U.S. patent application number 12/429594 was filed with the patent office on 2010-10-28 for soft shaped tortillas.
Invention is credited to Jonathan M. Griebel, Vincent Paul Sommer.
Application Number | 20100272863 12/429594 |
Document ID | / |
Family ID | 42651026 |
Filed Date | 2010-10-28 |
United States Patent
Application |
20100272863 |
Kind Code |
A1 |
Griebel; Jonathan M. ; et
al. |
October 28, 2010 |
SOFT SHAPED TORTILLAS
Abstract
The present invention encompasses edible carriers for foods that
are soft but still hold a preformed shape. Specifically encompassed
are soft shaped tortilla products that can be used to hold food
fillings. Exemplary shapes and sizes are provided for the products.
Also encompassed are methods of making, packaging, and using the
products.
Inventors: |
Griebel; Jonathan M.; (Maple
Grove, MN) ; Sommer; Vincent Paul; (Northfield,
MN) |
Correspondence
Address: |
GENERAL MILLS, INC.
P.O. BOX 1113
MINNEAPOLIS
MN
55440
US
|
Family ID: |
42651026 |
Appl. No.: |
12/429594 |
Filed: |
April 24, 2009 |
Current U.S.
Class: |
426/87 ; 426/112;
426/124; 426/128; 426/415 |
Current CPC
Class: |
A23L 7/13 20160801; A21D
13/33 20170101; A23P 30/10 20160801; A21D 8/06 20130101; A21D 13/42
20170101 |
Class at
Publication: |
426/87 ; 426/128;
426/124; 426/112; 426/415 |
International
Class: |
A21D 13/00 20060101
A21D013/00; B65D 81/32 20060101 B65D081/32; B65B 55/00 20060101
B65B055/00 |
Claims
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31. A packaged food article, comprising: a hermetically sealed food
package having a headspace; at least one baked soft shaped tortilla
piece having a thickness ranging from about 1-5 mm disposed therein
said soft shaped tortilla pieces having a water activity of 0.88 or
less; and, a headspace gas.
32. The packaged food article of claim 31 wherein the food piece
ranging from about 40-60 g in weight.
33. The packaged food article of claim 32 wherein the food piece is
fabricated from a cooked farinaceous tortilla dough having a
finished moisture content of 25% or less.
34. The packaged food article of claim 33 wherein the dough
additionally comprises: about 1%-10% sugar; about 4%-15% humectant;
about 1%-15% fat; about 1%-5% salt; about 1%-3% of a chemical
leavening system including at least one baking acid and soda.
35. The packaged food article of claim 34 wherein the dough
comprises at least 51% wheat flour.
36. The packaged food article of claim 35 wherein the sealed food
package is fabricated at least in part from a flexible packaging
film.
37. The packaged food article of claim 36 wherein the food package
has an oxygen permeability of less than 2.5 ccO.sub.2/cm.sup.2/day
and wherein the headspace gas has an oxygen level of less than
4%.
38. The packaged food article of claim wherein the headspace gas
includes N.sub.2 and CO.sub.2.
39. The packaged food article of claim 38 comprising a plurality of
soft shaped tortilla pieces each of a nestable configuration
arranged in nested stacked relationship to form at least one
stack.
40. The packaged food article of claim 33 wherein the stack is
mounted within a supplemental support carrier.
41. The packaged food article of claim 40 wherein the pieces are
arranged in at least two stacks.
42. The packaged food article of claim 31 having a shelf life of at
least six months at room temperature storage and wherein the piece
has a water activity ranging less than about 0.88.
43. The packaged food article of claim 42 wherein the headspace has
an oxygen level of less than 1%.
44. The packaged food article of claim 43 wherein the shaped
tortillas are in the form of a boat.
45. A meal kit for use in making a Mexican soft shaped tortilla,
comprising: an outer package; a first soft shaped tortilla base
pieces package food article disposed within the outer package
including: a hermetically sealed food package having a headspace; a
quantity of baked soft shaped tortilla pieces disposed therein said
soft shaped tortilla pieces fabricated from a farinaceous dough
having a water activity of 0.88 or less; and, a headspace gas
having an oxygen level of less than 4%; and, a second packaged food
article disposed within the outer package that is either a pouch of
dry seasoning mixture or a pouch of a wet sauce.
46. The meal kit of claim 45 wherein the seasoning mix includes
seasoning for flavoring meat.
47. The meal kit of claim 46 wherein the outer package is a carton
wherein the carton includes a front major panel and a rear major
panel.
48. The meal kit of claim 47 additionally including an instructions
legend for preparing Mexican tortilla using the meal kit.
49. The meal kit of claim 48 wherein the instruction legend is on
rear major panel of the carton.
50. The meal kit of claim 49 wherein the second packaged food
article is a pouch of dry seasoning mixture for meat.
51. The packaged food article of claim 50 wherein the first food
package article has an oxygen permeability of less than 2.5 cc
O.sub.2/cm.sup.2/day and a headspace oxygen level of less than
2%.
52. A method of preparing a baked soft shaped tortilla piece
packaged food article, comprising the steps of: A. providing a
quantities of a chemically leavened gluten plastic dough; B.
forming the quantities into shaped heat set three dimensional
pieces having a thickness of about 1-5 mm; C. baking the shaped
heat set pieces to form finished soft shaped tortilla piece having
a moisture content of about 25% or less and having a water activity
value of about 0.88 or less; and, D. packaging a number of finished
soft shaped tortilla piece within a modified atmosphere package to
form soft shaped tortilla piece packaged food article having a
shelf life of at least six months at room temperature storage.
53. The method of claim 52 wherein the dough is a worked
farinaceous dough, comprising: about 55 to 80% (dry weight basis)
of the dough as flour and wherein at least a majority of the flour
is wheat flour; about 1%-10% sugar; about 4%-15% humectant; about
1%-3% of a chemical leavening system including at least one baking
acid and soda; about 10%15% fat; about 1%-5% salt; and, about
30%-35% moisture.
53. The method of claim 52 wherein the dough is a rested
farinaceous dough.
54. The method of claim 53 wherein each quantity of dough in step A
ranges from about 40-60 g and wherein the dough has a Brabender
value ranging from about 500 to 1000 BU.
55. The method of claim 54 wherein the forming step is practiced in
a mold heated to about 190.degree. C. to 205.degree. C.
56. The method of claim 55 wherein forming step is practiced to
form a par-baked intermediate food item and the baking step is
practiced in a belt oven.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to edible holders for foods
that are soft but still retain a preformed shape. More
specifically, the present invention relates to soft shaped tortilla
products, that can be used to hold various edible fillings, and to
kits comprising a packaged multiplicity of soft shaped tortilla
base pieces. Also related are methods of making, packaging, and
using said products.
BACKGROUND OF THE INVENTION
[0002] Consumers are searching for healthy and yet convenient food
options, avoiding foods laden with excess fats. There is a movement
away from unhealthy choices such as crispy deep fried foods. As
healthier options, low fat options such as Lebanese breads and pita
pockets are used as a carrier for toppings or sandwich ingredients.
Yet, they can be too thick, and are likely to break while consumers
attempt to fold them into shapes that are convenient to hold and
carry. They also show a limited shelf life, and can dry out quickly
due to their formulation. Mountain breads can (flat square breads
sold in Australia) can also be used, but are more suitable for
lunch more than dinner. Also, they are too thin to be used with
sauces, and show a limited shelf life. Naans and chapatis are
exotic choices more suitable for a main meal than as a lunchtime
wrap. In addition, they tend to be inflexible, too small, and high
in fat.
[0003] By comparison, tortillas are shelf stable, highly soft and
flexible, and can fold and bend without breaking. The term
"tortilla" is used herein to refer to a Mexican style tortilla,
i.e., a generally flat unleavened cooked flexible pan baked dough
product generally circular in shape such as from a corn masa dough
("tortilla de maiz") or from a wheat dough ("tortilla de harina").
