U.S. patent application number 17/474670 was filed with the patent office on 2021-12-30 for microwaveable packaged food product.
This patent application is currently assigned to Hormel Foods Corporation. The applicant listed for this patent is Hormel Foods Corporation. Invention is credited to Kathryn M. Birchmeier, Rachel Catherine Brown, Judith G. Moca, Jennifer L.K. Rich, David L. Schroeder.
Application Number | 20210403222 17/474670 |
Document ID | / |
Family ID | 1000005839947 |
Filed Date | 2021-12-30 |
United States Patent
Application |
20210403222 |
Kind Code |
A1 |
Birchmeier; Kathryn M. ; et
al. |
December 30, 2021 |
MICROWAVEABLE PACKAGED FOOD PRODUCT
Abstract
A package containing nuts and suitable for microwave heating is
described herein. The package is configured to heat the nuts and
provide an aroma reminiscent of traditional, freshly-roasted nuts.
The freshly-roasted nut attributes include an aroma, temperature,
texture and taste, which are reproduced with the microwave package.
The package preferably, though not necessarily, incorporates one or
more susceptors in order to provide additional heating, such as
conductive heating, to the nuts. The package also preferably
includes a sufficient headspace to allow for the aromas to
develop.
Inventors: |
Birchmeier; Kathryn M.;
(Glenview, IL) ; Moca; Judith G.; (Palatine,
IL) ; Brown; Rachel Catherine; (Evanston, IL)
; Rich; Jennifer L.K.; (Arlington Heights, IL) ;
Schroeder; David L.; (Arlington Heights, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hormel Foods Corporation |
Austin |
MN |
US |
|
|
Assignee: |
Hormel Foods Corporation
Austin
MN
|
Family ID: |
1000005839947 |
Appl. No.: |
17/474670 |
Filed: |
September 14, 2021 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15636257 |
Jun 28, 2017 |
|
|
|
17474670 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 31/00 20130101;
B65B 11/58 20130101; B65D 81/3461 20130101; B65B 29/08 20130101;
B65D 65/40 20130101; B65D 2581/3497 20130101; B65B 11/48 20130101;
B65D 85/70 20130101; B65D 75/5805 20130101; B65D 75/008 20130101;
B65D 33/01 20130101 |
International
Class: |
B65D 81/34 20060101
B65D081/34; B65B 11/48 20060101 B65B011/48; B65B 11/58 20060101
B65B011/58; B65B 29/08 20060101 B65B029/08; B65B 31/00 20060101
B65B031/00; B65D 33/01 20060101 B65D033/01; B65D 65/40 20060101
B65D065/40; B65D 75/00 20060101 B65D075/00; B65D 75/58 20060101
B65D075/58; B65D 85/00 20060101 B65D085/00 |
Claims
1-18. (canceled)
19. A packaged food product, comprising: a flexible film forming a
pouch having an interior cavity formed by a first end seal and a
second end seal with a longitudinal fin seal extending
therebetween, the flexible film pouch being substantially
hermetically sealed in a closed configuration; at least one
susceptor disposed on a majority of an interior surface of the
flexible film pouch without contacting the first end seal, the
second end seal, or the fin seal; about 0.75 oz. to about 2.00 oz.
pasteurized or at least partially roasted shelled nuts disposed
within the interior cavity of the flexible film pouch, the shelled
nuts having been pasteurized or at least partially roasted prior to
being disposed within the flexible film pouch; a coating on the
shelled nuts being one of: a sweet glaze on the shelled nuts,
wherein the sweet glaze and the shelled nuts have a combined
moisture level within the range of 1.0% to 1.6%; or a savory
coating on the shelled nuts, wherein the savory coating and the
shelled nuts have a combined moisture level within the range of
1.5% to 2.6%; wherein the packaged food product is configured and
arranged to be heated in a microwave oven in the closed
configuration to roast the shelled nuts to a temperature of about
120.degree. F. to about 260.degree. F.; and wherein the coating and
the at least one susceptor are configured and arranged to moderate
heating of the shelled nuts by absorbing and/or reflecting
microwave energy thereby reducing an amount of microwave energy
absorbed by the shelled nuts and increasing homogeneity of heating
the shelled nuts.
20. The packaged food product of claim 19, wherein the flexible
film is a multilayered film including a barrier material configured
and arranged to limit migration of aroma components through the
flexible film during storage and during microwave heating.
21. The packaged food product of claim 20, wherein the barrier
material is selected from the group consisting of EVOH, AlO.sub.x,
and SiO.sub.x.
22. The packaged food product of claim 19, wherein the first end
seal, the second end seal, and the fin seal are configured and
arranged to remain sealed and not rupture during microwave
heating.
23. The packaged food product of claim 19, wherein a volume of
shelled nuts is less than 75% of a total internal package volume,
and wherein a volume of oxygen is less than 2% within the interior
cavity of the flexible film pouch, further comprising a headspace
within the interior cavity between the shelled nuts and the
flexible film configured and arranged to allow aroma to develop
during microwave heating.
24. The packaged food product of claim 19, wherein the coating is 1
mm to 3 mm thick on each of the shelled nuts.
25. The packaged food product of claim 19, wherein the flexible
film includes a bottom wall portion and a top wall portion
interconnected by the first end seal and the second end seal, the
fin seal extending between the first end seal and the second end
seal on the top wall portion, and wherein the at least one
susceptor includes a first discrete susceptor on the bottom wall
portion and a second discrete susceptor on the top wall
portion.
