US3655410A

US3655410A - Method of packaging two or more discrete foodstuffs

Info

Publication number: US3655410A
Application number: US801297A
Authority: US
Inventors: John H Forkner
Original assignee: Individual
Current assignee: Individual
Priority date: 1969-02-24
Filing date: 1969-02-24
Publication date: 1972-04-11
Anticipated expiration: 1989-04-11
Also published as: FR2032375A1; CA947249A

Abstract

A method of making a consumer food package consisting of at least two layers of different dried food materials by introducing the materials into a container in discrete form and there after causing one of the materials to take a set form whereby it remains as a solid.

Description

tates atent [151 3,655,410

Forkner [451 Apr. 11, 1972 [54] METHOD OF PACKAGING TWO 0R 2,789,058 4/1957 Ball et a1 ..99/186 MORE DISCRETE FOODSTUFFS 2,836,498 5/1958 Fennema 2,955,941 10/1960 Hultkrans et memo John Forkner 6037 North Van Ness 2 357585 91944 t 1 B1vd., Fresno, Calif. 93705 I Gall/m e 3 X [22] Filed: $14,198 FOREIGN PATENTS OR APPLICATIONS [21] APPLNO: 801,297 11,675 3/1933 Australia ..99/171 R Primary ExaminerTim R. Miles [52] US. Cl. ..99/171 R, 99/172 Assistant ExaminerSteven L. Weinstein [51] Int. Cl ..B65b 3/00 Attorney-Flehr, l-lohbach, Test, Albritton & Herbert [58] Field ofSearch ..99/186, 171 R, 172, 171CP,

99/171 H, 66, 138, 124; 206/47 A [57] ABSTRACT A method of makin a consumer food ackage consistin of at [56] References cued least two layers of different dried foocl materials by intr oduc- UNITED STATES PATENTS ing the materials into a container in discrete form and there after causing one of the materials to take a set form whereby it 1,855,145 4/1932 Jones ..99/138 remains as a m 2,502,196 3/1950 Ball ..99/186 2,768,086 10/1956 Bliley ..99/171 R UX 11 Claims, 8 Drawing Figures Dry discrete food material I Dry discrete food ll material with bonding medium Introducing into container 12 in successive layers Causing layer of material 13 to set form distinct selfretaining layer capable of being crumbled for use Packaged food product PATENTEDAPR i l i972 SHEET 1 BF 3 Dry discrete food material r Introducing into container l2 in successive layers Causing layer of material l3 to set torm distinct selfretaining layer capable of being crumbled for use Packaged food product Packaged product discrete material and set material Open container 2| Pour out material A and process Crumble and remove 22 material and separately process Combine processed materials for final food product Dry discrete food material with bonding medium FlG 2 FlG 5 INVENTOR JOHN H. FORKNER 1.4x, Wm M KL-lad:

ATTORNEYS PATENTEDAPR ll I972 SHEET 2 0r 3 Discrete dry Discrete dry 28 Discrete dry material A material B with material C (e.g.,pulver|zed cheese) bonding medium (e.g., pizza dough Heat with agitation 29 to softening point of wax Introducing into container 30 as successive layers of materials A, B 8% C Cooling with setting 3| of material B Storage 32 Product Dry discrete food D 42'-Dry discrete food material B material with bonding medium having softening point above ambient Introducing into package 43 in successive layers Heating to softening 44 point of bonding medium Cooling to 45 S61 material INVENTOR,

JOHN H. FORKNER Storage 46 BY 1%, W w; mc- W Product ATTORNEYS PATENTEBAPR 1 1 m2 SHEET 3 BF 3 INVENTOR. JOHN H. FORKNER METHOD OF PACKAGING TWO OR MORE DISCRETE FOODSTUFFS BACKGROUND OF THE INVENTION Many packaged food products for the consumer trade consist of two or more food materials that are in separate containers (e.g., polyethylene bags, etc.) sold individually or in a common container or carton. The consumer removes the materials from the separate containers and after processing the materials according to directions, they are incorporated in a final composite product. By way of example, one material may be a dry cake premix containing such ingredients as cereal flour, sugar, flavoring and shortening, and the other material may contain the ingredients for a cake icing or topping. The use of separate containers has been deemed necessary for separate consumer processing. However, this adds considerably to packaging costs.

