for
example a chocolate, a vegetable fat or compound to form a moisture
barrier and thus retaining a desirable crispiness.
[0009] Said edible container can be made of cereals, which could be
wheat, barley, corn, rice or rye and mixtures thereof. The edible
container can also be made by a mixture of cereals and fruits,
preferably dry nuts and/or almonds. All these raw materials are
further sheet-formed by means of a binder, which is usually a
batter. In a preferred embodiment, the container is in the shape of
a cone and can be filled with frozen confection for example.
[0010] The invention relates also to a process for manufacturing
edible containers for foodstuffs comprising the steps of: [0011]
pouring a liquid batter on baking plates, [0012] partially cooking
the batter for providing a sheet, [0013] depositing cereals and/or
fruit flakes as a layer onto the sheet, [0014] finally cooking the
sheet, [0015] giving the desired shape to the container, wherein
the inner surface of the container is very lightly patterned while
the outer surface of said container has a smooth texture with
embedded flakes.
[0016] The desired shape can be formed by using a rolling device
for example, in this case said rolling device could be a
mandrel.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The invention relates to an open-ended edible container for
foodstuffs composed of cereals and/or fruits in a sheet formed by
means of a binder characterized in that the inner surface of the
container is very lightly patterned while the outer surface has a
smooth texture with embedded flakes.
[0018] The cereals may be grains or seeds, for example, corn,
maize, wheat, oat, rice, and the like, or any combination of two or
more thereof in the form of flakes
[0019] The fruits are dried fruits and may be, for example, sliced
almond, nuts and mixtures thereof.
[0020] In addition, some seeds may be added which procure
additional benefits, e.g. in terms of nutrition, for example
linseeds or flaxseeds which add omega 3 fatty acids in the form of
triglycerides.
[0021] The edible container can also be made of a mixture of
cereals, seeds and dried fruits cited above.
[0022] The batter can be made from about 20% to 60% by weight of
flour, water, and sucrose (which may be brown or white) together
with smaller quantities of one or more ingredients typically used
in wafers, such as fat, milk powder, soya flour, salt, lecithin.
Optionally, colorings, cocoa powder, flavors, emulsifiers, vanilla
crystals, and a raising agent may be added. The flour is usually
wheat flour but it may be another flour, such as rice flour or a
flour admixed with a starch.
[0023] The containers of the present invention typically have a low
fat content, normally from 3-5% but which in some cases can be up
to 10%. The main function of the fat is as an
anti-sticking/releasing agent. Containers can have a sugar content
of less than 5% to from about 70%. It depends if the final product
has to be sweet or savory.
[0024] The cereals and/or fruits are deposited as a layer on a on a
partially cooked layer of batter, after that the cooking step
allows the evaporation and when the viscosity of the batter
increases, it act as a binder and forms a sheet. Said sheet is
afterwards rolled to form an open-ended container with a very
lightly patterned inner surface and an outer surface which has a
smooth texture and comprises embedded cereal flakes and/or sliced
fruits, which gives a hand-made aspect to it.
[0025] Said cereal flakes are interesting in the present case
because of their nutritional properties. Indeed, cereals are mainly
composed by fibers, which are known for their ability to control
energetic contributions. Then they make it possible to spread out
the absorption of the nutrients, and in particular of glucids, this
is very interesting for the diabetes problems. And finally, the
fibers would decrease the time of contact of potentially harmful
products with the colic mucous membrane. So including cereal flakes
in the composition of the present edible container allows a higher
concentration in fibers in said container.
[0026] The invention also pertains to a process for manufacturing
edible containers for foodstuffs comprising the steps of: [0027]
pouring a liquid batter on baking plates, [0028] partially cooking
the batter for providing a sheet, [0029] depositing cereals and/or
fruit flakes as a layer onto the sheet, [0030] finally cooking the
sheet, [0031] giving the desired shape to the container, wherein
the inner surface of the container is very lightly patterned while
the outer surface of said container has a smooth texture with
embedded flakes.
[0032] Under the phrase "very lightly patterned" it is intended to
mean that the network of lines which raise over the inner surface
of the container or of grooves which are depressed under the said
surface is very light in order to allow for uniformly applying of a
protective fat-based coating onto the surface.
[0033] The desired shape can be formed by using a rolling device,
for example, this device can be a mandrel.
[0034] The containers may have a variety of shape and sizes, for
examples, they may be cone-shaped, cup-shaped or tubular.
[0035] The invention described and claimed herein is not to be
limited in scope by the specific embodiment herein disclosed, since
this embodiments is intended as illustration of several aspects of
the invention. Any equivalent embodiments are intended to be within
the scope of this invention. Indeed, various modifications of the
invention in addition to those shown and described herein will
become apparent to those skilled in the art from the foregoing
description. Such modifications are also intended to fall within
the scope of the appended claims.