26. The packaged food product of claim 19, further comprising nut
flavorings comprising at least one of salt, black pepper, cinnamon,
honey, sugar, peanut oil, caramel, and coconut.
27. The packaged food product of claim 19, wherein the sweet glaze
or the savory coating is adapted to absorb and/or reflect microwave
energy during exposure of the packaged food product thereto and be
permeable to a portion of the microwave energy.
28. The packaged food product of claim 19, wherein the shelled nuts
are pasteurized with a moisture level decreased by 15% to 25%
during pasteurization.
29. The packaged food product of claim 19, wherein the shelled nuts
are at least partially roasted having a moisture level between
about 1.1% to about 1.4% due to the at least partial roasting.
30. The packaged food product of claim 19, wherein the shelled nuts
are caramel peanuts having about a 64-fold increase in
ethyl-pyrazine aroma compounds, about a 53-fold increase in
furfural aroma compounds, and about a 21-fold increase in diacetyl
aroma compounds after microwave heating.
31. The packaged food product of claim 19, wherein the shelled nuts
are cinnamon almonds having about a 31-fold increase in
ethyl-pyrazine aroma compounds, about a 144-fold increase in
furfural aroma compounds, and about a 50-fold increase in diacetyl
aroma compounds after microwave heating.
32. The packaged food product of claim 19, wherein the shelled nuts
are coconut cashews having about a 54-fold increase in
ethyl-pyrazine aroma compounds, about a 155-fold increase in
furfural aroma compounds, and about an 93-fold increase in diacetyl
aroma compounds after microwave heating.
33. The packaged food product of claim 19, wherein the food product
includes 20% to 40% sugar.
34. A packaged food product, comprising: a flexible film forming a
pouch having an interior cavity formed by a bottom wall portion and
a top wall portion, the bottom wall portion and the top wall
portion being interconnected by a first end seal and a second end
seal, a longitudinal fin seal extends between the first end seal
and the second end seal on the top wall portion, the flexible film
pouch including a barrier the flexible film pouch being
substantially hermetically sealed in a closed configuration; at
least one susceptor disposed on a majority of an interior surface
of the flexible film pouch on the bottom wall portion and the top
wall portion without contacting the first end seal, the second end
seal, or the fin seal; about 0.75 oz. to about 2.00 oz. pasteurized
or at least partially roasted shelled nuts disposed within the
interior cavity of the flexible film pouch, the shelled nuts having
been pasteurized or at least partially roasted prior to being
disposed within the flexible film pouch; a coating on the shelled
nuts being one of: a sweet glaze on the shelled nuts, wherein the
sweet glaze and the shelled nuts have a combined moisture level
within the range of 1.0% to 1.6%; or a savory coating on the
shelled nuts, wherein the savory coating and the shelled nuts have
a combined moisture level within the range of 1.5% to 2.6%; a
headspace between the shelled nuts and the flexible film; wherein
the packaged food product is configured and arranged to be heated
in a microwave oven in the closed configuration to roast the
shelled nuts to a temperature of about 120.degree. F. to about
260.degree. F., and wherein the first end seal, the second end
seal, and the fin seal are configured and arranged to remain sealed
and not rupture during microwave heating; and wherein the coating
and the at least one susceptor are configured and arranged to
moderate heating of the shelled nuts by absorbing and/or reflecting
microwave energy thereby reducing an amount of microwave energy
absorbed by the shelled nuts and increasing homogeneity of heating
the shelled nuts.
35. The packaged food product of claim 34, wherein the flexible
film is a multilayered film including a barrier material configured
and arranged to limit migration of aroma components through the
flexible film during storage and during microwave heating.
36. The packaged food product of claim 34, wherein a volume of
shelled nuts is less than 75% of a total internal package volume,
wherein a volume of oxygen is less than 2% within the interior
cavity of the flexible film pouch, and wherein the shelled nuts and
the headspace are configured and arranged to allow aroma to develop
during microwave heating.
37. The packaged food product of claim 34, wherein the sweet glaze
or the savory coating is adapted to absorb and/or reflect microwave
energy and be permeable to a portion of the microwave energy during
exposure of the packaged food product thereto.
38. The packaged food product of claim 34, wherein the shelled nuts
are pasteurized with a moisture level decreased by 15% to 25%
during pasteurization.
39. The packaged food product of claim 34, wherein the shelled nuts
are at least partially roasted having a moisture level between
about 1.1% to about 1.4% due to the at least partial roasting.
40. The packaged food product of claim 34, wherein the food product
includes 20% to 40% sugar.
Description
FIELD
[0001] This disclosure relates generally to microwaveable food
products, and more specifically to a packaged food product for
retail sale in which the packaging enables enhancement or
optimization of organoleptic properties of the food product
contained therein during microwave heating.
BACKGROUND
[0002] One of the challenges associated with microwave heating of
certain food products is the need to avoid generation of undesired
aroma components, e.g., those that may result from overheating or
scorching, while achieving desired aroma notes and while warming
the product generally uniformly.
[0003] Some food products have a well-defined configuration, e.g.,
solid, one-piece farinaceous food products, which can help to
provide consistency and repeatability in response to exposure to
microwave energy for a particular period of time at a particular
power setting in a particular type of oven. A package of mixed,
shelled nuts, on the other hand, can be subject to intra-package
reconfiguration before, during and after heating, and accordingly
different packages containing the same mass of shelled nuts can
react differently to the same microwave energy exposure. One
particular problem that can occur where nuts or nut pieces of
various varieties and sizes are included in a single package is
that small pieces may be susceptible to overheating, particularly
if they are disposed in "hot spots," e.g., in contact with a
susceptor, or at locations where microwave energy is concentrated
or of a higher magnitude due to variations in field strength within
a microwave oven cavity.