The two versions of the Mexican tortilla have different textures
owing to the grains from which they originate. The maize version is
somewhat thicker and heartier in texture, while the wheat version
is less easily broken, due to its elevated gluten content, and
therefore often larger in circumference. Tortillas are suitable for
lunch and dinner, with a unique taste and texture compared to other
forms of bread. However despite these advantages, consumers have
difficulties "managing" a tortilla. The amount of filling is often
miscalculated while folding, sealing and holding can be a
challenge. As such, tortillas can be inconvenient, messy, and
frustrating, especially for children and their parents. While the
art includes moulding precooked tortillas by heating in a
microwave, this produces an unsatisfactory product that fails to
hold its shape and lacks a true baked texture. Microwaving a
precooked tortilla is inadequate for setting the protein structure
in the tortilla to form a shape and relies upon drying to form
shaped article. With this method, one is forced to overcook the
tortilla to produce a hard (e.g., cardboard-like) and excessively
tough result.
[0004] Thus, there is a need in the art for a soft shaped tortilla
product that is easy to use, less messy, delicious to eat and
healthier than other options. Also, there is a need in the art for
methods for manufacturing and using such a product.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention generally encompasses a low fat shelf stable
soft tortilla fabricated from a Mexican tortilla such as a
chemically leavened cooked cereal dough that is formed into a
variety of thin walled rigid three dimensional shapes that are
rigid yet soft and flexible and which are useful for edible
containers of loose particulate food stuffing, and wherein the
shape is other than (a) flat, (b) flat or in the shape of a cup or
bowl, (c) flat or boat/canoe shaped or (d) flat, in the shape of a
cup or bowl or boat/canoe shaped.
[0006] In a particular aspect, the invention encompasses a soft
shaped tortilla that is formed into shape for holding fillings,
wherein the shape is other than (a) flat or (b) flat or boat/canoe
shaped, flat, and wherein the final moisture content of the
tortilla is between about 23% to about 25%.
[0007] In one aspect, the tortilla is formed to hold the shape of a
cup or bowl.
[0008] In other aspects, the tortilla is formed into the shape of a
U- or square bottomed shaped taco shell, boat/canoe, pita, flower,
pie, tube, envelope, pod, bun, or cone. (square bottomed)
[0009] In still other aspects, the tortilla comprises a flat bottom
and sealed sides.
[0010] In yet other aspects, the tortilla comprises an edible
string.
[0011] The invention also generally encompasses a method of making
a soft tortilla which is formed into a shape, wherein the shape is
other than flat.
[0012] In a first specific aspect, the invention encompasses a
method of producing a soft shaped tortilla, comprising: pressing
raw tortilla dough into a mould, and heating the dough in the mould
without deep fat frying until the dough is at least substantially
cooked and formed into the shape of the mould.
[0013] In a second specific aspect, the invention encompasses a
method of producing a soft shaped tortilla, comprising: pressing
raw tortilla dough into a mould, heating the dough without deep fat
frying long enough to form the dough into a rigid article
conforming to the shape of the mould, removing the shaped dough
from the mould, and heating the shaped dough (e.g., in an oven or
other heating device) until fully cooked.
[0014] In a third specific aspect, the invention encompasses a
method of producing a soft shaped tortilla, comprising: heating
flattened tortilla dough until fully cooked, pressing the
preheated/precooked tortilla into a mould while still warm and
pliable, and cooling the tortilla to set the tortilla into the
shape of the mould.
[0015] In a fourth specific aspect, the invention encompasses a
method of producing a soft shaped tortilla, comprising: rolling raw
tortilla dough into a sheet, pressing the sheet into a mould,
heating the dough long enough to form into the shape of the mould,
removing the shaped dough from the mould, and heating the shaped
dough until fully cooked.
[0016] In a fifth specific aspect, the invention encompasses a
method of producing a soft shaped tortilla, comprising: injecting
raw tortilla dough or batter into a mould, and heating the dough or
batter in the mould until it is fully cooked and formed into the
shape of the mould.
[0017] In a sixth specific aspect, the invention encompasses a
method of producing a soft shaped tortilla, comprising: injecting
raw tortilla dough or batter into a mould, heating the dough long
enough to form into the shape of the mould, removing the shaped
dough from the mould, and heating the shaped dough (e.g., in an
oven or other heating device] device) until fully cooked.
[0018] The method can further comprise causing the dough to rise in
an irregular manner so as to cause brown points.
[0019] The method can still further comprise using two cooking
moulds, wherein the first mould comprises a cavity in the shape of
the tortilla product; and the second mould comprises a protrusion
shaped to fit into the cavity of the first mould. The moulds can be
preheated prior to use.
[0020] In its principle article aspect, the present invention
provides packaged food articles comprising:
A hermetically sealed food package; [0021] A quantity of baked soft
shaped tortilla pieces disposed therein said soft shaped tortilla
pieces having a water activity of 0.88 or less; and, [0022] A
headspace gas having an oxygen level of less than 5%
[0023] In another article aspect of the one and same invention,
meal kits are provided. The meal kits include meal kit for use in
making a Mexican soft shaped tortilla, comprising: [0024] An outer
package; [0025] A first soft shaped tortilla base pieces package
food article disposed within the outer package including: [0026] A
hermetically sealed food package; [0027] A quantity of baked soft
shaped tortilla pieces disposed therein said soft shaped tortilla
pieces fabricated from a farinaceous dough having a water activity
of 0.88 or less; and, [0028] A headspace gas having an oxygen level
of less than 5%; and, [0029] A second packaged food article
disposed within the outer package that is either a pouch of dry
seasoning mixture or a pouch of a wet sauce. [0030] In another
article aspect of the one and same invention, methods are provided
of preparing a soft shaped tortilla base piece packaged food
article, comprising the steps of: [0031] providing a quantities of
a chemically leavened gluten plastic or viscoelastic dough; [0032]
forming the quantities into shaped heat set pieces; [0033] balking;
the shaped heat set pieces to form finished soft shaped tortilla
base pieces; and, [0034] packaging a number of finished soft shaped
tortilla base pieces within a modified atmosphere package to form a
soft shaped tortilla base piece packaged food article.
[0035] While multiple aspects are disclosed, still other aspects of
the present invention will become apparent to those skilled in the
art from the following detailed description, which shows and
describes illustrative embodiments of the invention.
[0036] As will be realized, the invention is capable of
modifications in various obvious aspects, all without departing
from the spirit and scope of the present invention. Accordingly,
the drawings and detailed description are to be regarded as
illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 depicts a model of a canoe/boat shaped soft
tortilla.
[0038] FIG. 1A depicts a model of a canoe/boat shaped soft tortilla
with extended sides.
[0039] FIG. 2 depicts a model of a pita shaped soft tortilla.
[0040] FIG. 3 depicts a model of a flower bud shaped soft
tortilla.
[0041] FIG. 4 depicts a model of a pie shaped soft tortilla.
[0042] FIG. 5 depicts a model of a tube shaped soft tortilla.
[0043] FIG. 6 depicts a model of an envelope shaped soft
tortilla.
[0044] FIG. 7 depicts a model of a bun shaped soft tortilla with
edible string.
[0045] FIG. 8 depicts a model of pod shaped soft tortilla
[0046] FIG. 9 depicts a bowl shaped soft tortilla.
[0047] FIG. 10 is an exploded perspective view of a meal kit of the
present invention including a carton housing a nested array of
shaped tortillas food packaged article of the present invention as
well as a dry pouch and a wet pouch of secondary food
ingredients.
DETAILED DESCRIPTION OF THE INVENTION
[0048] The present invention relates to improved shelf stable
consumer packaged food articles including components fabricated
from a Mexican tortilla like chemically leavened cooked farinaceous
dough in a variety of thin walled three dimensional set or rigid
shaped forms yet soft and flexible that are useful for edible
containers of loose particulate food stuffing and to methods for
their preparation.
[0049] Throughout the specification and claims, percentages are by
weight and temperatures in degrees Centigrade unless otherwise
indicated.
[0050] The present consumer packaged food articles comprise at
least one soft shaped tortilla piece as its principal edible
component. As used herein, a "soft shaped tortilla" or,
equivalently, a "shaped soft tortilla" means a fully cooked but
non-fried tortilla farinaceous dough product that is formed into a
thin walled three dimensional shape of sufficient rigidity to holds
its shape at room temperature. Thus, "tortilla" means a fully
cooked product. By comparison, "tortilla dough" means uncooked or
partly cooked product. "Fully cooked" is understood to be a product
that reaches about 85.degree. C. (+/-2 degrees), and is evidenced
by substantially all of the starch being gelatinized.