SUMMARY OF THE INVENTION AND OBJECTS The invention relates generally to packaged food products of the type comprising separate materials that are sold together for separate consumer processing to form composite products. Also it relates to methods for forming such food packages.

In general it is an object of the invention to provide packaged food products of the above character which have separate food materials in a single container without substantial intermixing during handling, shipping and storage, whereby the consumer may remove the separate materials for processing.

Another object of the invention is to provide a food package of the above character in which the separate materials are in layers, and in which at least one material is set as a self-retaining layer.

An additional object of the invention is to provide a novel method for manufacturing the above packaged product which can be carried out by modern high-speed packaging equipment. The method is characterized by introducing separate discrete materials into a container to form separate and distinct layers, with the resulting layers being in direct interface contact along a zone of demarcation, and then causing one of the materials to be set as a solid.

In general, the present invention is a consumer food package consisting of a container (e.g., plastic bag) within which are at least two layers of dry food materials, the materials being in direct interface contact along one or more regions of demarcation. One of the materials is in discrete form and may be poured out of the package, and the other consists of particles which are set as a solid by the use of an edible bonding medium. The method for making the product involves introducing the materials successively into a common container whereby the materials in discrete form are deposited as superposed layers with direct interface contact. One of the materials, which incorporates a bonding medium, is thereafter caused to set to form a self-retaining solid. The product can be made for distribution at ambient temperature or as refrigerated or frozen products. In one embodiment of the invention more than two layers of different discrete materials are deposited in a container and then one layer is set or solidified to form a solid layer, with separate adjacent layers of discrete material. In another embodiment two layers are set as solids and disposed below and above a layer of discrete material.

Additional objects and features of the invention will appear from the following description in which the preferred embodiments have been set forth in detail in conjunction with the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING FIG. I is a flow diagram illustrating one method for carrying out the invention;

FIG. 2 is a side elevational view showing a typical packaged product produced by the method;

FIG. 3 is a flow diagram illustrating the manner in which a consumer uses the packaged product of FIG. 2;

FIG. 4 is a flow diagram illustrating another embodiment of the method, involving the use of at least three layers in a single container;

FIG. 5 is a side elevational view showing a sample product produced by the method of FIG. 4;

FIG. 6 is a flow diagram illustrating another embodiment of the method, in which materials are subjected to heat treatment after being positioned in the container;

FIG. 7 is a schematic side elevational view showing equipment for effecting molding of the package; and

FIG. 8 is an enlarged detail in section illustrating operation of the machine.

DESCRIPTION OF THE PREFERRED EMBODIMENTS As illustrated particularly in FIG. I, the method involves the use of at least two materials 10 and 11 in discrete form. In the diagram these are indicated as material A and material B. One or both materials may be a single substance in discrete form, but in most instances they will be discrete mixtures of more than one ingredient. Material B is indicated as containing a bonding medium. This medium is an edible ingredient and may be inherently contained in one or more of the ingredients of the mix, or may be an added medium. As examples of suitable bonding mediums reference can be made to natural and synthetic fats and waxes, having fusion and melting points well above ambient or above refrigerating or freezing temperatures where the product is to be sold in refrigerated or frozen condition. As examples of natural fats, reference can be made to materials like coconut butter, chocolate, hydrogenated vegetable and animal fats and waxes like beeswax. Also many natural and synthetic materials normally referred to as shortenings, and used as such in the baking industry, have softening points within the ranges specified and can be used as bonding mediums. Synthetic waxes such as Myvacet can likewise be used. Whatever bonding medium is employed, it is generally a minor ingredient of the mix comprising material B. The bonding medium may be dispersed in the discrete material while in the form of an atomized liquid, or it may be added as a powdered material with agitation to effect uniform dispersion in the mix.