[0004] Another problem is that variations in microwave field
strength and configuration among various microwave ovens can
present problems with respect to providing a package that will
perform satisfactorily in a variety of commonly used, commercially
available microwave ovens.
[0005] Another problem relates to quantification of desirable aroma
characteristics. Different consumers may perceive the same aroma
components in different ways. Thus, application of objective
standards in order to provide desirable aroma characteristics while
also reducing or eliminating undesirable aroma components can be
difficult.
SUMMARY
[0006] Described herein is a packaged food product comprising a
measured quantity of a food product contained within a package that
optimizes or enhances organoleptic properties of the food product
during microwave heating. The food product may comprise almonds,
including, e.g., Mission, Carmel and Non-Pareil almonds, Brazil
nuts, cashews including e.g. 320 cashews, chestnuts, granola,
hazelnuts, macadamia nuts, peanuts including e.g. Jumbo Runner
peanuts and Virginia Extra Large peanuts, pecans, pistachios, pine
nuts, pumpkin seeds, sunflower seeds, walnuts, and/or other food
items. The food product may include GMO ingredients, or may be free
from GMO ingredients. In some embodiments, the nuts in the package
are shelled nuts, i.e., nuts from which shells have been removed.
In other embodiments, the nuts in the package may be partly or
entirely unshelled, i.e., they may include shells which have not
been removed, or shells that have been only partially removed. In
some embodiments, the nuts may include shells that have been partly
opened to expose the kernels within the shells.
[0007] In some embodiments, the food product comprises one or more
varieties of raw or partially-roasted shelled nuts. A modified
atmosphere comprising, e.g., nitrogen, carbon dioxide, and/or
combinations of these or other gases may be also provided by gas
flushing the package, thereby reducing the volume of oxygen in the
package. The package may be configured to cooperate with a
microwave oven to heat the shelled nuts and provide an aroma
reminiscent of traditional, freshly-roasted nuts, as well as
additional freshly-roasted nut attributes including temperature,
texture and taste. The package preferably, though not necessarily,
incorporates one or more susceptors to provide localized enhanced
heating, such as conductive heating, to certain components of the
food product, while the entire food product is heated as a result
of exposure to microwave energy. The package also may include a
predetermined volume of headspace to facilitate aroma
development.
[0008] In some embodiments, the package comprises a pouch formed of
a flexible film. The pouch may be hermetically sealed. In some
embodiments, the pouch may contain a measured quantity of a food
product such as shelled nuts, wherein the total weight of the food
product is at least 0.75 oz., and no more than 2 oz. In some
embodiments, the food product may consist of about 1.0 oz. to about
1.5 oz., or about 1 oz., of shelled nuts. In other embodiments, the
food product may include a larger quantity of nuts weighing, e.g.,
about 6 oz.
[0009] Where susceptors are employed, they are preferably disposed
within the flexible film pouch, and may be incorporated into one or
more walls of the pouch or attached thereto. The packaged food
product may be capable of being microwaved while sealed in a closed
configuration to roast the food product to a temperature of, e.g.,
about 120.degree. F. to about 260.degree. F., 150.degree. F. to
about 230.degree. F., or 180.degree. F. to 200.degree. F. In some
embodiments, the flexible film pouch may be capable of withstanding
expansion and/or internal pressure generated during microwave
heating so that it will remain sealed in closed configuration
during heating. In other embodiments, the pouch may be equipped
with a relief valve, frangible seal, vent, or other means to limit
interior pressure to a desired level within the pouch during
microwave heating, and/or to enable internal pressure to decrease
at a desired rate after completion of microwave heating. The
flexible film pouch can include a longitudinal seal extending
between end seals, and the one or more vents can include a pin hole
or other small opening at a juncture between two seals.
[0010] The pouch may be expandable to accommodate increased
interior volume during heating.
[0011] In some embodiments wherein the food product comprises about
0.75 oz. to about 2 oz. of mixed, shelled nuts, the time period
during which microwave heating of the packaged food product takes
place may be, for example, between 20 seconds and 130 seconds,
between 60 seconds and 90 seconds, or between 70 seconds and 80
seconds, using a 900 to 1200 W microwave oven. In other
embodiments, wherein the food product comprises up to about 6 oz.
of mixed, shelled nuts, the time period may be about 45 to 360
seconds, or 180 to 360 seconds, again using a 900 W to 1200 W
microwave oven. In some embodiments, the packaging may include
instructions that specify one or more time periods for microwaving
at one or more power levels, with one or more longer time periods
specified for lower powered microwave ovens, and one or more
shorter time periods specified for higher powered microwave ovens.
In some embodiments, the food product may comprise a 1 oz. package
of mixed nuts comprising almonds, peanuts and cashews, and the
instructions may specify heating for a time period such as 30
seconds or 40 seconds in a 1200 W microwave oven. The quantities of
almonds, peanuts and cashews may be approximately equal or may
vary, for example with each type of nut comprising about 10% to 50%
of the total, by weight. In some embodiments, the microwave heating
may comprise warming pre-roasted shelled nuts, finishing roasting
of partially roasted shelled nuts, or roasting of raw shelled
nuts.