[0051] Broadly, in one article aspect, the present invention
comprises a soft shaped tortilla in a variety of specific three
dimensional shapes or configurations. These shaped food articles
are useful as the principal edible components of consumer packaged
food product articles. Traditionally, in northern Mexico, tortillas
are cooked unleavened flexible flat breads typically in thin or
flat, circular or elliptical shape useful as an edible bread wrap
for small quantities of other foods such as meat pieces, rice,
and/or vegetables mixture. Thus, the present food articles are to
be distinguished from egg or egg omelet based dishes often referred
to as "tortillas" (Tortilla de patatas) in other Spanish speaking
locations.
[0052] In one aspect, the present disclosure encompasses a soft
shaped tortilla product with the shape being defined as being other
than flat. (a) flat, (b) flat or in the shape of a cup or bowl, (c)
flat or boat/canoe shaped, or (d) flat in the shape of a cup or
bowl, or boat/canoe shaped.
[0053] In another aspect, the disclosure encompasses a soft shaped
tortilla that is formed into three dimensional shape suitable for
holding fillings, wherein the shape is other than (a) flat or (b)
flat or boat/canoe shaped.
[0054] The final moisture content of the soft shaped tortilla is
less than about 28% (.about..ltoreq.28%), preferably
.about..ltoreq.25%. In preferred form, the soft shaped tortillas
are shelf stable and exhibit a water activity value ("A.sub.w") of
.about..ltoreq.0.88. In less preferred variations, the soft shaped
tortilla pieces are suitable only for refrigerated distribution and
sale and exhibit an A.sub.w of .about..ltoreq.0.92.
[0055] The particular selection of ingredients and concentration
are selected to provide finished soft shaped tortilla products
having a water activity ("Aw") of 0.88 or less and for best results
less than 0.85 to about 0.7. Selection of such water activity value
is important in achieving a balance between microbial shelf
stability and dough handling characteristics. Water activity can
also be reduced by using polyols such as glycerol and sorbitol.
Good results are obtained when the moisture content of the finished
product ranges from about 10% to about 25%, preferably about 15% to
20%.
[0056] The invention disclosure further encompasses a method of
making a soft shaped tortilla product.
[0057] In one particular aspect, the invention disclosure
encompasses a tortilla (e.g., round, flour tortilla) that is hot
formed to hold the shape of a cup or bowl, e.g., a salad bowl. In
other aspects, the tortilla can be formed to rigidly hold the shape
of taco (i.e., U-shaped taco shell) or the shape of a boat/canoe.
In still other aspects, the tortilla can be formed to hold the
shape of a pita, flower bud, pie, tube, envelope, pod, bun, or
cone. The formed shape can have a flat bottom and sealed sides.
[0058] In accordance with the invention, the soft shaped tortilla
articles can be provided in a variety of sizes from jumbo burrito
size to mini chalupa size. A "chalupa" (Spanish for "boat" or
"launch") is a tortilla dough formed into a shape reminiscent of a
small boat. As starting material, it is possible to use round
precooked tortillas or rounded flatted tortilla dough that is about
76 mm, about 102 mm, about 127 mm, about 152 mm, about 178 mm,
about 191 mm, about 203 mm, about 229 mm, about 254 mm, or up to
about 305 mm, or more, in diameter. For example, a 190 mm diameter
precooked tortilla or flattened tortilla dough can be used to give
a cup dimension of about 89 mm diameter and about 51 mm height. It
is also possible to use precooked tortillas or flattened, pre-cut
pieces of dough that are cut to easily fit into a mould for
shaping. The starting material can be any shape suitable for the
final mould, for example, round, oval, crescent, square,
rectangular, trapezoid, triangular, etc.
[0059] In one aspect, the overall size of the soft shaped tortilla
is such it is portable to hold, and that the consumer can take
mouth sized bites. In this aspect the width of the soft shaped
tortilla is no wider than the distance an average adult mouth may
comfortably open when consuming a sandwich. In another aspect, the
width of the soft shaped tortilla is no wider than the distance an
average child mouth may comfortably open when consuming a sandwich.
In one particular aspect, the overall width after forming is about
25 mm or less, or about 12 to about 25 mm, for example, for
children. In one other aspect, the width is about 37 mm or less, or
about 12 to 37 mm, for example, for adults.
[0060] In another aspect, the height of the soft shaped tortilla is
limited to the distance an average adult mouth can comfortably open
when consuming a sandwich. In another embodiment the height of the
soft shaped tortilla is limited to the distance an average child's
mouth can comfortably open when consuming a sandwich. In a specific
aspect, the height of the soft shaped tortilla is about 25 mm or
less, or about 12 to about 25 mm, for example, for children. In
another aspect, the height is about 37 mm or less, or about 12 to
about 37 mm, for example, for adults.
[0061] As a larger size, the soft shaped tortilla will have a width
of at least about 25 mm. In another aspect, the width is limited to
the bite width of an average adult mouth. In yet another aspect,
the width is limited to the bite width of an average child's mouth.
In a particular aspect the width of the soft shaped tortilla is
about 25 to about 51 mm, for example, for children. In one other
aspect, the width is about 37 to about 75 mm, for example, for
adults.
[0062] Depending on the final form of the tortilla, the overall
diameter of the soft shaped tortilla (e.g., for the leading part
which is directed into the mouth) can be any size from about 10 mm,
about 12 mm, about 15 mm, about 20 mm, about 25 mm, about 30 mm,
about 35 mm, about 37 mm, and about 40 mm, or for example, from
about 12-37 mm.
[0063] Regardless of specific shape, a feature of the present soft
shaped tortilla articles is a thin walled construction
characteristic of a tortilla. Good results are obtained in terms of
sufficient rigidity as to maintain the desired structure while
nonetheless providing a soft eating quality characteristic of wheat
tortillas, is obtained when the present articles are fabricated
with wall thicknesses ranges from about 1-5 mm, preferably about 24
mm. For example, in one specific embodiment, the thickness of the
soft shaped tortilla can be about 1.3 mm, about 2.3 mm, about 3.3
mm, or about 3.8 mm.
[0064] Good results are obtained when the present shaped tortilla
articles are fabricated having a length ranging from about 50 mm to
about 250 mm. In certain embodiments, the articles range from about
70 mm to about 200 mm in length. In certain specific embodiments,
the articles have a length of, about 150 mm, while in certain other
specific embodiments having a length of about 170 mm, about 190 mm,
about 200 mm, about 250 mm, or more or in a range of from about
50-mm to about 200 mm.
[0065] In another variation, the shaped tortilla of the present
invention can be made using a standard tortilla having a thickness
less than 1.5 mm or a thickness greater than or equal to 1.5 mm. As
mentioned above, range on thickness could be 0.5-5 mm Consequently,
in one aspect, the shaped tortilla can be made from a standard
tortilla having a thickness of about 1.5 to about 3.0 mm, or
greater. In one aspect, then, the shaped tortilla can be made from
a standard tortilla having a thickness of about 1 to about 2.0 mm,
or greater.
[0066] In one particular aspect, the cavity of the shaped tortilla
is larger than the cavity of the conventional tortilla.
Consequently, the shaped tortilla can hold a greater amount of
filling than the conventional tortilla. In this way, the shaped
tortilla can be filled with greater amounts of meat and still have
room for adequate amounts of all other available fillings. The
cavity of the shaped tortilla can also provide consistent wrapping
to filling ratio throughout the product. As such, the tortilla
fillings can be enjoyed down to the last bite, as opposed to the
last bite being a mouthful of dough. This provides for greater
eating satisfaction and, as a result, will be preferred by a
consumer. In addition, the larger cavity allows a utensil (e.g.,
spoon) to be used to access the cavity when used to load the
filling.
[0067] Notably, each of the disclosed shapes provides benefits to
the consumer. The boat/canoe shape (e.g., FIG. 1) is easy to fill,
holds a large amount of fillings, and allows layering of fillings.
