U.S. patent application number 16/101473 was filed with the patent office on 2018-12-06 for food product including fully or partially cooked egg.
This patent application is currently assigned to Michael Foods, Inc.. The applicant listed for this patent is Michael Foods, Inc.. Invention is credited to Jason W. Mathews, Wanda P. Paine.
Application Number | 20180343903 16/101473 |
Document ID | / |
Family ID | 51528172 |
Filed Date | 2018-12-06 |
United States Patent
Application |
20180343903 |
Kind Code |
A1 |
Mathews; Jason W. ; et
al. |
December 6, 2018 |
FOOD PRODUCT INCLUDING FULLY OR PARTIALLY COOKED EGG
Abstract
A food product involving an integral combination of an egg layer
and an edible, grain-based solid substrate can be provided by a
method that involves providing a precursor product which then is
heated to provide the food product. The precursor product can be
provided by introducing an egg mixture to a primary surface of the
edible solid substrate. The heating of the precursor converts the
egg mixture into the at least partially cooked egg layer of the
food product.
Inventors: |
Mathews; Jason W.; (Gaylord,
MN) ; Paine; Wanda P.; (Gaylord, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Michael Foods, Inc. |
Minnetonka |
MN |
US |
|
|
Assignee: |
Michael Foods, Inc.
Minnetonka
MN
|
Family ID: |
51528172 |
Appl. No.: |
16/101473 |
Filed: |
August 12, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15588672 |
May 7, 2017 |
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16101473 |
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|
13839852 |
Mar 15, 2013 |
9642383 |
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15588672 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23L 15/00 20160801;
A23P 20/20 20160801; A21C 9/06 20130101; A23V 2002/00 20130101;
A23V 2002/00 20130101; A23P 20/10 20160801; A23V 2200/3322
20130101; A21C 9/066 20130101 |
International
Class: |
A23L 15/00 20160101
A23L015/00; A23P 20/10 20160101 A23P020/10; A23P 20/20 20160101
A23P020/20 |
Claims
1. A method of making a food product that comprises an at least
partially cooked egg layer and an edible, grain-based solid
substrate, said method comprising: a) introducing from about 1.5 to
about 3 ounces of a flowable egg-containing composition to a
primary surface of said edible solid substrate, wherein the
thickness of said flowable egg-containing composition is from about
0.3 to about 0.5 inches, said edible solid substrate being amenable
to being handheld, b) allowing said flowable egg-containing
composition to soak or wick beyond the topmost layer of said
primary surface of said edible solid substrate so as to provide a
food product precursor, and c) heating said food product precursor
so as to convert said flowable egg-containing composition to said
at least partially cooked egg layer, which is integrally connected
with and bound to said substrate, thereby providing said food
product.
2. The method of claim 1 further comprising repeating steps (a),
(b) and (c) so as to provide a second food product and introducing
said second food product to said food product so as to provide a
sandwich construction.
3. The method of claim 1 wherein, at the time of being introduced
to said primary surface of said edible solid substrate, said
flowable egg-containing composition is at a temperature of from
about 90.degree. to about 150.degree. F.
4. The method of claim 3 wherein said flowable egg-containing
composition has had its temperature elevated via exposure to a
kettle heater, convection, conduction, microwaving, tube heating,
RF or induction heating.
5. The method of claim 1 wherein said flowable egg-containing
composition comprises one or more solid additives.
6. The method of claim 1 wherein said primary surface of said
edible solid substrate comprises macroscopic roughness.
7. The method of claim 6 wherein said edible solid substrate is a
portion of a bagel.
8. The method of claim 6 wherein said edible solid substrate is a
portion of an English muffin.
9. The method of claim 1 wherein said primary surface of said
edible solid substrate comprises microscopic roughness.
10. The method of claim 9 wherein said edible solid substrate is a
tortilla.
11. The method of claim 1 further comprising packaging said food
product and then cooling the resulting packaged food product.
12. The method of claim 1 wherein said heating step involves
raising the internal temperature of said at least partially cooked
egg layer to at least 165.degree. F., thereby providing a fully
cooked egg layer.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. patent application
Ser. No. 15/588,672, filed 7 May 2017 and presently pending, which
is a continuation of U.S. patent application Ser. No. 13/839,852,
filed 15 Mar. 2013 and now issued as U.S. Pat. No. 9,642,383, the
disclosures of which are incorporated herein by reference.