[0012] The pouch may be made from a flexible material such as a
multilayer flexible film. Examples of layers that may be included
in the flexible material include a barrier layer; a printable film
layer; an oriented film or PET layer; a sealable layer; a
protective varnish; and a coefficient of friction modified layer.
In some embodiments, the flexible material may include all of the
above layers. In other embodiments, the flexible material may
include fewer than all of these layers. In some embodiments, one or
more of the above layers may extend over the entire area of the
flexible material. In some embodiments, one or more of the above
layers may be partial or patterned layers, extending over less than
the entire area of the flexible material. In some embodiments, the
pouch may include a paper layer that provides stiffness and
insulation.
[0013] In some embodiments, the pouch may be a generally
rectangular structure that includes a top seal, two side seals and
one or more folds, with the fold(s) in the form of a gusset, which
can provide the pouch with stand-up stability. In other
embodiments, the pouch may comprise a generally rectangular
structure having transverse end seals, a longitudinal seal along a
top or bottom wall, and longitudinal folds connecting the top and
bottom walls. In still other embodiments, the package may have a
different from configuration. In some embodiments, a tear notch,
area of weakness, or other means to facilitate opening of the pouch
by a consumer can be provided in a seal such as a longitudinal
seal, transverse seal, side seal, a top seal, or another
location.
[0014] In some embodiments, headspace of the flexible film pouch
can be reduced or minimized via vacuum packaging after shelled nuts
are disposed therein, thereby reducing the overall volume of the
package and providing efficiencies in connection with shipping,
handling and storage. Reduction of headspace can also be
advantageous from the standpoint of increasing the capacity of the
package to accommodate expansion of nitrogen, carbon dioxide, water
vapor, and/or other gases during heating. In other embodiments, the
package may be sealed without taking steps to reduce or minimize
headspace.
[0015] In some embodiments, where the food product comprises
shelled nuts, the volume of shelled nuts may be less than 75% of a
total internal package volume. In some embodiments, the volume of
shelled nuts is between 20% and 40% of the total internal package
volume. In some embodiments, the volume of shelled nuts is about
30% of the total internal package volume. In some embodiments, the
shelled nuts may be arranged in a single layer within the
package.
[0016] The susceptor(s) may comprise discrete components that are
attached to the film by adhesive bonding, heat sealing, or other
means, or may comprise a layer deposited on the film or otherwise
provided as an integral part of the film. In some embodiments, the
susceptor(s) may consist of one or more metalized layers on the
film. Such metalized layers may be treated with an acid solution
that removes portions of the metalized layer, thereby forming a
continuous metalized layer into a patterned susceptor. In some
embodiments, the susceptor(s) may comprise one to three discrete
susceptors. In some embodiments, a first wall of the pouch can have
a first susceptor thereon, and a second wall of the pouch can have
a second susceptor thereon spaced from the first susceptor, with
care being taken to avoid contact between the susceptors. The
susceptors can be positioned and configured to heat and brown
portions of the shelled nuts and provide an aroma release without
excessive heating or scorching. In some embodiments, the susceptor
can be disposed in a pattern on the flexible film, spaced from
package seals. In some embodiments, the packaged food product can
include flavorings, which may include aroma-enhancing compositions,
which may be applied to the nuts prior to placing them in the
pouch, and/or otherwise placed in the package. Flavor application
may comprise, e.g., soaking shelled or unshelled nuts in a liquid,
spraying a liquid onto the nuts, tumbling the nuts in a drum with a
particulate flavor treatment such as a powder or granular material,
and/or spraying or otherwise introducing liquid and/or particulate
flavor treatments into the package after the nuts have been placed
therein. Methods of providing flavor treatments may alternatively
or additionally further include at least one of: depositing
flavoring on an inside surface of the multi-layer flexible film
that forms the film tub; spraying flavoring into the film tube
prior to forming the second seal of the flexible film pouch; and
spraying flavoring onto the shelled nuts prior to depositing the
shelled nuts in the flexible film pouch. The method can
alternatively or additionally include depositing flavoring on an
inside surface of the multi-layer flexible film prior to forming a
film tube, and/or spraying flavoring into a film tube prior to
forming it into a pouch, and/or other steps.
[0017] In some embodiments, flavorings may include without
limitation one or more natural natural flavors, savory or sweet
seasonings or spices. Examples include without limitation salt,
black pepper, cinnamon, honey, sugar, peanut oil, caramel, coconut,
and other liquid or dry seasonings. The flavor treatments may
include a first coating and a second coating, wherein the first
coating functions to improve retention of a second coating. The
coating can be effective to absorb and/or reflect a portion of the
microwave energy to which it is exposed while also being permeable
to another portion of the microwave energy. To enhance flavor,
aroma and/or other organoleptic properties, an aromatic compound
can be disposed on an inside surface of the flexible film pouch
prior to packaging the shelled nuts. Alternatively or in addition,
a sprayable aromatic compound can be sprayed into the flexible film
pouch after depositing the shelled nuts therein. In some
embodiments, the shelled nuts can include one or more of whole
nuts, halves, or other pieces with dimensions of about 1/4'' to 1''
in length and 1/8'' to 1/2'' in width. Shelled nuts may be
pre-roasted at various roast levels and/or steam pasteurized prior
to packaging within the flexible film pouch. The shelled nuts may
be partially roasted, with final roasting being accomplished by
microwave heating by the consumer. The shelled nuts can have a
moisture level that decreases by 15%-25% during pre-roasting, while
increasing the composition of volatile compounds associated with a
darker roast. The pre-roasted shelled nuts may optionally have
undergone at least one of a dry roast or an oil roast. In some
embodiments, the shelled nuts in the packaged food product comprise
roasted or partially roasted peanuts and other nuts having a
moisture level of about 1.1% to about 1.4%. Standard moisture
levels for the shelled nuts may range from 2.6%-2.9% for almonds,
1.4-1.6% for peanuts, and 1.8%-2.4% for cashews. In some
embodiments, savory coated nuts in the packaged food product may
have a moisture level of 1.5%-2.6%, including moisture in the
coating and nuts. In some embodiments, sweet glazed nuts in the
packaged food product may have a moisture level of 1.0%-1.6%,
including moisture in the glaze and nuts.