Although in some instances such as products for refrigerated distribution, I can use hydrogenated fats of a lower melting point like conventional shortening, for stable products at ambient temperature I prefer to use the fats generally classifed as hard fats. Such hard fats, illustrated by cocoa butter but including many other fats, are characterized by a melting point above that of body temperature (i.e., above 98 F.) and also by a small temperature differential between their softening or melting states and hardened condition e.g., a differential as low as 3 to 5 F.).

Step 12 represents the successive introduction of materials A and B in discrete form into a suitable container. Although the invention can be used with various kinds of containers, it is deemed preferable to use containers of the types commonly used in the food industry, such as flexible bags or packages made of materials like plastic films, metal foil, wax or glassine paper and the like. Shortly after introducing the two discrete materials A and B into the container, the material B is caused to set to form a self-retaining layer. As will be presently explained, the setting can be carried out by introducing the discrete material B at an elevated temperature (above the softening point of the bonding medium) into the container and then pennitting it to cool below the softening point of the medium to cause the particles of material B to be bonded together. Another procedure is to introduce both materials A and B into the container at ambient temperature, and then subject the package to heating to a temperature above the softening point of the bonding medium, whereby after cooling the particles of material B are bonded together.

10103] mas The solid mass formed by setting should be sufi'iently hard or firm for the temperature range at which it is to be marketed to withstand handling, storage or shipment, without material change in the form of the mass and without physical disintegration, and to be separable from an adjacent layer or layers of discrete material. Within these requirements the set mass may be relatively hard, or it may be sufficiently friable to permit it to be broken by hand into smaller pieces, thereby facilitating its removal from the container and/or facilitating mixing with or dispersion in various other materials. For example, the bonding medium can be controlled to produce a layer which is capable of being broken or crumbled by hand when the package is used. Thus with such a set layer the consumer is capable of breaking or crumbling the layer by hand, thus facilitating removal from the container and/or dispersion in a liquid medium. In other instances the set layer may be a body that can be removed intact from the container and readily mixed with or dispersed in other ingredients.

A typical package produced by the method of FIG. 1 is shown in FIG. 2. The container 14 in this instance is a bag made of a plastic film, such as polyethylene, and is heat sealed at its ends. Within the bag can be seen the dry discrete material 16 comprising material A, and the layer 17 which is set and solid. Between the two layers there is a distinct zone of demarcation 18 which is first established when the materials are introduced successively into the bag, and which is subsequently maintained by virtue of the fact that the layer 17 is set. Throughout handling, shipment and storage, the layer 17 remains set in substantially its original form, thus preventing any intermixture between materials A and B, and maintaining the demarcation zone 18. In this connection it will be evident that during handling, shipment and storage there may be some minor cracking or breaking away of the solid material without detracting from the desired separation of discrete and solid materials when the package is used.

When the package shown in FIG. 2 is used by the consumer, the upper end is opened and the discrete material A is poured out into a suitable receptacle. The material B is then removed from the bag. Depending upon its hardness, the set layer B may be crumbled merely by kneading forces applied by hand to the lower end of the bag. Also material B may be removed as an intact body and then subdivided in subsequent operations. The two discharged materials are then processed by the consumer in accordance with directions furnished, and eventually the two materials are combined to form a composite food product. For example, if material A is a cake premix, the housewife or consumer mixes the dry ingredients with additives such as liquid milk, eggs and the like, to form a better for introduction into a cake pan. The material B may be an icing mix consisting largely of sugar and fat which in turn may be mixed with liquid ingredients such as liquid milk to form an icing which is applied to the top of the cake after baking.

The steps taken by the consumer to use the package as described above are illustrated in diagram FIG. 3. Thus in step 21 the container is opened and the material A is poured out into a suitable receptacle. In step 22 the material B is crumbled by hand and poured from the container. Step 23 represents the ultimate consolidation of the two processed materials to make the final food product.

FIG. 4 represents the method to produce a package having a set layer between and serving to divide two discrete layers.