The pita shape (e.g., FIG. 2) is easy to hold and use, fitting
naturally into the hands. It is a familiar shape and provides
consumers with an indication when maximum filling is reached. The
flower bud shape (e.g., FIG. 3) is easy to fill and provides the
option to fold or leave open. It allows one handed eating, which is
easy for kids and suitable for consumers on the go. The round
bottom allows filling down to the last bite. The pie shape (e.g.,
FIG. 4) is unique, impressive, and ideal for entertaining. It has a
large opening which is easy to fill.
[0068] As another option, the tube shape (e.g., FIG. 5) is easy to
hold together, making it neater to eat. It has a wide bottom which
allows for large amounts of filling. The envelope shape (e.g., FIG.
6) provides a flap to fold over. This looks tidy and prevents
ingredients from falling out. It also sits flat on the plate making
it easier to fill. The pod shape (e.g., FIG. 8) is unique, fun, and
adaptable. The pods can be used separately, for example, for dips,
or can be used as a set, for example, to fill with different
ingredients. The boat shape (e.g., FIG. 7) is kid friendly and very
adaptable, as it can also work as a dessert option. For example, it
can be presented as a sweetened tortilla filled with fruit
chocolate, cinnamon, etc. In another aspect, the shaped tortilla
can be formed into that of a salad bowl (e.g., FIG. 8). Although
not as portable as other shapes, it does offer an alternative for
use in restaurant or food service venues, as a non-fried taco salad
option.
[0069] In a preferred aspect, the precooked tortilla or tortilla
dough is formed into a rounded shape, e.g., a cup or a bowl, or
optionally, a taco shape (i.e., U-shaped taco shell), boat/canoe
shape, pita shape, flower shape, pie shape, tube shape, bun shape,
or cone shape. Yet, it is understood that the disclosed shapes are
exemplary, and that any shape can be utilized in accordance with
the invention. In addition, each of the described shapes can be
modified as needed, for example, for the boat/canoe shape, one or
more of the ends can be folded high, and for the pita shape, the
product can include a flap that folds over.
[0070] It will be further understood that the shaped tortillas can
be prepared from a variety of cereal flours, for example, with
white flour, corn flour, masa flour, whole wheat flour, multigrain
flour, whole grain flour, rice flour, gluten-free flour, or any
combination thereof. The dough can additionally include added
herbs, seasonings and flavour ingredients to provide general
flavours such as Mexican, Italian, Mediterranean, Asian, Caribbean,
and Indian; and specific flavours such as jalapeno, chipotle,
cheese, black bean, red chilli, pesto, herb, garlic, rosemary,
vegetable, spinach, sundried tomato, basil, cilantro, or any
combination thereof; and dessert flavours such as chocolate,
blueberry, pineapple, banana, honey, and apple cinnamon, or any
combination thereof.
[0071] In one aspect, the shaped tortillas (e.g., bun shaped
products) are used in conjunction with edible string. This can be
used to provide fun for kids and increased portability for work
lunches. In various aspects, one or more different flavours of
string can be used with one tortilla.
[0072] In accordance with the invention, the shaped tortillas can
be used as `blank canvas` allowing consumers to create own taste
preferences and also experiment as tortilla taste compliments all
kinds of flavours and ingredients. The shaped tortillas allow a
large number of options for fillings and folding. The texture and
thickness of the shaped tortillas is ideal for a variety of meal
choices. It is flexible enough to hold fillings and avoid breakage,
and moist enough to please the palate.
[0073] In particular, the shaped tortillas can be used as a
breakfast alternative (e.g., with cooked eggs, omelettes, ham,
bacon, or VEGEMITE.TM. brand food paste (which is a dark brown food
paste made from yeast extract, used mainly as a spread on
sandwiches, toast and cracker biscuits, as well as a filling of
pastries. VEGEMITE food paste is made from leftover brewers' yeast
extract, a by-product of beer manufacturing, and various vegetable
and spice additives), for lunch (cold fillings such as salad, ham,
lunch meats, etc.), and for dinner (hot fillings such as meats,
vegetables, etc.). It will be understood that Mexican fillings
(e.g., taco, burrito fillings) are specifically envisioned,
including lettuce, beans, peppers, cheese, cooked meat or poultry,
sauce, sour cream, guacamole, etc.
[0074] The present invention features a number of advantages. It
allows consumers to place many types of fillings (e.g., salad
greens, taco fillings, etc.) inside, but is lighter and healthier
than a fried shell or a bread bowl. It gives the advantage of being
able to hold the fillings in the tortilla while reducing the
problem of filling falling out the sides of a typical taco shell or
tortilla. The ends of the formed tortilla can be sealed, so there
is minimized leaking out of the end of the tortilla. The sides of
the tortilla can rise from the base slightly so that fillings are
less likely to leak out during filling. Optional side extensions
can make the tortilla enclosed.
[0075] In this way, the invention provides the convenience of a
pre-formed shell, in pliable, healthier, low mess presentation. The
invention gives consumers the option of a soft, neater to eat
tortilla. The shaped tortillas remain tender and malleable to give
the true tortilla eating experience with minimal cracking. The
shaped tortillas of the invention are clearly distinguished from
shells which are deep fried and crispy. The invention is unique in
that it provides for tortillas to retain a predetermined shape
without the need for frying, while maintaining a soft texture.
Also, the present products are to be distinguished from smaller
bite-sized tortilla chips which are crisp and frangible whether
made by deep fat frying or baking or other bite sized carriers, or
holders.
[0076] As further advantages, the shaped tortillas can be made on a
sheeting line with high throughput. The shapes can be stackable for
compact packaging. The tortilla products can be provided in a shelf
stable format with re-sealable packaging. The soft format of the
formed tortillas avoids the breakage and wastage associated with
hard shelled holders. The portability of the shaped tortillas gives
consumers the freedom to eat at home, at work or on the go. It
provides consumers with convenient eating solutions, including
spontaneous and last minute meal options.
[0077] The invention also encompasses a method of making a soft
tortilla which is formed into a shape. The method can comprise
putting raw tortilla dough in a mould and cooking it to completion
to set the shape. Alternatively, the method can comprise heating
raw tortilla dough in a mould to set the tortilla shape without
fully cooking it. The shaped dough is then heated in a further step
to fully cook it, so as to cause the structure to become firm, and
to lower the moisture level.
[0078] As another alternative, the method can comprise preheating
flattened tortilla dough; further heating the flattened dough in a
mould to set the shape; and further heating the moulded dough to
fully cook it and to reduce the moisture content. In a further
alternative, the method can comprise heating a flat precooked and
preheated tortilla; wrapping the heated, flat precooked and
preheated tortilla around a mould to form a shape; and allowing the
warm, shaped soft tortilla product to cool in a manner that retains
the shape and reduces the moisture content.
[0079] As a still further alternative, the method can comprise
injecting raw dough or batter into a mould and cooking it to
completion to set the shape. In an even further alternative, the
method can comprise injecting raw dough or batter into a mould and
heating it to set the shape without fully cooking it. The shaped
dough is then heated in a further step to fully cook it, so as to
cause the structure to become firm, and to lower the moisture
level.
[0080] The method can further comprise causing the dough to create
gas bubbles in an irregular manner so as to cause browned areas or
points. The method can still further comprise using two heated
cooking moulds, wherein the first mould comprises a cavity in the
shape of the tortilla product; and the second mould comprises a
protrusion shaped to fit into the cavity of the first mould. These
are commonly called male and female moulds.
[0081] It should be noted that, while the present invention finds
particular suitability for use in connection with the provision of
white flour based recipes, the skilled artisan will appreciate that
the present invention finds usefulness in provision of recipes
encompassing corn flour, masa flour, rice flour, wheat flour,
multigrain flour, whole grain flour, or any combination thereof,
including wheat/white blends, multigrain/white blends, masa/white
blends. The shaped tortillas can be prepared as products that are
reduced fat (,i.e., reduced or lower in fat compared or relative to
fried tortilla shells) having a fat content of 20% or less, or low
fat, reduced or low carbohydrate, or reduced or low sodium, or
"lite", or any combination thereof. By "low fat" is meant herein a
product having a fat content of 10% or less. In certain preferred
embodiments, the present tortilla products have fat levels ranging
from about 5-9% fat.