[0018] In some embodiments, the packaged food product can further
include a sealed overwrap around the flexible film forming the
pouch that is removed prior to microwaving. The overwrap can be gas
flushed prior to sealing.
[0019] A method can be provided that includes wrapping a web of
multi-layer flexible film into a film tube; providing at least one
susceptor inside the film tube; forming a first end seal to
partially form a flexible film pouch; depositing about 0.75 oz. to
about 2 oz. shelled nuts in the partially formed flexible film
pouch; gas flushing the partially formed flexible film pouch to
reduce oxygen therein; forming a second end seal in the flexible
film pouch; wrapping the flexible film pouch in an overwrap film
thereby forming an overwrap pouch; gas flushing the overwrap pouch
to reduce oxygen in the overwrap pouch; and sealing the overwrap
pouch around the flexible film pouch. Gas flushing may comprise
replacing oxygen with nitrogen, carbon dioxide, and/or another gas
or mixture of gases so that less than about 2% oxygen is present in
the pouch headspace to reduce or minimize oxidation during the
product shelf life. In some embodiments, where the gas flushed
pouch is made of a material that includes an oxygen barrier, the
product may have a shelf life of about one year or 365 days,
whereas a similar product without gas flushing may have a shelf
life of only about one month.
[0020] A method of using a packaged food product is also provided
herein. In some embodiments, the packaged food product may include
about 1 oz. to about 1.5 oz. of shelled nuts. In some embodiments,
the packaged food product may include about 1.0 oz. of shelled
nuts. The packaged food product may also include a heat-activated
aroma-release composition. In some embodiments, each of the shelled
nuts individually has a mass of 28 grams+/-5 grams to 42 grams+/-5
grams. The shelled nuts may be arranged in a single layer on a
susceptor within a sealed flexible package having a vent opening
with a frangible closure, the shelled nuts comprising about 1.0% to
about 2.0% moisture and having a predetermined aggregate surface
area. The method may include first maintaining the packaged food
product at ambient temperature and pressure; thereafter exposing
the packaged food product to microwave energy for a period of about
25 seconds to about 100 seconds, or a period of about 30 seconds to
70 seconds, or a period of about 35 to 65 seconds, to heat the
shelled nuts and reduce their moisture content to between about
0.9% and about 1.3%, and simultaneously vaporizing moisture within
the package to expand the package and increase its interior
pressure, wherein the increase in interior pressure .DELTA.P does
not result in rupture of the package seals except for the frangible
closure associated with the vent opening. Preferably, heating the
nuts results in a darkening of portions of the aggregate nut
surface area. In some embodiments, the darkened portions are in
contact with or in close proximity to the susceptor during heating.
The darkened portions may comprise, e.g., about 10% to about 25% of
the aggregate nut surface area. The method may further include
thereafter removing a portion of the package or otherwise opening
the package to release a roasted-nut aroma, and in some
embodiments, to provide an open-topped container to provide
hand-held access to the heated shelled nuts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a front perspective view of a first embodiment of
a microwave susceptor package containing unshelled nuts, showing a
pair of end seals and a fin seal configured to form a top panel and
a bottom panel;
[0022] FIG. 2 is a plan view of a segment of a susceptor material
disposed on one of the panels of the package of FIG. 1;
[0023] FIG. 3 is a front perspective view of a second embodiment of
a bottom-gusseted, standup microwave susceptor package containing
unshelled nuts, showing a pair of side seals, a top portion having
been removed, and showing a food product comprising shelled nuts
following microwave heating;
[0024] FIG. 4 is a schematic diagram of a process for providing a
heated food product, including placing a packaged food product in a
microwave oven, heating the packaged food product, then removing a
portion of the package to serve the food product;
[0025] FIG. 5 is a front elevation view of a packaged food product
in accordance with FIG. 3, empty and prior to removal of the top of
the package, showing a peripheral seal area along the top and sides
of the package;
[0026] FIG. 6 is a plan view of a web of film showing sealing areas
and cut lines for use in forming the package of FIG. 5;
[0027] FIG. 7 is a plan view of a first alternative web of film
showing sealing areas and cut lines for use in forming the package
of FIG. 5, similar to that of FIG. 6 but showing a susceptor added
to the interior of what will be one of the panels of the
package;
[0028] FIG. 8 is a plan view of a second alternative web of film
showing sealing areas and cut lines for use in forming the package
of FIG. 5, similar to that of FIG. 6 but showing susceptors added
to the interior of what will be both panels of the package;
[0029] FIG. 9 is a plan view of a third alternative web of film
showing sealing areas and cut lines for use in forming the package
of FIG. 5, similar to that of FIG. 6 but showing one or more
susceptors added to the interior of what will be one of the panels
of the package;
[0030] FIG. 10 is a graph showing comparative magnitudes of
selected aroma components associated with shelled mixed nuts at
room temperature, and after warming with and without a
susceptor;
[0031] FIG. 11 is a table showing comparative magnitudes of
selected aroma components associated with individual varieties of
shelled nuts at room temperature and after warming with a
susceptor; and
[0032] FIGS. 12-15 illustrate examples of raw data generated using
gas chromatography-mass spectroscopy to measure aroma
components.
