GB2447682A

GB2447682A - Moulded popcorn

Info

Publication number: GB2447682A
Application number: GB0705414A
Authority: GB
Inventors: Bibiana Christina Nelson
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-03-21
Filing date: 2007-03-21
Publication date: 2008-09-24
Also published as: WO2008113859A2; WO2008113859A3; GB0705414D0

Abstract

A food article is formed from the expansion of at least one kernel of corn in a mould cavity. There may be provided first and second mould sections 1 and 3. The first section 1 has first mould halves 5 cut into it and has slots 10, which receive lugs 12 on the second section 3. The latter also includes second mould halves 15 cut into it and which correspond to halves 5 to form mould cavities. Kernels of corn 20 are inserted into halves 5, with one kernel 20 positioned in each half 5. The second section 3 is placed in the first section 1 such that the lugs 12 are pushed into slots 10 to hold the mould sections 1 and 3 closed by friction fit. The closed mould is heated so as to allow expansion of corn kernels to take up the shape of the mould into popcorn article.

Description

* 2447682 Shaped Popcorn This invention relates to shaped popcorn, a

method of making shaped popcorn and a mould for making shaped popcorn.

Popcorn is well known as a snack food and is very popular. it is sold either in its popped form or in the form of unpopped kernels which can be converted into popcorn in a microwave, a pan or in special popcorn machines.

Popcorn is made from the explosion of a kernel of a particular type of corn (maize). For the purposes of this application, we will refer to the unexpanded kernel as being corn or a kernel of corn and the expanded kernel as being popcorn or popped corn. By expanded, we mean that the hull of the kernel of corn has ruptured and the starch inside has expanded.

As with all cereal grains, each kernel of corn contains a certain amount of moisture in its starchy endosperm.

Unlike most other grains, the outer hull, or pericarp, of the popcorn kernel is both strong and impervious to moisture, and the starch inside consists almost entirely of a hard, dense type. As the kernel of corn is heated past the boiling point, water in the kernel turns to superheated, pressurized steam, contained within the moisture-proof hull. Under these conditions, the starch inside the kernel gelatinizes, softening and becoming pliable. The pressure continues to increase until it reaches the breaking point of the hull, which is typically a pressure of about 135 psi (93OkPa). The hull ruptures rapidly, causing a sudden drop in pressure inside the kernel and a corresponding rapid expansion of the steam, which expands the starch and proteins of the endosperm into an airy foam. As the foam rapidly cools, the starch and protein polymers set into the normal exploded popcorn form.

Standard methods for exploding the corn kernel are either by heating the corn kernels in hot air or by cooking them in oil.

It is known to form popcorn into balls by mixing several popcorn pieces together in a syrup solution to form a large mass of popcorn and syrup together. In some cases, this Popcorn-syrup mixture can be shaped into other large and Unsophisticated objects. However, the individual pieces of popcorn used to make the popcorn balls are produced using standard methods and are themselves in the random shapes which cannot be controlled. It would be desirable to produce popcorn having specific shapes which would have a more attractive appearance.

In accordance with the first aspect of the present invention, there is provided a food article, wherein the article is formed from the expansion of at least one kernel of corn in a mould cavity.

In a second aspect of the present invention, there is provided a method of forming a food article in a mould cavity having at least one opening comprising the steps of: placing at least one corn kernel in the mould cavity; closing the mould cavity; heating the mould cavity until the at least one corn kernel expands; opening the mould cavity; and removing the food article from the mould cavity.

The resultant food article is an article made from popcorn which has a particular selected shape which corresponds generally to the shape of the mould cavity in which the kernel is expanded.

Although the mould is closed, in a preferred embodiment, the mould cavity is not completely sealed. In order for the kernel to expand, there must be some means by which air can leave the mould cavity. Some mould materials are air permeable, thereby allowing air to leave.

Alternatively, air could evacuate via an imperfect seal between the different parts of the mould cavity.

However, in a pref erred embodiment, the mould cavity has a small air hole which allows air to escape from the mould cavity. Typically, the air hole has a diameter of less than 2mm, preferably less than 1mm.

In one preferred embodiment of the present invention, a plurality of mould cavities are positioned in a mould.

Suitably the mould has a lid to close all of the mould cavities at the same time. A mould of this kind is useful for making relatively small quantities of shaped popcorn. it can be used both at home or to produce shaped popcorn commercially.

In a third aspect of the present invention, there is provided a mould for forming food articles comprising: a first moulding section comprising a first plurality of mould halves; a second moulding section comprising a second plurality of mould halves shaped and positioned to correspond to the first plurality of mould halves to form a plurality of moulds cavities; attachment means for attaching the first moulding section to the second moulding section, wherein each mould cavity has a volume of less than or equal to 1.2cm3. Preferably the first moulding section and the second moulding section are formed from a microwaveable material.