[0036] In accordance with the present embodiment each layer when it
is still soft and deformable after the baking operation is rolled
to form a cone.
[0037] The batter is poured on to a baking plate and partially
cooked by closing plate for approx 10 seconds. The plate is
reopened and cereal and/or fruits flakes are deposited on to the
said batter. This mixture is then cooked using, for example, a
continuous baking oven. Such ovens have endless baking-tong chains
which revolve continuously and have baking tongs each containing a
baking mold consisting of two flat baking plates for the production
of layers. These baking ovens have a longitudinally extending oven
housing, which on the outside has a heat-insulating end closure
consisting of doors and plates. In the oven housing a
longitudinally extending parallellepipedic inner space is provided,
through which extends the endless baking tong chain through two
superimposed transport levels and over two guide mechanisms
provided respectively at each end of the inner space. The length,
widths and height of this inner space depend on the size of the
substantially rectangular baking tongs and the length of the baking
tong chains. The size of the baking tongs is selected according to
the size of the layers to be produced. The width of the inner space
is primarily determined by the width of the baking tongs. The
length of the baking tongs determines the diameter of the guide
mechanisms of the baking tong chain, by determining the vertical
distance between the two transport levels, and thereby the height
of the inner space.
[0038] In the upper transport level of the baking oven, a discharge
or removal station wherein the baked layers are removed from the
opened baking molds, a pouring station, wherein the flowable batter
is poured, into the opened baking molds, followed by closing and
reopening of the baking mold, wherein the cereal and/or fruits are
deposited on to the partially cooked batter, followed by a final
closing of the mold, is arranged in succession in the travel
direction of the baking tong chain. In the travel direction of the
baking tong chain, the pouring station is followed by a long baking
space, which ends shortly before the removal station and which
contains the baking tong chain segment located in the lower
transport level. The baking tong chain revolves at a constant speed
and transports the closed baking tongs through the longitudinally
extending baking space provided with gas burners. After leaving the
baking space, the baking tongs are released for the opening of the
baking molds and are again clamped together after passing through
the pouring station thereby closing the baking molds.
[0039] During one revolution of a baking tong, at the pouring
station a precisely measured amount of flowable batter is poured
onto the lower baking plate of an open baking mold. After the
pouring station, the baking mold is closed by clamping together the
baking tongs. After a predetermined time the baking tongs are
reopened thereby allowing depostion of cereal and/or fruit on to
the partially cooked batter. After this stage the tongs are closed
for the full baking. While the closed baking tongs travel through
the baking space, from the dough portion a cake is formed inside,
which is plastically deformable while warm. Before reaching the
discharge station, the baking mold is opened by releasing the
baking tongs. At the discharge station the cake is removed from the
opened baking mold and transferred to the cone-making machine in a
plastically deformable state, while the baking tong is transported
further to the dough-pouring machine for the production of the next
cake. The travel time of the baking tongs from the dough-pouring
station through the baking space to the discharge station
corresponds to the predetermined baking time of the cake.
[0040] The production capacity of the baking oven depends mainly on
the number of baking plates which are transported by the baking
tongs chain at a constant speed during the predetermined baking
time from the dough-pouring station through the baking space to the
discharge station. The running speed of the baking tongs chain is
selected so that each baking tong will complete its travel from the
dough-pouring station through the baking space to the discharge
station within the predetermined baking time.
[0041] In order to increase the production capacity of the baking
oven it is possible to lengthen the baking tongs chain by a few
baking tongs and to increase the running speed of the baking tongs
chain, so that each baking tongs will complete the lengthened
travel path in the predetermined baking time of the cakes.
[0042] These longitudinally extending baking ovens are combined
with forming machines, wherein a rigid rotary frame revolving
around a stationary rotation axis comprises roll-up mechanisms
assigned to the baking molds of the baking oven, which are
transported by the rotary frame in a closed circuit from a loading
station through a work path to a discharge station, while the
plastically deformable layers pulled in by them at the loading
station are formed, rolled up into cones for example, and the cones
are allowed to cool in order to increase the stability of their
shape.
[0043] Between the baking oven and the cone-making machine a
transfer device is provided, which transports the plastically
deformable layers from the very hot baking molds of the baking oven
to the considerably cooler roll-up mechanisms of the cone-making
machine and whose work pace is synchronized with that of the baking
oven and of the cone-making machine.