[0033] FIG. 16 provides numerical data that is illustrated
graphically in FIG. 10.
[0034] FIG. 17 is a table showing comparative magnitudes of
selected aroma components associated with individual varieties of
shelled nuts at room temperature and after warming with a
susceptor.
[0035] FIG. 18 is a side elevational sectional view of the packaged
food product of FIG. 1.
[0036] FIG. 19 is an end sectional view of the packaged food
product of FIG. 1.
[0037] FIG. 20 is a side view of a packaged food product in
accordance with FIG. 3.
[0038] FIG. 21 is a front view of the packaged food product in
accordance with FIG. 3.
DETAILED DESCRIPTION
[0039] Packaged food products suitable for microwave heating are
described herein, including with reference to FIGS. 1-21.
[0040] In one embodiment, a packaged food product, shown in FIGS.
1, 18 and 19, has a low profile and is configured to be microwaved
on its side, i.e., in a generally horizontal position such that its
length and width are greater than its height. In this embodiment,
the packaged food product includes a pouch or package 10 that
includes an uninterrupted, continuous bottom wall 22, pair of end
seals 12, 14 and a top wall 16 having a fin seal 18 extending
longitudinally thereof. In some embodiments, the package 10 may be
made in a high-speed, high volume automated form-fill-seal
operation in which a web of film is formed into a tube, with edges
brought together to form the longitudinal fin seal, and with the
transverse end seals formed at predetermined spacing before and
after loading of product and gas flushing, and with the packages
being separated from one another by cuts through the end seals. The
interior of the package optionally includes one or more susceptors
20. For example, a grid-like susceptor material, shown in FIG. 2,
can be provided on one or both sides, i.e., on one or both of the
top and bottom of the package so as to be positioned above, below,
or both above and below the food product during heating. In some
embodiments, the package contains a large number of discrete food
items, e.g., a mixture of shelled nuts, such as almonds, cashews
and peanuts. In some embodiments, the food items may be arranged in
a single layer or primarily in a single layer, with all or most of
the discrete food items being in contact with or at least in close
proximity to the bottom of the package during heating. In these
embodiments, most or all of the food items may also be in contact
with, or at least in close proximity to, the top of the package as
well, at least initially during microwave heating. As microwave
heating progresses, expansion of the pouch may lift the top surface
and an associated susceptor from the food items, which may have a
self-regulating effect on the heating operation to reduce or avoid
overheating and/or or scorching due to variations in microwave
energy, heating time or other parameters. Expansion of the pouch
may also result in the edges of the bottom wall being raised from
the floor of the microwave oven, and may change the arrangement of
some or all of the food items from a single-layer configuration to
a multiple-layer configuration in which some of the food items to
overlie others, which may also have a self-regulating effect on the
heating operation to help reduce or avoid overheating and/or
scorching.
[0041] In a second embodiment, shown in FIGS. 3, 5, 20 and 21, a
packaged food product includes a package or pouch 24 that is
configured to stand up during and/or following microwave heating.
The pouch 24 can include a pair of side seals 26, a top seal 28 and
a bottom 30, shown schematically in FIG. 5. A top portion of the
pouch, which encompasses the top seal, is configured for removal.
The pouch is shown after removal of the top portion in FIG. 3.
[0042] As shown in the schematic diagram of FIG. 4, in some
embodiments, a packaged food product such as either of the
above-described packaged food products can be inserted into a
microwave oven, heated using microwave energy, then removed from
the microwave oven, after which a portion of the package may be
removed, separated or otherwise opened to provide access to the
contents.
[0043] In some embodiments including but not limited to those
described above, the pouch can be formed from a web of film 36,
various examples of which are shown in FIGS. 6-9. The web of film
can be folded so that regions 38 and 40 form the front and rear of
the package, with seals 42 and 44 being formed on the sides and
top. In some embodiments, the bottom can comprise a single fold
along line 46. Alternatively, a gusseted bottom may be provided. A
web of film can be configured without a susceptor, as shown in FIG.
6, or with one or more susceptors 48 added prior to singulating the
package from the web of film, as shown in FIGS. 7-9. For example, a
single susceptor 48 can be attached to the web of film in an area
that will be an interior surface of one of the front or rear walls
of the package, as shown in FIG. 7. Alternatively, a pair of
susceptor surfaces can be provided on the web of film in areas that
will be interior surfaces of the front and rear walls of the
package, as shown in FIG. 8. In another alternative, multiple types
of susceptors may be incorporated on a single panel, as shown in
FIG. 9, or on other panels, to provide increased localized
conductive heat transfer in a particular region of a susceptor.
Optionally, the susceptor surfaces can be positioned closer to the
bottom of the package than the top such that they will be adjacent
the food product near the bottom of the package during microwave
heating.