Materials

26, 27 and 28 represent the materials A, B and C and are respectively indicated as being pulverized dry cheese, a topping mix with an edible wax having a softening point above ambient, and lastly a dry premix containing the main ingredients required for making pizza dough. In step 29 material B is heated to a temperature above ambient to effect softening of the wax. Such heating can be carried out with agitation to maintain the material in discrete form. In step 30 the three discrete materials are introduced successively into a suitable container, such as a polyethylene bag, to form three superposed layers. The bottom layer may be material A, the intermediate layer material B, and the upper layer material C. In step 31 the container and contents are cooled or are permitted to cool to ambient temperature, thereby causing material B to set as a solid. Thereafter the filled container may be stored at 32 before being marketed.

FIG. 5 illustrates a finished product such as is produced by FIG. 4. The container 34 has a bottom layer 35 of material A, an intermediate layer 36 of material B, and a top layer 37 of material C. Layers 35 and 37 are in discrete form, whereas layer 36 is set as a solid. The regions of

demarcation

38 and 39 are distinct, and during handling, shipment and storage, no substantial intermingling of the material occurs and the materials can be readily separated when the package is used by the consumer.

When the product of FIG. 5 is used by the consumer, the top of the bag 34 is opened to permit pouring out the material C. The bottom of the bag may now be opened to permit pouring out the material A. Finally material B is crumbled by hand and the contents discharged from the bag, or it may be removed as an intact mass and then subdivided to facilitate further processing. With the making of a pizza, the material A may also have its particles somewhat bonded together because of the inherent character of this material. However, the mass can be readily separated into smaller clusters by hand. The material C is processed by mixture with liquid ingredients such as liquid milk, to form a dough of suitable consistency. The dough may be further processed by customary kneading and proofing. The topping mix comprising material B may in this instance be largely sugar as a dispersant for herbs and spices and intended to be subdivided and mixed with liquid ingredients like tomato paste, added fat and milk. The sheeted dough is placed over a baking pan, after which materials A and B are introduced to form the desired filling. Thereafter the pizza is subjected to customary baking.

In the embodiment of FIG. 6 a dry discrete food material A designated at 41 is used together with a dry discrete material B containing a minor percentage of a bonding medium having a softening point above ambient. Instead of preheating the material B above ambient, as in step 29 of FIG. 4, in this instance the two materials A and B are successively introduced in discrete form and at ambient temperature into the container, as indicated in step 43. Thereafter in step 44 the container is heated together with the contents to a temperature above ambient and to effect softening of the bonding medium. This causes the particles of the material B to be adhered together by the bonding medium. In step 45 the container and contents is cooled to cause the solidification of the bonding medium with setting of material B. Thereafter the product may be stored at 46 before marketing.

In the setting, means may be employed to constrain flexible walled containers in a mold to provide a desired form for the set solid material. Such a mold may apply some compaction to the material during setting to attain a desired increased density. The molding means may be arranged to heat material to cause it to set as a solid, and in addition it may cool the material after heating. The molding means shown schematically in FIGS. 7 and 8 consists of a belt 51 provided with cooperating hollow molds 52. The arrangement may be such that when the belt is flexed about the

rotatable drums

53 and 54 the containers may be introduced or withdrawn, but for the upper run the molds engage and shape the lower portions of the flexible walled containers between the same. Hot and cold air currents may be introduced by way of

pans

56 and 57 to heat and thereafter cool the molds. The belt and the molds may be provided with perforations to facilitate the air flow.

To summarize some of the data in the foregoing description and the examples to follow, the set layer remains solid for the range of temperatures at which the product is to be marketed. The bonding medium employed should have a softening point above this range. For a product to be marketed under refrigeration (e.g., 3540 F.) the bonding medium may have a softening point of the order of 60 F. or higher. For marketing without refrigeration the bonding medium may have a softening point of the order of F. or preferably above about F.

Depending upon the character of the materials employed, the bonding medium and the nature of the container walls, the walls will more or less adhere to the adjacent surfaces of the set solid layer. To the extent that such adhesion does not make it difficult to remove the solid layer from the container, such adhesion is desirable in that it serves to prevent discrete material from an adjacent layer from finding its way between the container walls and the solid material. Also it tends to prevent bypassing of discrete material about the solid layer, when this layer divides two discrete materials. Such adherence but with the capability of stripping flexible container walls from the solid material can be promoted by use of edible thermoplastic coatings (e.g., beeswax) on the container walls.