[0044] The transfer device has a rotary star frame rotating about a
vertical axis, which at the end of its star-shaped work arms has
small stamps by means of which it seizes the layers at their upper
side and pulls them on an arched horizontal slide from the
discharge station of the baking oven to the loading station of the
cone-making machine. Each stamp is applied with minimal pressure to
the upper side of the cake which are easily deformable in their
plastically deformable state, in order to keep at a minimum the
friction between the layer and the slide, in order to avoid
deformation of the layer during transport.
[0045] In order to insure the plastic deformability of the cones
arriving at the roll-up mechanisms, the cooling of the cakes
occurring during their passage through the transfer device, and the
therewith necessarily connected reduction of their plastic
deformability, cannot surpass a certain limit.
[0046] During the rolling operation the edges of the layer disc
move freely without any restraint. When a rolled cone has been
formed, that cone is shortened to a predetermined length by
subjecting the edge portions of the cone at its large end and, if
desired, also at its small end, to a plastic deformation so that
any irregularities which have resulted from the rolling operation
will be eliminated and the cone will be given an exactly defined
length. Thereafter the cone is permitted to harden.
[0047] The edible container of the present invention may be used in
a variety of confectionery products together with confectionery
materials such as ice creams, chocolates, or other fatty materials
such as fat-based creams. The edible container may be filled with
confectionery materials, preferably of low water activity so that a
minimum of moisture migration occurs. For example the confectionery
material may be ice cream, or fat-based creams containing
yogurt.
[0048] If the water activity of the filling is so to high, some
moisture will pass into the container and thus said container will
lose its crispiness. To avoid this phenomenon, in case of a high
moisture content filling, the edible container has to be coated
with a fat-based coating such as chocolate, vegetable fat or
compound coating for example. The method to coat the container can
be all method known. For example, it can be coated by using a feed
hopper behind the rolling and cooling structure, so as to pour the
coating into the container or by spraying or showering.
[0049] The invention is further defined by reference to the
following example describing in detail the preparation of the
edible containers of the present invention. In the example parts
and percentages are by weight unless specified otherwise.
EXAMPLES
Example 1
[0050] A liquid batter is prepared which has the following
composition:
TABLE-US-00001 Water 51.85 Sucrose 16.00 Coconut fat 3.60 Lecithin
1.00 Wheat flour 27.00 Salt 0.14 Flavouring 0.16 100.00
[0051] Using a continuous in line type baking oven with gas heating
provided with baking plates, 14 g of batter is dosed on a plate,
the plate is closed in order to allow partial cooking of the batter
in a sheet, then opened after 10 s and a suitable quantity of
skinless sliced almond 4-8 mm sliced is deposited so as to produce
11 g wafer to 2 g sliced almonds in the cooked wafer.
[0052] The baking plates are to have a smooth surface on the upper
plate and a fine pattern on the lower plate. The smooth surface on
the upper plate helps to make the sliced almond visible on the
outer surface of the container. The fine pattern on the lower plate
serves to hold the batter in place during the initial stage of
cooking where it is still liquid. The fine pattern which results on
the inner surface of the container is such that a fat-based coating
can be uniformly applied on the whole surface. After almond dosage
the plate is closed and the cake sheet is finally baked. The
running speed of the machine is 2400 plates per hour. The baking
process is approx 1.1 minutes per plate. Temperature in the oven is
175-205.degree. C. and preferably 185.degree. C. When the cake is
baked the plate is opened and the cake is transferred to a rolling
device.
[0053] The cone-rolling device is configured to roll the cone with
the upper surface from the plate rolled to the outside of the cone.
After forming the cone shaped cake is refrigerated and packed into
a sleeve.
[0054] Finally it is coated on the inside with a plain chocolate
layer which serves as moisture barrier, filled with vanilla ice
cream and topped with chocolate chips.
[0055] In FIG. 1 of the enclosed drawing a cone-shaped container
made according to the invention is schematically represented before
being coated and filled.
[0056] It comprises a rolled sugar wafer 1 which has an exterior
surface 2 that is smooth and has adjuncts of sliced almonds 3
embedded in it. In place of almonds flaked cereals, nuts or seeds
may be embedded instead. Its internal surface 4 is very lightly
patterned and perfectly suited for being uniformly coated with
chocolate as moisture barrier.
Example 2
[0057] The process of example 1 is carried out except that 14 g of
batter is dosed on a plate, the plate remains open in order to
allow partial cooking of the batter in a sheet on its lower
surface, and after 10 s a suitable quantity of skinless sliced
almond 4-8 mm sliced is deposited on the upper surface of the
batter sheet so as to produce 11 g wafer to 2 g sliced almonds in
the cooked wafer.
Example 3
[0058] The process of example 2 is carried out except that 2 g
whole flaxseeds is deposited on the upper surface of the batter
sheet.
* * * * *