[0044] Aroma is created during microwave heating due to a
combination of the product and the packaging, and is released upon
opening of the package following microwave heating, and/or through
a vent during heating. The aroma from the product can be generated
not only by the nuts but also by additional ingredients. Liquid
coatings, dry seasonings and/or other ingredients may include heat
stable components that are added to nuts prior to packaging and
provide aroma upon opening of the package following microwave
heating. In addition to a dry seasoning or coating, a liquid
seasoning can optionally be added to the nuts either before or
after the application of a dry seasoning to increase the amount of
volatile components released during microwave heating. One option
is to also or instead add aroma-contributing compounds to the
packaging material, such as by spraying the compounds on one or
more interior surfaces of the package, such as in the headspace,
after depositing the nuts and prior to sealing.
[0045] The blend of sizes of particulates in the coating as well as
the physical characteristics, such as high melting temperatures,
can help to moderate heating of nuts by absorbing or reflecting
microwave energy and/or by shielding shelled nuts from microwave
energy. This can advantageously reduce the amount of microwave
energy that is absorbed by the interior and surface of the nut,
thereby leading to increased homogeneity of the heating among the
nuts and allowing the product to achieve an overall higher
temperature without overheating individual areas of the nuts.
Certain coatings may tend to increase susceptor temperature by
reflecting microwave energy that would otherwise be absorbed by
shelled nuts or other edible substrates to which the coatings are
applied. This can help to provide desirable organoleptic properties
such as crunchiness of the coatings and underlying shelled nuts,
while avoiding undesirable organoleptic properties such as
undesirable softness of the shelled nuts. Other coatings may tend
to decrease susceptor temperature by absorbing microwave
energy.
[0046] In some embodiments, low-moisture sugar-based coatings or
other low-moisture coatings may be preferable to higher moisture
coatings including those based on corn syrup from the standpoint
that coatings based on corn syrup may tend to flow more easily when
heated to temperatures of, e.g., 215.degree. or 230.degree. F.,
with portions of the coatings undesirably liquefying and running
off the underlying food items when heated rather than remaining
adhered thereto. Specific flavor notes that may be provided by the
food products and/or coatings include but are not limited to sweet,
savory, and salty flavor notes, and combinations thereof. Specific
flavors for food products and/or coatings may include but are not
limited to, e.g., salted caramel, cinnamon almond, and sweet
roasted cashew flavors. Examples of specific product formulas that
may be used in some embodiments are provided below.
TABLE-US-00001 Seasoned Cashew Ingredient Range (%) Cashew 92-98
Peanut oil 0.5-2.5 Powdered seasoning 2-6
TABLE-US-00002 Sea Salt Nut Blend Ingredient Range (%) Almond 30-50
Cashew 24-44 Peanut 16-36
TABLE-US-00003 Sea Salt Almond Ingredient Range (%) Almond 94-99
Peanut oil 0.5-3 Salt 0.5-3
TABLE-US-00004 Coconut Cashew Ingredient Range (%) Cashews 60-85
Sugar 20-40 Coconut 2-5 Corn syrup 2.5-5 Butter 1-2 Salt 0.5-2
Flavor 0.05-.2
TABLE-US-00005 Salted Caramel Peanut Ingredient Range (%) Peanuts
60-85 Sugar 20-40 Salt 0.5-2 Caramel seasoning 0.25-0.75
TABLE-US-00006 Cinnamon Almond Ingredient Range (%) Almonds 55-85
Sugar 20-40 Salt 0.5-2 Cinnamon 0.5-3
[0047] In some embodiments, thicker coatings can contribute to
increased cooking homogeneity. In some embodiments, coatings may
have a thickness of about 1 to 3 mm, and in some cases may have an
average thickness of about 1 mm.
[0048] The packaging can contribute to the aroma by providing
suitable barrier layers and a headspace for the aroma to
accumulate. For example, the pouch can be a multilayered structure
that contains a barrier material, such as EVOH (ethylene vinyl
alcohol), AlO.sub.x (aluminum oxide) or SiO.sub.x (silicon oxide),
that limits the migration of aroma components through the package
during both shelf life and microwave heating. The barrier material
can be provided either as part of the pouch or in outer packaging
that is removed prior to microwave heating. The package is
preferably sealed during microwave heating so that volatile
compounds that provide the aroma do not leave the package until
opened. It can be desirable to optimize the headspace in the
package in order to enable a more concentrated aroma while also
ensuring space for the aroma to develop.
[0049] The temperatures achieved during microwave heating
contribute to the aroma as well as to heating of the nuts. One way
to use temperatures during microwave heating to contribute to aroma
is to design the coating and dry seasoning ingredients to maximize
their dielectric properties when applied to a nut to enable more
quick and homogenous heating. Another way to use temperatures
during microwave heating to contribute to aroma is to add one or
more susceptors within the package to enable localized, conductive
heating with the package. The susceptor can be disposed and/or more
concentrated in an area of the package most likely to contain the
nuts, e.g., the bottom portion in a stand-up package.
[0050] In one example, the package contains about 1 to 1.5 ounces
of either cashews, almonds or shelled peanuts, or combinations
thereof. The package can include a susceptor to optimize heating of
the nuts during microwave heating. The package can optionally be
gas-flushed. The package can be heated in a microwave for between
30 and 60 seconds, for example.
[0051] In some embodiments, strategically-configured susceptors are
provided in a configuration that enables localized heating of
certain portions of the mixed nuts to a higher temperature that
enhances the aroma characteristics of the product without
unacceptably overheating the shelled nuts, optionally in
combination with one or more coatings that may provide quantitative
and qualitative aroma enhancements. Coatings may also enable
positive or negative variation of the shelled nuts' thermal
response to microwave heating.