BACKGROUND INFORMATION
[0002] Large portions of society continue to experience an increase
in the pace of daily life. That quickened pace has been accompanied
by increases in the appreciation of and demand for convenience,
particularly in connection with food.
[0003] The importance of convenience can be seen in the growth in
fast food restaurants, made-to-order vendors, and ready-to-eat
frozen and refrigerated foods. These trends have been particularly
pronounced in connection with food items commonly associated with
breakfast, many of which include some type of cooked egg
product.
[0004] Interest in and demand for protein-rich foods also continues
to grow and, at least in connection with egg-origin protein, this
intersects with the increased demand for convenience discussed
above.
[0005] Probably in response to these trends, multitudes of
bread-egg combinations have been made available. In these, whole
eggs and egg components (e.g., egg white only) have been prepared
in a variety of forms including fried, scrambled, Benedict, omelet,
etc., while bread products have included muffins, bagels, toasted
or untoasted bread, rolls, tortillas, etc.
[0006] In addition to made-to-order products using fresh
ingredients, vendors have become comfortable with offering
sandwich-like constructions that are wholly or partially made
elsewhere. For example, a fast food restaurateur might purchase a
pre-made egg-based sandwich and merely heat it prior to serving or,
more commonly, fully heat a partially cooked egg product for
assembly with a bread product. In the home, made-to-order and
ready-to-heat products are most common, with the middle ground
option (partially cooked, ready-to-assemble) being less common.
[0007] Bread-egg combinations are not without drawbacks, of course.
For example, where the egg component of the combination is in a
Benedict-type form, it can fall out from between the top and bottom
bread components. Also, because of the nature of a sandwich
construction, the ratio of protein-to-carbohydrate can be
relatively low.
[0008] A sandwich-type construction that increases the
protein-to-carbohydrate ratio and eliminates the possibility of
spills while, at the same time, maintains the advantages of quick
preparation and ease of handling has significant commercial
value.
SUMMARY
[0009] Hereinafter is described a method of making a food product
that is easy to handle, can be prepared quickly and easily, and has
a higher-than-usual ratio of protein-to-carbohydrate.
[0010] The resulting food product can be analogized to an
open-faced egg sandwich with one important proviso, specifically,
the egg-based component of the sandwich is integral with the bread
component, which eliminates the possibility that the two components
can become separated, e.g., the egg-based component does not fall
off or out of the bread-based component.
[0011] The food product involves an integral combination of an egg
layer that is at least partially cooked with an edible, grain-based
solid substrate. This food product can be provided by a method that
involves providing a precursor product which then is heated to
provide the food product. The precursor product can be provided by
introducing an egg mixture to a primary surface of the edible solid
substrate. The heating of the precursor converts the egg mixture
into the at least partially cooked egg layer of the food
product.
[0012] The egg mixture can be introduced to the primary surface of
the edible solid substrate in at least two different ways. One such
way involves depositing the egg mixture directly on the primary
surface of the edible, grain-based solid substrate. Another way
involves depositing the egg mixture into or onto a carrier,
followed by applying a primary surface of the edible solid
substrate to the upper surface of the deposited egg mixture.
[0013] The heating step of the process can involve baking,
broiling, microwaving, steaming, hot air, combinations (e.g., any
of a variety of TurboChef.TM. ovens from TurboChef Technologies,
Inc., of Carrollton, Tex.), and the like.
[0014] The resulting food product can be refrigerated or frozen for
later use, either by an end consumer or by a vendor.
[0015] The food product, when ready for consumption (either
immediately or after reheating), is both easy to handle and
convenient.
[0016] It also provides flexibility in sizing. The food product can
be less caloric than the heretofore standard breakfast sandwich
because one of the two bread layers has been eliminated. However,
because each food product includes an edible, grain-based solid
substrate carrying an integrated egg layer, two (or more) food
products can be combined to form something that looks akin to the
standard breakfast sandwich, albeit with cooked egg layers that are
integral with and partially integrated into the bread layers.