[0082] For corn tortillas, masa dough can be formed. This can be
done by purchasing masa dough from a vendor, purchasing masa flour,
and mixing it with water, annatto (an optional yellow colouring),
salt, and rework to form the dough, or by purchasing raw corn and
processing it to make the masa dough. If raw corn is purchased, the
raw corn is cooked with lime and then steeped. The corn is then
washed and ground into masa flour, which is then mixed with other
ingredients to form the dough.
[0083] The dough (i.e., any type or flavour) can be processed
through a sheeting machine to form flat raw tortilla dough. In one
embodiment, the flat raw highly developed tortilla dough is placed
onto moulds prior to heating. In another embodiment, the tortilla
dough is pre-heated during flattening, before placement. In an
alternate embodiment, the tortilla dough is cooked before placement
onto the moulds. According to the invention, the moulds can be
solid, or vented and/or perforated, or conventional forms having
upper and lower plates.
[0084] The tortillas or tortilla dough (preheated or not) can then
be heated to adopt the form of the moulds. For this heating, the
tortillas or tortilla dough can optionally be baked, resulting in
tortillas with toast marks. This also reduces moisture content.
After heating, the moulded products exit as one or more shapes
described herein. Since the formed tortillas are still pliable for
short periods while still hot immediately after heating, care is
taken to preserve the desired shape. The shapes become more rigid
as the tortillas cool.
[0085] The shaped products are heated to reduce the moisture
content. For this, any warm heat source can be used. Baking is
preferred, including baking by conventional ovens, convection
ovens, rotary rack ovens, brick ovens, infra-red ovens, tortilla
ovens, and toaster ovens. Grilling can also be used. In certain
aspects, the invention specifically excludes the use of microwave
heating. Preferably, the shaped tortillas are heated to retain
softness while avoiding a tough, chewy, or soggy texture. In
various aspects, the moisture content of the final product can be
in a range from about 23% to about 28%, or specifically, about 24%,
about 25%, or about 26%. In particular aspects, the water activity
of the final product can be in a range of about 0.82 to about 0.92,
or less than 0.88.
[0086] In the preferred embodiment, the shaped soft tortilla piece
is fabricated from a dough formulation from a chemically leavened
wheat based or farinaceous baked developed or gluten structured
dough. Batters and doughs as used herein are distinguishable
compositions even though each comprises some number of common
ingredients. "Dough" as used herein refers to an intermediate food
product that has a gluten-based structure. In dough, the gluten
forms a continuous dough elastic medium into which other
ingredients are embedded. A dough is typically prepared by mixing,
and kneading or "working" and is often stiff enough to cut into
various shapes.
[0087] In contrast, "batter" as used herein refers to an
intermediate food product that comprises flour, water, eggs and
salt and optionally fat and sugars that are a starch batter-based
composition. In a batter, gluten development is purposefully
minimized. Batters are inelastic. Liquid added to make the batter
forms a continuous batter medium in which other ingredients are
dispersed. A batter cooks into a soft, moist and sometimes crumbly
product. A batter is typically prepared by blending, creaming,
stirring or whipping and is generally thin enough to pour or scoop
or squeeze out of container. Thicker batters in the form of a paste
have certain properties of thickness similar to doughs but
nonetheless are quite different therefrom.
[0088] "Dough" as used herein further refers to an intermediate
food product that has a low water concentration. Prior to piece
forming and case hardening, the dough, has a water activity within
a range of about 0.95 to 0.99 and a moisture content ranging from
about 30-40%
[0089] In the present invention, in the preferred embodiment, at
least a major portion (greater than about 51%) of the flour used to
prepare the dough is a wheat flour. The flour ingredients can
further include a minor portion (less than about 49%) of additional
flour types. For example, in certain variations, the minor portion
can includes corn flour, corn masa, masa harina and mixtures
thereof. Good results are obtained when a medium protein of
"all-purpose" wheat flour (having a gluten based protein content
ranging from about 9-12% is used to supply wheat flour. Bread flour
(having a higher gluten protein content ranging from about 12% to
16%) can also be used. Lower protein content cake flours (having a
protein content of less than 6%) are less preferred although blends
of cake or pastry flours and bread flour (to achieve an averaged
wheat flour protein content ranging from about 6-9%) can be used.
In a preferred embodiment, a flour is employed having about 11.5%
protein.
[0090] The doughs can also comprise added ingredients to increase
dough stability, to improve eating quality, and to prolong
palatability.
[0091] Unlike traditional fresh tortilla dough formulations, the
present dough formulation of the present invention, in highly
preferred embodiments, comprise from about 1% to about 15% of an
edible fat or shortening ingredient, preferably about 4-10% and for
best results about 9%. A shortening component adds richness to the
eating properties of the finished baked goods as well as aids in
the leavening process. Most importantly, the shortening component
provides additional flexibility or pliability to the tortilla
product over its extended shelf life.
[0092] Preferred for use herein are shortening ingredients that are
solid at room temperature to provide physical stability. Useful
herein to provide such room temperature solid fats are hydrogenated
fats such as obtained from common vegetable oils such as soy, corn,
canola, safflower, cottonseed, and the like. However, since
hydrogenated fats can be sources of undesirable trans fatty acids,
current health trends disfavour usage of hydrogenated fats. Thus,
preferred for use herein are those naturally occurring fats that
are solid at room temperature without hydrogenation. Among these,
preferred for use herein are palm, coconut, palm kernel oil, and
fractions and mixtures thereof. Of course, mixtures of naturally
solid fats and fats obtained by hydrogenation are contemplated.
[0093] The present invention can further comprise about 2% to about
15% of a humectant on a dry weight basis, preferably about 4% to
about 8%. Humectant addition is helpful in achieving the present
water activity levels and the microbial shelf stability at room
temperature provided by the present food products. The humectant
can be any commonly employed humectants ingredient. Preferred
humectants for use herein are selected from the group consisting of
glycerin, glycerol, mannitol, propylene glycol, sorbitol, xylitol
and mixtures thereof. Preferred for use herein is glycerin by
itself or a mixture of sorbitol and glycerin.
[0094] The dough can additionally include about 0.1% to about 4%
salt, preferably about 0.5% to 3% salt.
[0095] Unlike traditional fresh tortilla dough formulations, the
dough of the invention can and in preferred embodiments do, also
comprise a chemical leavening system or baking powder to provide a
chemically leavened wheat dough. The chemical leavening or baking
powder useful herein are such as those containing sodium
bicarbonate and the combination of one or more baking acids with
sodium bicarbonate. Baking acids useful for chemical leavening and
dough mixtures include monocalcium phosphate, glucano-deltalactone,
potassium hydrogen tartrate, dimagnesium phosphate, and mixtures
thereof. One or more baking acids can be combined with the sodium
bicarbonate to form the chemical leavening agent.
[0096] Baking acids useful for chemical leavening and dough
mixtures include monocalcium phosphate monohydrate, sodium aluminum
sulfate, sodium aluminum phosphate, dicalcium phosphate,
glucano-deltalactone, potassium hydrogen tartrate, dimagnesium
phosphate, and mixtures thereof. One or more baking acids can be
combined with the sodium bicarbonate to form the chemical leavening
agent.
[0097] One preferred leavening system which provides this
combination of fast and slow acting leaveners is baking powder that
combines baking soda or sodium bicarbonate with any of sodium
aluminum sulfate, sodium aluminum pyrophosphate, monocalcium
phosphate and mixtures thereof. In another preferred embodiment,
medium acting leaveners such as SAPP 28 (sodium acid pyrophosphate)
can be used. (SAPPs can react in a range of rates with SAPP 28
being about in the middle). It is believed that the fast acting
leavening agent provides improved texture or rheology when the
dough is heat set, and the slow acting leavening agent provides
desired textural attributes when the dough is finish cooked such as
by baking.
[0098] The formulations for the dough from which the present shaped
tortilla pieces are fabricated additionally can include one or more
emulsifiers. Specifically, the present formulations can further
comprise about 0.2% to about 1.5% of a emulsifier on a dry weight
basis, preferably about 0.4% to about 0.8%. Emulsifiers, which
strengthen the dough, give improved mixing and handling tolerance,
increase loaf volume, improve mechanical slicing characteristics,
and can retard staling. Emulsifiers typically are surface active
agents that stabilize mixtures of hydro-phobic and hydrophilic
substances by lowering the interfacial tension between usually
immiscible substances. Emulsifying agents which can be used include
mono- and diglycerides of fatty acids, propylene glycol
mono-diesters of fatty acids, glycerol-lactose esters of fatty
acids, ethoxylated or succinylated mono- and diglycerides,
lecithin, diacetyl tartaric acid esters or mono-diglycerides,
sucrose esters of glycerol, or equivalents thereof and mixtures
thereof. Preferred emulsifiers include mixtures of diacetyl
tartaric acid esters, and succinylated mono- and diglycerides.