Preferably the mould is formed of two moulding sections in which the first moulding section comprises a plurality of first mould cavity halves and the second mould section comprises a plurality of second mould cavity halves which are shaped and Positioned to correspond to the first mould cavity halves. In use, at least one corn kernel is positioned in each first mould cavity half and the two moulding sections fitted together to close the mould cavities. The resultant closed mould can then be heated so that the corn kernels explode to form the shaped popcorn articles.

A mould can be formed of more than two pieces, depending on the complexity and size of the mould. However, the greater the number of pieces in the mould, the more likely it is that errors will occur when fitting the various pieces together.

Preferably, the mould additionally has a closure for keeping the mould cavities closed during heating. Any closure is suitable so long as the mould cavities do not open before the corn has expanded or during expansion.

One preferred closure form of closure is a friction fit between a first mould section and a second moulding section which holds the two sections together. In a pref erred embodiment, the moulding sections have lugs and holes which have a friction fit. It is Particularly preferred that the lugs are shaped and/or positioned such that the first moulding section and the second mould section can only be fitted together so that the correct mould halves are positioned together.

In alternative embodiments, separate closures can be provided such as straps or clips to keep the mould cavities closed.

The mould must be made out of a material which is Sufficiently hard so that it does not deform excessively under the pressure of the expansion of the corn kernel and is also temperature stable. it is preferred that the mould will have a Shore A hardness of greater than 50 and preferably greater than 60.

One preferred method of heating the closed mould cavities is in a microwave oven. Therefore, in this embodiment, the mould and closure must be suitable for use in a microwave oven. The mould can be made out of any suitable microwavable material. However, one preferred material which is commonly available is silicone.

Any material used for making the food articles must, of course, be food safe.

Where the mould is not to be used in a microwave, it can be formed of a metallic material which provides improved heat transfer when the mould is heated in an oven.

In an alternative preferred embodiment, each of the mould cavities is heated individually, for example using a small electric heating element. it is further preferred that each mould cavity is provided with a sensor to check when the kernel has expanded. Once the kernel has expanded, the heating element for that mould cavity automatically switches off.

The mould can be formed by any method known to the skilled person. Suitable methods include moulding or milling blocks to the correct shape.

S

There is no limitation on the shape of the mould. The mould is preferably any shape suitable to include several mould cavities.

There is no specific shape for each mould cavity. it can be formed in any shape that the user wishes. The mould cavities in any given mould can be identical or can be different All of the mould cavities could be different from each other or else there could be several mould cavities of each different type. Some suitable simple shapes include cubes, cylinders, triangular prisms and star shaped prisms. However, it is possible to make more elaborate shapes. For example, it is possible to make the mould cavity in the form of jigsaw pieces. Popcorn produced in such mould cavities can then be fitted together. Alternatively, the mould cavities could have the shape of cartoon figures or other well-known characters. it is preferred that the mould cavity does not have narrow portions, as the expanding corn may not be able to fill such portions.

In one preferred embodiment, the mould cavity has a volume of less than 1.2 cm3 and more preferably less than 1 cm3. A standard piece of popcorn typically has a volume of greater than 1cm3 and therefore a corn kernel will expand to fill the entire of such a mould cavity and thereby take on the shape of the mould cavity. it is further preferred that the mould cavity has a volume of greater than 0.5 cm3, more preferably greater than 0.6 cni3, and most preferably greater than 0.7cm3. The size of the mould cavity is selected partially based on the shape of the cavity. For example, the more complicated the shape, the smaller the mould cavity should be where only a single kernel is used as the greater expansion force will ensure that there is expansion into the more difficult to reach corners.

It is possible to form shaped articles by putting more than one kernel of corn in each mould cavity. In this embodiment, the mould cavity can be greater than 1cm3.

However, it is pref erred that the mould cavity has at least one dimension which is less than 1cm.

One preferred method of heating the mould is a microwave oven. The amount of time required to produce the popcorn articles depends on the power of the microwave oven, the thickness of the mould and the size of the mould. For an 850w microwave oven, most of the kernels of corn will have expanded after 5 minutes. For a 600w microwave oven, it will take 7 minutes or more. Where a mould has already been used, and therefore is already warm, the time required for subsequent uses is reduced.