[0052] The aroma data in FIGS. 10 and 11 were compiled by exposing
shelled nuts to microwave energy with and without susceptors, and
using gas chromatography-mass spectroscopy to quantify increases in
particular aroma components as a result of use of a particular
susceptor configuration.
[0053] FIGS. 11 and 17 show data from shelled nuts, some including
flavor treatments, measured at room temperature and after microwave
heating with a susceptor in a package as described above. FIG. 11
shows, for example, that microwave warming of almonds resulted in
about a two-fold increase in an ethyl-pyrazine aroma component,
which is associated with a "roasted" or "nutty" aroma, an
eighteen-fold increase in a diacetyl aroma component, which is
associated with a "buttery" aroma, and a relatively small increase
in furfural (caramel) aroma. FIG. 17 provides additional data for
the same microwave warming, showing that it resulted in a two-fold
increase of methyl pyrazine (roasted) aroma.
[0054] In some embodiments, microwave heating of a 1 oz. package of
cinnamon almonds, i.e. almonds with a cinnamon coating as described
above, according to instructions provided on packaging as described
above, may desirably result in a significant increase of aroma
components in the headspace, e.g., an increase in furfural aroma by
a factor of 100 to 200, or more specifically a factor of 120 to
170, or a factor of about 144; an increase in ethyl pyrazine aroma
by a factor of 10 to 50, or more specifically, a factor of about
31; an increase in methyl pyrazine by a factor of 15 to 100, or by
a factor of about 50 to 60, or by a factor of about 56; and an
increase in diacetyl aroma by a factor of 5 to 200, a factor of 40
to 60, or a factor of about 50. (See FIGS. 11 and 17.)
[0055] In some embodiments, microwave heating of a 1 oz. package of
cashews according to instructions provided on the packaging as
described above may desirably result in a significant increase of
aroma components in the headspace, e.g., an increase in furfural
aroma by a factor of 100 to 250, or more specifically a factor of
150 to 200, or a factor of about 167; an increase in ethyl pyrazine
aroma by a factor of 50 to 200, or more specifically, a factor of
100 to 150, or a factor of about 125; an increase in methyl
pyrazine by a factor of 25 to 80, or by a factor of about 50 to 60,
or by a factor of about 56; and an increase in diacetyl aroma by a
factor of 200 to 400, a factor of 250 to 350, or a factor of about
289. (See FIGS. 11 and 17.)
[0056] FIGS. 10 and 16 illustrates differences in aroma values that
result from using a particular susceptor package or a non-susceptor
package in microwave heating of mixed nuts.
[0057] The data in FIGS. 10, 11, 16 and 17 correspond to desirable
aroma properties of packaged food products described herein, and
such packaged food products in some embodiments may enable
consumers to achieve increases in various key aroma components
similar to those described herein, e.g., within 10%, 20%, 30%, 40%
or 50% of the values in FIGS. 10, 11, 16 and 17, while also
providing other desirable organoleptic properties, without
scorching or generation of undesirable aromas.
[0058] Examples of raw data generated using gas chromatography-mass
spectroscopy to measure selected individual aroma components are
provided in FIGS. 12-15. The areas under the plots shown in FIGS.
12-15 is the "Peak Area" represented by the y-axis in FIG. 10.
[0059] Data shown in FIGS. 12-15 was gathered by collecting gases
from within pouches containing a mixture of shelled nuts,
specifically almonds, cashews and peanuts, on thermal desorption
tubes before and after microwaving with and without susceptors.
Sampling was performed using adhesive septas (Illinois Instrument
PPL-193456). Headspace samples were collected for 2 min using a
vacuum pump pulling 50 mL/min (FIG. 1). Gas displaced was replaced
using food grade nitrogen.
[0060] The following additional equipment was used in sampling and
analysis:
Agilent Technologies 5975 Mass Spectrometer
Agilent Technologies 6890N Network GC System
Gerstel TDS3 Thermal Desorption System
Gerstel TDSA Thermodesorption Autosampler
Envirochem Multiple Tube Conditioner
[0061] Thermal Desorption tubes; 3.8 mm Tenax-TA, 2.0 mm Carboxen
1003
[0062] Additional information on equipment and parameters used is
set forth below:
[0063] GC-MS Parameters:
[0064] Oven
Equilibration time: 1.00 min Maximum temp: 250 C Initial temp: 35 C
(On) Initial time: 4.00 min
[0065] Ramps:
TABLE-US-00007 # Rate Final Temperature Final Time 1 3.00 82 0.00 2
6.00 210 10.00 3 0 (off)
Post temp: 240 C Post time: 5.00 min Run time: 51.00 min
Column: Agilent VF-WAX P/N CP9295
[0066] Back Inlet (CIS4)
Mode: Solvent Vent
[0067] Initial temp: 0 C (Off)
Pressure: 8.8 psi (On)
[0068] Vent time: 0.00 min Vent flow: 50.0 mL/min
Vent Pressure: 8.8 psi
[0069] Purge flow: 50.0 mL/min Purge time: 2.00 min Total flow:
54.0 mL/min Gas saver: Off Gas type: Helium
[0070] Thermal AUX 2
Initial temp: 240 C (On)
[0071] Gerstel Maestro
[0072] System Settings
Maestro Runtime: 55.99 min
GC Cool Down Time: 8.00 min
Cryo Timeout: 25.00 min
* * * * *