[0017] Other aspects will be apparent from the accompanying figures
and the more detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Illustrative configurations set forth in the description
that follows are shown in the drawings, where similar numbers refer
to similar parts or features. The figures are not necessarily to
scale.
[0019] FIG. 1 is a side view of one embodiment of a food product
according to the present invention.
[0020] FIG. 2 is a sectional view taken along line 2-2 of FIG.
1.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0021] The following description is provided to explain and
exemplify the aforedescribed food product, particularly exemplary
constructions and methods of making. The appended claims define the
inventions in which exclusive rights are claimed, and they are not
intended to be limited to particular embodiments shown and
described.
[0022] Food product 10 involves an integral combination of an egg
layer 14 that is at least partially cooked and an edible,
grain-based solid substrate 12.
[0023] Essentially any type of cereal can be used as the grain from
which edible substrate 12 is made, examples of which include, but
are not limited to, wheat (all types), buckwheat, oats, barley,
sorghum, millet, maize, rye, quinoa, and rice. Certain other plant
origin materials, e.g., soybeans, can be used in the manufacture of
bread-like products, and these also can be used.
[0024] The particular form of edible solid substrate 12 also is not
limiting. In FIGS. 1 and 2, edible solid substrate 12 is depicted
as a half of a bagel, but this is not limiting. Grains have been
converted into multitudes of edible products; as long as any of
these products is amenable to being held in the hand and can
support and integrally connect with the egg layer (discussed
below), they can be used in the food product of the present
invention. Non-limiting examples include bread slices, bagels
(sliced or unsliced), bagel thins, muffins, English muffins,
croutons, crackers, rolls and baguettes (sliced or unsliced),
flatbreads (including tortillas), cornbread, and the like.
[0025] The thickness of edible solid substrate 12 generally ranges
from .about.0.1 to .about.1.0 inches, commonly from .about.0.2 to
.about.0.8 inches, and typically from .about.0.3 to .about.0.7
inches. The weight of edible solid substrate can vary widely but
generally ranges from .about.0.5 to .about.5 ounces, commonly from
.about.0.75 to .about.3 ounces, and typically from .about.1 to
.about.2.5 ounces.
[0026] If desired, edible solid substrate 12 can be toasted,
browned, or otherwise heat treated prior to usage in the method
described below.
[0027] Further, edible solid substrate 12 optionally can be soaked
in, coated with or otherwise treated with any of a variety of
spices such as salt, pepper, paprika, sesame seeds, granola, poppy
seeds, coriander, cumin, curry powder, cinnamon, rosemary, and the
like, any of a variety of oils and oil-based spreads such as
margarine, butter or any of a variety of other types of dairy
spreads, and any of a variety of glazes.
[0028] Egg layer 14 is at least partially cooked, meaning that it
is cooked at a time/temperature combination that solidifies egg
layer 14 sufficiently to permit it to adhere to and become integral
with a primary surface of edible solid substrate 12. Typically, for
a food product to be described as pre-cooked, it must have reached
a certain minimum temperature, e.g., 165.degree. F. More details on
the heating are provided below in connection with the discussion of
the food product precursor.
[0029] Egg layer 14 can be provided from a flowable egg-containing
composition. This composition can be provided from whole eggs, egg
whites, egg yolks, synthetic eggs, synthetic egg whites, synthetic
yolks, or a combination of such ingredients.
[0030] Optionally but preferably, the flowable egg-containing
composition also can contain any of a variety of solid taste and/or
texture enhancers 16. These can include, but are not limited to,
meats such as ham, bacon, sausage, steak, ground beef, poultry,
pork, fish, and vegetarian versions of each, produce such as
peppers, tomatoes, onions, carrots, parsley, pomes (including
potatoes), corn, citrus fruits, and the like, and any of a variety
of cheeses. These solid additives can be provided in whole form if
sufficiently small but, in most case, will be provided in a
parceled form such as diced, minced, shredded, cubed, cut, torn,
mashed, julienned, and the like. In FIGS. 1 and 2, cheese and
ground sausage are employed as solid taste and/or texture enhancers
16.