The use of a shrunk film type of container also tends to ensure permanent contact between the set solid layer and the container walls. Assuming that the container is a bag made of a plastic film that is shrunk by heat treatment (e.g., to 120 F.), then the one layer may be set by heat treatment and at the same time the film shrunk to tighten it about the contents.

It will be evident from the foregoing that my method makes possible use of a single container for a plurality of different materials, with each material being maintained separate from the other. The method facilitates filling of the containers because at that time the materials are introduced in discrete form. in the final product there is a sharp region of demarcation between the different materials, and interrnixture between the different substances is prevented during handling, shipment and marketing. The consumer may separately dispense the different materials from the container, thus maintaining their identity during processing and for their reincorporation into a single food product.

Examples of the invention are as follows:

EXAMPLE I.

This example serves to illustrate application of the invention to cake mixes and icings. A dry cake mix was prepared using the following formula:

Sugar 41.00%

Flour 36.00%

Cocoa 5.00%

Soy Protein 1.00%

Salt 1.00%

Starch 1.00%

Leavening Acid 1.00%

Soda 1.25%

Flavor 0.25%

Shortening 12.25% (with mono and di glycerides) Total: 100.00%

Ten pounds of icing dry mix was also prepared using the following formula:

Sugar 75.0% Dextrose 15.0% Agar 2.0% Albumen 3.0%

Flavor 1.0%

' Salt 0.5% Cream of Tartar 0.5% CMC 1.0%

Starch 2.0%

Total: 100.0%

Discrete cocoa butter was used as a bonding medium, having a particle size of 60 mesh, and in an amount equal to about percent by weight of the icing mix. The discrete cocoa butter was prepared by first chilling by contact with dry ice, followed by grinding to the size desired. Two feeding devices of the vibrating type were provided for feeding the two discrete materials. Before commencing a bag filling operation, the icing mix was heated while being agitated to about 140 F., which was above the softening point of the cocoa butter. The hot icing mix was then fed into polyethylene bags in an amount equal to 10 ounces of the icing for each bag being filled. Some vibration was applied to the contents of the bags to cause settling, after which 18 ounces of the discrete cake mix was introduced into the bags upon top of the icing mix. After some further vibration to cause settling, the bags were heat sealed. Bags filled in this manner were stored at ambient temperature, and after 2 days it was observed that the lower layer of icing mix had set to form a self-retaining body, whereas the upper layer of cake mix remained in discrete form. After a total of 2 weeks in storage, a package was opened from the top and it was found that the cake mix could be readily poured from the bag. Only an insignificant quantity of the cake mix remained adhered to the bottom icing layer. It was found that the bottom layer could be removed bodily from the bag and then crumbled by hand into a bowl. It was also found possible to crumble the bottom layer by hand while in the package, thus permitting the crumbled material to be poured from the bag. The cake mix was then processed in the prescribed fashion by adding two eggs and 1% cups of water with slow mixing until the ingredients were unifonnly blended and mixed 2 minutes at medium mixer speed. This batter was introduced into two greased pans and baked 35 minutes at 350 F. During baking the icing was prepared by mixing with the material about 1 ounce of hot water and 3 tbs. of soft butter. Beating was applied to obtain a desired fluffy consistency. After the baked cake had cooled, the icing was applied in the usual manner.

The above Example 1. demonstrated use of a hard vegetable fat (i.e., cocoa butter) as a bonding medium. Such a fat has a softening point above F. and well above the ambient temperature range for normal marketing of dry food mixes. It will be apparent that other fats may be used, such as fats that are less expensive or having higher softening points.

EXAMPLE II.