Emulsifying agents can be used singly or in combination with
typical usage levels of less than 3% by weight.
[0099] The formulations for the dough from which the present shaped
tortilla pieces are fabricated additionally can include one or more
dough conditioners. The present formulations can her comprise about
0.2% to about 1.5% of a dough conditioners on a dry weight basis,
preferably about 0.4% to about 0.8%. The dough conditioners used
herein can be of the oxidizing type, reducing type or both.
Oxidizing agents or oxidizing type dough conditioners strengthen
the dough. Thus employment of oxidizing dough conditions can lead
to economies with shortened makeup times or by compensating for low
protein in the flour. More commonly used oxidizers today include
azodicarbonamide (ADA), which can be used at up to 45 ppm in the
United States, and L-ascorbic acid (LAA), or vitamin C, for which
there is no usage limit in the United States. ADA works very
quickly, and can easily be overused, producing dry dough that is
hard to work, low volume and cracked bread surfaces. LAA works
slowly; moderate overuse has no deleterious effect on quality and
it is commonly used at about 75 ppm. LAA is currently the only
oxidizing agent permitted in the European baking industry.
[0100] Useful dough conditioners can also include reducing agents,
which serve to encourage the development of gluten, thus shortening
the mixing time and decreasing the amount of mixing energy that is
needed. The most commonly used reducing agent, L-cysteine. Also
useful is sodium metabisulfite.
[0101] The chemically leavened dough of the present invention
optionally includes a variety of ingredients suitable for rendering
finished baked goods prepared therefrom more organoleptically
desirable. These optional components include an anti-mycotic agent,
anti-oxidants or preservatives, and flavor/coloring agents.
[0102] Especially preferred for use herein are flavour and color
additives intended to mimic the yellow color of traditional yellow
corn. While in certain jurisdictions, certain synthetic yellow
colorants are permitted, especially useful herein for such color
additives are those natural yellow colorants such as turmeric, beta
carotene, and/or annatto and mixtures thereof. Also, while any
edible vegetable oil can be used, preferred for flavor and color is
corn oil.
[0103] Useful anti-mycotic agents include sorbic acid and its
derivatives such as sodium or potassium sorbate, propionic acid and
its derivatives, sodium diacetate, monocalcium phosphate, lactic
acid, citric acid parabens and so on. These agents are present in
an amount to aid in the inhibition of growth of undesirable yeast
and/or molds, typically about 0.01 to 1.0% of dry weight basis
ingredient such as sodium propionate, potassium sorbate, calcium
propionate, sorbic acid and mixtures thereof. The anti-mycotic
ingredient can be present in a range of about 0.01% to about 1.0%
on a dry weight basis of the dry mix composition Where legally
permitted, the products herein can additionally include common
levels and types of anti-oxidants and preservatives such as vitamin
E, BHA (butylated hydroxyanisole), BET (butylated hydroxytoluene),
TBHQ (tert-butyl hydroquinone), and mixtures thereof, up to levels
permitted by current food laws.
[0104] The tortilla dough is preferably not acidified and thus
ranges in pH from about 6.0 to 8.0.
[0105] The present invention provides methods for preparing a
finished package soft shaped tortilla food article. The present
methods can include steps of providing a quantities of a chemically
leavened gluten plastic dough; forming into shaped heat set pieces;
baking; and packaging a number of pieces within a modified
atmosphere package.
[0106] The chemically leavened doughs of the present invention are
prepared by blending the essential and optional components such as
wheat flour, optionally corn flour or corn masa, salt, sugar,
shortening or oil, water; glycerol or other polyol; and leavening
system together in such a conventional manner as to produce a well
blended developed gluten dough. Conveniently, the chemically
leavened dough can be prepared from a first liquid premix blend and
a second dry premix blend. The liquid premix blend can include the
oil or liquid shortening, eggs, glycerol, emulsifiers and so on.
The dry blend can include flour(s), sugar(s), salt; leavening and
so on. The dry blend and liquid blend are then combined to form a
gluten based plastic or viscoelastic dough. The chemically leavened
dough is, for example, prepared in a batch or a continuous mixing
device. The moisture content of the dough can range from about 20%
to about 40% resulting in an A.sub.w ranging from about 0.95 to
about 0.99.
[0107] In a preferred variation, the dough is a highly developed
dough as expressed in Brabender units. Characterization of the
doughs in Brabender unit ("BU's") is well known in the dough art
and these units measure the doughs resistance to turning on a mixer
hook. More highly developed or worked doughs exhibit greater
resistance to turning. Good results are obtained herein when the
present doughs have a Brabender value ranging from about 500 to
1000 BU. In more preferred variations, the dough is developed to
its peak or, otherwise expressed, to maximum gluten strength
development.
[0108] The dough is provided in small measured quantities useful
herein for making the present sized and shaped pieces. In a
preferred embodiment in the preparation of smaller base pieces,
these quantities range from about 5-25 g each. For larger soft
shaped tortilla base pieces, a larger quantity (e.g., 40-60 g) can
be used. Any technique or apparatus can be used to provide such
measured quantities of dough. For example, the dough can be formed
into a continuous shape such as a rope, sheet or ribbon and the
continuous strand sectioned (such as by a reciprocating guillotine
knife) into desired uniform (.+-.10%) quantities, e.g., if a 10 g
quantity is desired, then each quantity will be 10 g.+-.1 g. In
small scale commercial production, simple manual cutting the dough
into such small quantities is the preferred technique.
[0109] In preferred embodiments, the preparation methods
additionally comprise a step dough of resting the measured quantity
of dough to provide a measured quantity of rested dough. Good
results are obtained when the measured quantities of dough, e.g.,
dough balls, are allowed to rest for 5-10 minutes at ambient
temperatures. A resting step is useful for better facility of the
dough conforming to the shape of the dough without thickness
variations or weak spots in the finished pieces.
[0110] The present methods can further include the step of forming
the individual quantities of chemically leavened dough, preferably
rested, into shaped, leavened heat set soft shaped tortilla pieces.
In one variation, this step is practiced as a single step cooking
and forming operation employing a suitably shaped and configured
heated shape press molds. The tortilla press mold is heated to
provide a mold surface temperature ranging from about 190.degree.
C. to 205.degree. C. (375.degree. F. to about 400.degree. F.). A
quantity (e.g., 40-60 g) of the rested dough is placed within the
shape press mold and closed and heated to initiate leavening and to
heat set the soft shaped tortilla base piece. Good results are
obtained when the heating step is practiced for about 45-60
seconds, preferably about 45-55 seconds. The heating operation
heats the dough to temperatures sufficient to gelatinize and
hydrate the starch components substantially completely and to
denature the protein of its gluten content (85-95.degree. C.;
185-200.degree. F.). The formed heating step results in some
moisture loss that adds to the leavening effect and results in hot
cooked shaped pieces having a moisture content ranging from about
28% or less. The now cooked and set shaped soft tortilla piece is
then allowed to coot in the mold through its glass transition
temperature ("T.sub.g") to room temperature to provide a tortilla
piece in a sized and shaped set form piece that is no longer
entirely plastic but semi-rigid, i.e., sufficiently rigid (although
still pliable) to hold or maintain its shape.
[0111] However, in more preferred variations, the cooking step is
practiced in sub-steps wherein only a par-bake operation is
practiced at shorter times, e.g., in the heated press mold and the
cooking step is completed in a subsequent finish baking sub-step.
By reducing the time required in the press mold, greater
through-puts can be obtained for greater cost efficiency. In this
preferred variation, the initial heating or forming sub-step
results in a par-baked or intermediated food item that is no longer
a plastic dough.
[0112] During the forming sub-step, the fast and medium acting
acids of the leavening system initiates the leavening process such
that about 90% or more of the leavening occurs during this step.