[0031] Other additives that can be included in the flowable
egg-containing composition include, but are not limited to, any of
a variety of spices (e.g., salt, pepper, paprika, coriander, cumin,
curry powder, oregano, thyme, parsley, sage, rosemary, onion
powder, etc.), preservatives such as BHT, citric acid, EDTA, nisin,
texture modifiers including any of a variety of starches, gums
(e.g., xanthan and guar), enzymes, emulsifiers, baking soda, baking
powder, lecithin, various caseinates, glucono delta-lactone,
various phosphates, and the like.
[0032] The flowable egg-containing composition can be pre-heated
prior to introduction to edible solid substrate 12. This
pre-heating can be accomplished by kettle heaters, convection,
conduction, microwaving, tube heating, RF, induction, etc., and
preferably results in a flowable egg-containing composition at a
temperature of from .about.90.degree. to .about.150.degree. F.
[0033] For egg layer 14 to become integral with, or integrally
connected with, edible solid substrate 12, the latter preferably
has sufficient surface roughness to permit the flowable
egg-containing composition to partially soak into the substrate
prior to solidifying at elevated temperature. Some materials useful
as substrates, like sliced bagels and English muffins, have
substantial macroscopic roughness and, accordingly, are very
amenable to receiving the flowable egg-containing composition in
such a way so as to permit soaking and wicking of the flowable
egg-containing composition beyond the very topmost layer of edible
substrate 12. Other materials potentially useful as substrates,
e.g., tortillas, appear much smoother but have significant
microscopic texture, which often is sufficient to permit the
flowable egg-containing composition to soak or wick into and become
integral with the substrate.
[0034] The amount of flowable egg-containing composition to edible
solid substrate 12 can vary widely but generally ranges from
.about.0.5 to .about.6 ounces, commonly from .about.0.75 to
.about.5 ounces, typically from .about.1 to .about.4 ounces, more
typically from .about.1.25 to .about.3.5 ounces, and preferably
from .about.1.5 to .about.3 ounces. The thickness of the flowable
egg-containing composition generally ranges from .about.0.1 to
.about.1 inches, commonly from .about.0.2 to .about.0.75 inches,
and typically from .about.0.3 to .about.0.5 inches.
[0035] Introduction of the flowable egg-containing composition to
edible solid substrate 12 results in provision of a precursor
product which, upon heating, converts the flowable egg-containing
composition into egg layer 14, resulting in food product 10.
[0036] The precursor product can be provided by introducing the
flowable egg-containing composition to a primary surface of edible
solid substrate 12. The introduction of these two components can be
accomplished in at least two ways.
[0037] First, the flowable egg-containing composition can be
applied to a primary surface of edible solid substrate 12. The
application can be accomplished by any of a variety of techniques
including, but not limited to, pouring, extruding, curtain coating,
knife coating, and the like. Once the flowable egg-containing
composition is applied, the precursor product then can be heated.
Where this process is performed in a commercial setting, a
plurality of edible solid substrates can be provided, optionally in
an array, while being carried on a moving conveyance such as a
belt. After flowable egg-containing composition is applied to the
substrates, the one or more precursor products are conveyed to an
oven or other heating unit. A precursor product can be inverted
after application of the flowable egg-containing composition to the
substrate, if desired; in such situations, preference can be given
to those moving conveyances made from non-stick materials or
treated so as to have low surface energy.
[0038] Second, the flowable egg-containing composition can be
deposited onto a belt or into a mold prior to being covered, in
whole or part, by a primary surface of edible solid substrate 12.
Deposition of the flowable egg-containing composition can be
accomplished by any of a variety of techniques including, but not
limited to, pouring, extruding, curtain coating, and the like. Once
the deposited flowable egg-containing composition is covered by
edible solid substrate 12, the resulting precursor product then can
be heated. Where this process is performed in a commercial setting,
many molds can be filled and covered, and such molds optionally can
be provided in an array. (If a belt is used, one or more
essentially continuous columns of deposited flowable egg-containing
composition can be applied to the belt.) The belt and/or molds can
be conveyed, to an oven or other heating unit.