In an alternative embodiment, the shaped popcorn articles can be formed in a Continuous production process. it would be apparent to the skilled person how to produce shaped popcorn continuously. In one possible embodiment of a continuous process, open mould cavities are positioned on a conveyor belt. One or more kernels are added to each cavity as it passes a corn kernel dispenser. Thereafter, each cavity is closed and then passed through an oven to expand the kernel. The oven is of sufficient temperature and length such that the kernel would expand. On average, a corn kernel needs to be heated to 175 C before complete expansion. Therefore, the mould cavity needs to be heated to a temperature in excess of 175 c to ensure expansion of the corn kernel.

After expansion of the corn kernel, the cavity is opened and the shaped popcorn removed. The mould Cavity then returns on a conveyor belt to be filled again. In a process such as this, shaped popcorn could be produced on an industrial scale.

In a further preferred embodiment, it is possible to include additives in the mould when producing the shaped popcorn article. Suitable additives include for example glitter or colourant. Any additives should be safe for consumptjon. Alternatively, such additives can be applied to the popped corn after expansion.

Any one embodiment of the present invention can be used in combination with any other embodiment of the present invention.

Preferred embodiments of the present invention are shown in the following figures, in which: Figure 1 shows kernels of corn being inserted in a first moulding section; Figure 2 shows the second moulding section being positioned on the first moulding section; and Figure 3 shows the shaped popcorn articles after explosion of the kernels in the mould.

Figure 1 shows a first moulding section 1 and a second moulding section 3. The first moulding section 1 has eight first mould halves 5 cut into the first moulding section. The first moulding section 1 also has eight slots 10 spaced throughout the first moulding section.

The slots 10 are positioned for receiving corresponding lugs 12 which are positioned on the second moulding section 3. The second moulding section also has eight second mould halves 15 cut into it. The second mould halves 15 are shaped to correspond with the first mould halves 5 to form mould cavities. Kernels of corn 20 are inserted into the first mould halves 5, with one kernel being positioned in each first mould half 5.

As shown in Figure 2, once the kernels 20 are positioned in each first mould half, the second moulding section 3 is placed on the first moulding section 1 such that the lugs 12 are pushed into the holes 10 to hold the two moulding sections 1, 3 together by a friction fit. The closed mould is then placed in an 850w microwave and heated on full power for 5 minutes.

After heating, the closed mould is removed from the microwave and the second moulding section 3 removed from the first moulding section 1. As shown in Figure 3, the corn kernels have expanded into popcorn articles wherein the articles have taken the shape of the mould.

The skilled person would appreciate that the present invention can be applied not only to individual moulds of the type shown in the Figures, but also to continuous processes, which involve passing the kernels in the mould cavities through an oven and then opening the mould cavities are the kernels have expanded.

Claims

Claims 1. A food article, wherein the article is formed from the

expansion of at least one kernel of corn in a mould cavity.
2. A food article as claimed in Claim 1, wherein the article is formed from one kernel of corn.
3. A method of forming a food article in a mould cavity having at least one opening comprising the steps of: placing at least one kernel of corn in the mould cavity; closing the mould cavity; heating the mould cavity until the at least one kernel of corn expands to fill the mould cavity; opening the mould cavity; and removing the food article from the mould cavity.
4. A method as claimed in Claim 3, wherein the mould cavity has a volume of less than or equal to 1.2cm3.
5. A method as claimed in Claim 3 or Claim 4 for producing a plurality of food articles, wherein a mould comprises a plurality of the mould cavities.
6. A method as claimed in Claim 5, wherein the mould comprises a first moulding section having a first plurality of mould cavity halves and a second moulding section having a second plurality of mould cavity halves shaped and positioned to correspond to the first plurality of mould cavity halves to form the mould cavity, and wherein at least one corn kernel is put in each of the first mould cavity halves.
7. A method according to Claim 3 or Claim 4, wherein the method of forming the shaped popcorn article is a Continuous process whereby a plurality of closed mould cavities containing at least one kernel of corn pass through a heater.
8. A mould for forming food articles comprising: a first moulding section comprising a first plurality of mould halves; a second moulding section comprising a second plurality of mould halves shaped and positioned to correspond to the first plurality of mould halves to form a plurality of moulds cavities; attachment means for attaching the first moulding section to the second moulding section, wherein each mould cavity has a volume of less than or equal to 1.2cm3.
9. A mould for forming food articles as claimed in Claim 8, wherein the first moulding Section and the second moulding section are formed from a microwaveable material.
10. A mould for forming food articles as claimed in Claim 8 or Claim 9, wherein at least two of the mould cavities have different shapes.
11. A mould for forming food articles as claimed in any one of claims 8 to 10, additionally comprising a plurality of air holes, each air hole being positioned to allow evacuation of air from a corresponding mould cavity.
12. A method for forming food articles substantially as hereinbefore described with reference to and as illustrated by the drawings.
13. A mould substantially as hereinbefore described with reference to and as illustrated by the drawings.