While the center plain portion is confined to a thickness of 1-2 mm
by the tortilla press to provide a density in the center plain
portion ranging from about 0.7-0.9 g/cc, Further expansion in the
oven during the baking step allows the piece to chemical leavening
to expand to a density of about 0.3-0.5 g/cc and a thickness of
about 1-5 mm.
[0113] The present method can further include a step finish cooking
the set par cooked base piece to form a finished soft shaped
tortilla base piece food product. In preferred form, the finish
cooking is a baking step that reduces the moisture content of the
par cooked set piece from an initial value of about 26%-30%
moisture to a finish moisture content ranging from about 25% or
less and an A.sub.w of 0.88 or less. (There is actually only a
small reduction in moisture in the press, the moisture went from 37
to 33% moisture. Most of the moisture loss is in the oven.)
Conveniently, the par cooked base piece items are baked at about
175.degree. C. to 210.degree. C. for about 1-5 minutes, preferably
about 2-4 minutes. Preferred for use herein is a belt oven using a
combination of radiant, and conduction heating to provide a
finished product having not only the desired finished moisture
content but also the desirable toast points described above. In
commercial form, a moving belt conveys the par cooked pieces into
an elongated oven of sufficient length and at a line speed
sufficient to provide a residence time within the oven to provide
the desired baking or finish cook times herein. In other
variations, a combination of one or more baking and heating steps
can be practiced to provide not only the finish cooking of any raw
portions of the piece but also to provide any desired toast points
feature herein. The preferred method for us is to use a tortilla
baking oven that is a series of plates or belts where the soft
shaped tortilla are heated by conduction and radiant heat. An
impingement oven using high velocity hot air would also work but
the belt oven is preferred.
[0114] The finished base pieces so prepared are generally entirely
cooked and any raw dough such as in the peripheral ring portion is
finish cooked to at least 90% starch gelatinized.
[0115] After cooling to about room temperature, a number of
finished soft shaped tortilla base pieces are packaged in a
suitable food package. In one embodiment, the number of soft shaped
tortilla pieces are formed or aggregated into one or more stacks or
other ordered arrangement or arranged array such as the two
side-by-side short stacks (not shown). In certain variations,
preparation of the arranged array or protection of the arranged
array is facilitated by a tray, support board or other secondary
package element such as the U-board described above. In these
variations, the packaging step can include a sub-step of mounting a
number of finished soft shaped tortilla base pieces such as in a
confronting relationship on a support member or carrier prior to
disposing the numbers of finished pieces within the food
package.
[0116] In another less preferred embodiment, the number of finished
base pieces are in the form of a loose random mixture in the food
package. While easier to add to a food package in a random form,
such arrangements are less visually appealing. Also, such
arrangements can provide less protection to the finished soft
shaped tortilla base pieces against breakage during handling.
[0117] Suitable for use herein is a food package capable of
hermetic sealing against moisture and optionally oxygen transport
over extended shelf lies ranging from about 6-18 months are room
temperature storage. In preferred form, the food package is
fabricated at least in part from a flexible packaging film to form
a bag or pouch. In certain variations, one or more stacks each
individually wrapped in a sealed flexible packaging film with a
modified packaging atmosphere are bundled together and provided
with an overwrap also conveniently fabricated from a flexible
packaging film.
[0118] The packaging step can also, and in the preferred
embodiment, does include providing the food package with a modified
packaging atmosphere. More particularly, the sub-step can include
flushing the food package immediately prior to finish sealing with
a low oxygen level (below 4% O.sub.2, preferably below 1% O.sub.2)
packaging gas such as CO.sub.2, N.sub.2, N.sub.2O and/or other
inert gas. The food package is then sealed to provide finished
packaged food articles of the present invention. Preferably, the
finished food packaged is hermetically sealed such as to provide a
low oxygen packaging headspace environment of less than 4% O.sub.2,
preferably 1%, and for best results less than 0.5% during an entire
six month of room temperature storage.
[0119] For some embodiments, the headspace comprises at least 10%
(v/v) of CO.sub.2, and can be at least 20%. In a preferred
embodiment, the headspace comprises a blend of 40% CO.sub.2 and 60%
N.sub.2. At such levels, the CO.sub.2 provides modest preservative
properties against spoilage.
[0120] In the preferred embodiment, the food package can be
provided or made from a moisture loss resistant low oxygen
permeability flexible packaging film to provide a hermetically
sealed food package. In preferred form, the packaging material has
an oxygen permeability value of less than 2.5 cc/cm.sup.2/day. In
other embodiments, the packaging can be in the form of a tin,
plastic tub or cup or a paperboard canister provided that the
container can maintain a low oxygen packaging atmosphere for the
extended shelf lives contemplated herein. Thereafter, the present
inventions in its method of preparation aspect can further include
a step of inserting the finished packaged food articles into a
carton. The shelf stable multi-texture wheat based soft shaped
tortilla base pieces can be combined with wet or dry sauce pouches
to provide meal kits for the at home preparation of Mexican soft
shaped tortilla finished food products of superior taste and
texture.
[0121] In a preferred variation, the packaging film is clear or has
at least portion that are transparent so that the product can be
view within the food package. In another variation, at least a
portion of the packaging film is provided by a low oxygen
permeability flexible laminate packaging film having a foil
layer.
[0122] While the package can be overpressurized, preferred herein
is an unpressurizable container for containing and storing the soft
shaped tortilla since overpressurized containers are more expensive
and unnecessary herein.
[0123] Also, pouches of wet and/or dry secondary food components
can be prepared and inserted into the carton to form dinner kits.
The kits can also include cans or tins of other ingredients, e.g.,
diced olives, pimentos, or peppers, or refried beans. The filled
cartons are then finished seated to provide the finished kit items
of the present invention. The kit can include preparation
instructions such as by a preparation instruction legend printed
onto the carton exterior.
[0124] The present kits can be used to provide a multi-component
finished soft shaped tortilla food article. The consumer can add
various supplemental food ingredients such as cooked meat fresh
vegetables (onions, peppers, tomatoes), shredded cheeses, sour
cream, chives, guacamole, retried beans and the like. If desired,
the consumer can reheat the finished soft shaped tortilla base
pieces prior to preparation of fished soft shaped tortilla meal
items herein. In other variations, assembled soft shaped tortilla
items can be warmed prior to consumption.
[0125] More specifically, FIG. 10 depicts a meal or dinner kit of
the present invention. FIG. 10 depicts that the meal kit can
include a carton or other container. The kit includes at least one
packaged soft shaped tortilla base pieces article or the like as
described above disposed within a container. The container can be a
conventional paperboard carton optionally having an easy open
feature such as tear strip. The kit also includes at least one
seated container of secondary ingredients. The container of
secondary ingredients can be, for example, either a wet and/or a
dry pouch. The kit can further include one or more preparation
instruction legends. Legend(s) can include reheating suggestions,
recipes for making toppings, or instructions on how to prepare a
seasoned meat toping ingredient. Such legends can be on the carton
as depicted and/or on the individual pouches (not shown). The kit
container does not need to have a modified atmosphere. In certain
variations, the kit can additionally include a clear film overwrap
(not shown) to provide extra packaging protection. In still other
variations, the kit can include a sealed container such as can or
cup for including additional ingredients, e.g., refried beans in
addition or in substitution for the wet or dry pouches. In still
other variations, the kit can include a tray or other supplemental
packaging support element (not shown) to prevent component movement
within the carton.
[0126] For example, the pouch can contain a wet sauce such as a
salsa sauce or cheese sauce. Wet sauce pouches are typically
aseptically packaged for extended shelf lives. In another
variation, the pouch can include a dry mix of seasoning ingredients
to add to meat to form a flavored meat topping such as a taco
seasoning blend. In this variation, dry blends of solid seasonings,
salt, colors, seasoning, can be blended with pre-gelatinized
starch. The dry seasonings can be mixed by the consumer with water,
heated to form a flavored thickened liquid or thin paste and
blended with consumer supplied cooked meat to form the flavored or
seasoned meat topping ingredient or component. While a variety of
seasoning mixes can be prepared, since cumin is a component of many
Mexican dishes, the dry mix preferably includes at least cumin and
salt. In still other variations, the pouch can include a cream
ingredient such as a ready-to-spread topping frosting for those
executions wherein the soft shaped tortilla is used as a dessert
foundation. In certain variations, the kit can contain one or more
pouches of dry and/or wet secondary kit ingredients such as
pouches.