[0039] The precursor product is heated so as to convert flowable
egg-containing composition to egg layer 14. The heating can be
accomplished by convection, conduction, induction, microwaving,
HTST, and preferably raises the temperature of egg layer 14 to at
least .about.100.degree. F., more preferably to at least
.about.125.degree. F., and most preferably to at least
.about.150.degree. F. for a time of at least .about.10 seconds. For
certain applications, ensuring that egg layer 14 reaches a
temperature of .about.145.degree. to .about.165.degree. F. for at
least 20 seconds, at least 25 seconds, or at least 30 seconds can
be desirable. For taste and texture reasons, the heating step
preferably does not occur at an oven temperature of more than
.about.450.degree. F., more preferably no more than 400.degree. F.,
and is not performed for more than .about.500 seconds, commonly no
more than .about.450 seconds, and typically no more than .about.400
seconds.
[0040] Egg layer 14 can be partially or fully cooked. The term
"partially cooked" means that egg layer 14 has become integral with
edible solid substrate 12 but its internal temperature has not
reached 165.degree. F., while "fully cooked" means that the
internal temperature of egg layer 14 has reached at least
165.degree. F.
[0041] Upon heating, the precursor product is converted to food
product 10 where egg layer 14 is integral and interconnected with
the upper portion of a primary surface of edible solid substrate
12. This feature is best seen in FIG. 2, which is a cross-sectional
view of food product 10 from FIG. 1. To remove egg layer 14 from
the primary surface of edible solid substrate 12 often results in
cohesive failure of a portion of the edible solid substrate 12 as
opposed to an adhesive failure between egg layer 14 and edible
solid substrate 12.
[0042] Any of a variety of flavor enhancers can be added to food
product 10. These include, but are not limited to cheese,
artificial cheese, spices, artificial flavor solids, any of a
variety of crunchy toppings (e.g., bacon or bacon bits), and the
like.
[0043] Food product 10 thus is provided in a convenient,
easy-to-handle format. A consumer can be confident that egg layer
14 will not separate or detach from edible solid substrate 12.
Further, food product 10 includes one fewer edible substrate layer
than a typical breakfast sandwich, thereby reducing the amount of
carbohydrates and increasing the protein-to-carbohydrate ratio
ingested during consumption.
[0044] Unless food product 10 is to be consumed immediately after
preparation, it can be introduced into packaging that permits both
heating and cooling of its content. Preferably, food product 10 is
cooled when cooking is complete. The amount of time necessary to
cool a cooked food product varies based on weight but, typically,
refrigerated temperatures (e.g., .about.33.degree. to
.about.40.degree. F.) can be reached in .about.10 to .about.20
minutes, and freezer temperatures (e.g., 32.degree. F. or below)
can be reached in .about.15 to .about.30 minutes using, for
example, a batch or spiral chilling methods.
[0045] Similarly, food product 10 typically is packaged after
cooking. The nature of the cooling method(s) and the packaging
employed typically is driven by the expected shelf life and storage
temperatures. For example, some food products might be intended to
be used in .about.10 or fewer days, while others might be intended
to be stored for up to several months. The former might be packaged
using less costly materials and stored at .about.33.degree. to
.about.40.degree. F., while the latter might employ more robust
packaging and be stored at .about.10.degree. to as low as about
.about.10.degree. F.
[0046] In situations where food product 10 is not consumed
immediately after preparation and, instead, cooled and packaged,
reheating prior to consumption is contemplated. This can be
accomplished in a number of ways including convection, conduction,
induction, microwaving, hot air, etc., as long as the internal
temperature of the egg layer reaches at least .about.150.degree.,
commonly at least .about.160.degree., and typically at least
.about.165.degree. F.
[0047] The following table summarizes in list form the terms and
phrases used to identify suitable parts and materials.
TABLE-US-00001 TABLE 1 List of reference symbols Number Description
10 food product 12 edible, grain-based solid substrate 14 egg layer
16 solid taste and/or texture enhancer
[0048] The foregoing description has employed certain terms and
phrases for the sake of brevity, clarity, and ease of
understanding; no unnecessary limitations are to be implied
therefrom because such terms are used for descriptive purposes and
are intended to be broadly construed. The relevant portion(s) of
any patent or publication specifically mentioned in the foregoing
description is or are incorporated herein by reference.
[0049] The foregoing configurations and methods have been presented
by way of example only. Certain features of the described
configurations and methods may have been described in connection
with only one or a few such configurations or methods, but they
should be considered as being useful in other such configurations
or methods unless their structure or use is incapable of adaptation
for such additional use. Also contemplated are combinations of
features described in isolation.
* * * * *