[0127] In still another embodiment, a previously formed tortilla
(e.g., a conventional store-bought tortilla) is used to form a bowl
after shaping and further heating to form a shaped product that is
then heated until it retains its shape after cooling.
[0128] Preferably, the shaped tortillas are prepared so as to
minimize the formation of discontinuities (e.g., bubbles and voids)
during commercial production. Discontinuities in tortillas can be
minimized by providing flour of the proper granulation, using the
proper ratios of ingredients, maintaining the proper moisture level
in the dough, heating and baking properly, and avoiding the use of
moulds having unnecessarily complex geometries.
[0129] In one particular aspect, the shaped tortilla is reheated
prior to being filled with heated filling. In another aspect, a
heatable filling is placed in the shaped tortilla and then heated
together. In yet another aspect, an individual or machine fills one
or more shaped tortillas with heatable filling and then leaves the
one or more tortillas for another individual to or machine to fill
with other types of filling. Finally, in still another aspect, an
individual or machine leaves one or more shaped tortillas for
another individual or machine to fill with filling.
EXAMPLES
[0130] The examples described herein are for purposes of
illustrating embodiments of the invention. Other embodiments,
methods, and types of analyses are within the scope of persons of
ordinary skill in the molecular diagnostic arts and need not be
described in detail hereon. Other embodiments within the scope of
the art are considered to be part of this invention.
Example 1
TABLE-US-00001 [0131] Wheat Tortilla Formula Formula % Ingredient
ranges Typical usage levels Wheat flour; 11-13% 45-60% 45%, 50%,
55%, 60% protein Water 15-30% 15%, 20%, 25%, 30% Hydrogenated
Vegetable 5-10% 5%, 7.5%, 10% fat such as canola, cottonseed, corn,
soy, safflower; naturally solid fats such as palm, coconut,
Glycerine 0-10% 0%, 2%, 4%, 6%, 8%, 10% Salt 1-2% 1%, 1.5%, 2%
Leaveners; Baking 0.5-1% 0.5%, 0.6%, 0.7%, powder, baking soda,
0.8%, 0.9%, 1% leavening acids such as MCP, SAPP, SALP Dough
conditioners; 0.25-1% 0.25%, 0.5%, 0.75%, 1% Mono-glycerides, Di-
glycerides, SSL, L- cysteine, DATEM
Example 2
Standard Tortilla Procedure
[0132] 1.) Combine ingredients in mixer 2.) Mix 4-10 minutes on
medium speed until dough is fully developed 3.) Allow dough to rest
five minutes 4.) Divide dough into 40 gram balls 5.) Press dough
balls in tortilla press @ 400.degree. F. (.about.205.degree. C.)
for 1-3 seconds 6.) Bake in tortilla oven @400.degree. F.
(.about.205.degree. C.) for 30-90 seconds 7.) Cool five minutes on
cooling rack 8.) Package tortillas 9.) Final tortilla moisture
content of 23-28%, Water Activity at <0.880
Example 3
Soft Shaped Tortilla Procedure 1
[0133] 1.) Ingredients were combined in mixer 2.) These were mixed
4-10 minutes on medium speed 3.) The dough was allowed to rest five
minutes 4.) The dough was divided into 40-60 gram balls 5.) The
dough balls were pressed in press comprising a preheated male and
female mould with desired shape @400.degree. F. (.about.205.degree.
C.) for 1-3 seconds 6.) The shapes were removed from the moulds and
baked in a tortilla oven @400.degree. F. (.about.205.degree. C.)
for 30-90 seconds 7.) The shapes were cooled five minutes on
cooling rack 8.) The soft shaped tortillas were packaged 9.) Final
tortilla moisture content was measured at 23-28%, Water Activity at
<0.880
Example 4
Soft Shaped Tortilla Procedure 2
[0134] 1.) Ingredients were combined in mixer 2.) These were mixed
4-10 minutes on medium speed 3.) The dough was allowed to rest five
minutes 4.) The dough was divided into 60 gram balls 5.) The dough
balls were pressed in press comprising preheated male and female
moulds with desired shape @400.degree. F. (.about.205.degree. C.)
for 15-90 seconds 6.) The shapes were removed from the moulds and
cooled 5 minutes on cooling rack 7.) The soft shaped tortillas were
packaged 8.) Final tortilla moisture content was measured at
23-28%, Water Activity at <0.880
Example 5
Soft Shaped Tortilla Procedure 3
[0135] 1.) Ingredients were combined in mixer 2.) These were mixed
4-10 minutes on medium speed 3.) The dough was allowed to rest five
minutes 4.) The dough was divided into 40 gram balls 5.) The dough
balls were pressed in tortilla press @400.degree. F.
(.about.205.degree. C.) for 1-3 seconds 6.) These were baked in
tortilla oven @400.degree. F. (.about.205.degree. C.) for 30-90
seconds 7.) The baked tortillas were pressed into male and female
moulds of desired shapes 8.) These were cooled, while still in the
moulds, five minutes on cooling rack 9.) The soft shaped tortillas
were packaged 10.) Final tortilla moisture content was measured at
23-28%, Water Activity at <0.88
Example 6
Soft Shaped Tortilla Procedure 4
[0136] 1.) Ingredients were combined in mixer 2.) These were mixed
4-10 minutes on medium speed 3.) The dough was allowed to rest five
minutes 4.) The dough was sheeted to a thickness of 1-3 mm 5.) The
sheeted dough was folded around male mould 6.) The sheeted dough
was cut around male mould 7.) The sheeted dough was pressed into
female mould 8.) The dough was in heated in the preheated moulds at
400.degree. F. (.about.205.degree. C.) for 1-3 seconds 9.) The
shapes were removed from the moulds and baked in tortilla oven
@400.degree. F. (.about.205.degree. C.) for 30-90 seconds 10.) The
shapes were cooled five minutes on cooling rack 11.) The soft
shaped tortillas were packaged 12.) Final tortilla moisture content
was measured at 23-28%, Water Activity at <0.88
Example 7
Soft Shaped Tortilla Procedure 5
[0137] 1.) Ingredients are combined in mixer 2.) These are mixed
1-10 minutes on medium speed 3.) Dough or batter is injected into
preheated mould at 400.degree. F. (205.degree. C.) for 1-3 seconds.
4.) The shapes are removed from mould. 5.) The shapes are baked in
tortilla oven @400.degree. F. (.about.205.degree. C.) for 30-90
seconds 6.) The shapes are cooled 5 minutes on cooling rack 7.) The
soft shaped tortillas are packaged 8.) Final tortilla moisture
content is measured at 23-28%, Water Activity at <0.88
Example 8
Soft Shaped Tortilla Procedure 6
[0138] 1.) Ingredients are combined in mixer 2.) These are mixed
1-10 minutes on medium speed 3.) Dough or batter is injected into
preheated mould at 400.degree. F. (.about.205.degree. C.) for 3-20
seconds. 4.) The shapes are removed from mould 5.) The shapes are
cooled 5 minutes on cooling rack 6.) The soft shaped tortillas are
packaged 7.) Final tortilla moisture content is measured at 23-28%,
Water Activity at <0.88
[0139] The invention has been described herein, with reference to
certain preferred embodiments, in order to assist the reader in
practicing the invention without undue experimentation. However, a
person having ordinary skill in the art will readily recognize that
many of the components and parameters can be varied or modified to
a certain extent without departing from the essence of the
invention. Furthermore, titles, headings, or the like are provided
to enhance the reader's comprehension of this document, and should
not be read as limiting the scope of the present invention.
[0140] The entire disclosures of any patent applications, patents,
and publications, cited above and below, if any, are hereby
incorporated by reference in their entirety. Any discussion of such
disclosures throughout the specification should in no way be
considered as an admission that such disclosure is widely known or
forms part of common general knowledge in the field.
[0141] Throughout this specification, and any sections which
follow, unless the context requires otherwise, the words
"comprise," "comprising" and the like, are to be construed in an
inclusive sense as opposed to an exclusive sense, that is to say,
in the sense of "including, but not limited to".
* * * * *