In this instance the binding agent was an active ingredient of one of the materials. An icing formula was prepared as follows:

Shortening 20% Flour 7% Salt V2% Confectioners Sugar 72% Powdered Flavors Wk (Vanillin 84 Lemon) Total:

Five lbs. of the shortening, flour and salt formulation were mixed and formed into a sheet about A inch thick. This sheet was frozen to the brittle state by contact with dry ice, after which it was ground into particles about A inch in diameter. The separate sugar and flavor formulation was prepared as a dry discrete mix and refrigerated. By the use of a feeder of the vibrator type, each bag was first supplied with 7- /2 oz. of the refrigerated pulverulent sugar-flavoring mix. Then 2- /2 02. of the shortening-flour-salt mixture was introduced, and the bag vibrated to settle the contents. Thereafter 18 oz. of discrete cake mix made in accordance with the formula specified in Example I was fed to the bag upon the top of the previously introduced material. The bags were cased and stored for about 24 hours in a heated chamber at about 80 F. until the inner bag temperature of each case reached about 7080 F. During this time the shortening composition softened from the brittle state, but without becoming semifluid or liquid. The bags were then refrigerated to about 38 F. and stored at that temperature. After storage for a period of 2 weeks, the top of the bag was opened and it was found that the cake mix was in dry discrete form and could be readily poured into a mixing bowl. Substantially no cake mix was left adhering to the surface of the intermediate shortening-flour-salt material. The bottom of the bag was then opened and it was found that the sugar-flavoring material was in discrete free flowing form. This material was then poured from the bag, leaving the central shortening-flour-salt material. The central layer was then removed as a semiplastic mass. This could be readily dispersed by adding milk and heating with stirring. Also after dispersing the shortening-flour-salt material, it was a simple matter to add and disperse the sugar-flavoring composition.

1n the foregoing Example ll the shortening functioned as a bonding agent and dividing layer. Although such an agent may be plastic at ambient temperature, it has suflicient hardness under refrigeration to maintain the shortening-flour-salt material as a solid separating layer.

EXAMPLE III.

In this example the method was carried out in such a manner that heat was applied to cause setting of one layer of material, after the materials had been placed in a bag. A dry dough mix was prepared according to the following formula:

Flour 86% Shortening 7% (no emulsifier) Sugar 4% (granulated) Corn Sugar 1% Milk Solids 1% Salt 1% Total: 100% Packet of active dry yeast 2% lbs. of Myvacet (acetylated monoglycen'des) having a melting point of about 105 F. was chilled to about 20 F. to make it brittle. Together with a small amount of dry ice, the Myvacet was ground to -30 mesh, thus forming a free-flowing granular material. 30 lbs. of raisins were heated to about 130 F. and while being slowly agitated, the low temperature Myvacet was sifted onto the raisins. The Myvacet melted upon contact with the warm raisin surfaces,'thus forming thin transparent films for the purpose of lending free-flowing properties and to extend the shelf-life of the raisins. The raisins were then permitted to cool to ambient temperature with agitation. A 5 oz. quantity of such raisins, at about 60 F. were first added to each bag, and then 8 oz. of the dry discrete dough mix was added to each bag, together with a small packet of dry yeast. The bags were then sealed and heated to elevate the temperature of the contents to about 108 F. This served to cause contacting coated surfaces of the raisins to fuse together. The bags were then permitted to return to ambient temperature and then they were placed in storage. It was found that the layer of raisins in the bottom of each bag was set as a selfretaining layer and that there was a sharp region of demarcation between the upper surface of the raisin layer and the dough mix layer. After storage for 2 weeks the bags were opened and it was found that the dough mix remained in discrete form and could be readily poured from the bag into a mixing bowl. The compacted mass of raisins could likewise be readily removed from the bag, either as an intact mass by slitting the bags, or as clusters of raisins by crumbling the mass in the bags and then pouring the clusters of raisins from the bag. Some powdered dough clung to the raisin surfaces, but most of this could be dusted off and the remaining amount was inconsequential. The raisins were presoaked in hot water, drained and cooled before subsequent inclusion in the dough. The dough mix was then processed by the addition of water, the yeast and butter. These ingredients were first mixed in a mixer of the kitchen type, the mixing however being completed by hand to form a dough ball. After permitting the dough ball to stand for about 60 minutes, the raisins were intermixed with the dough, and the dough permitted to stand for about 10 minutes for preliminary resting." The dough was then divided into 1- /2 02. portions which were deposited in a muffin pan and then permitted to proof. They were then baked in the usual fashion to form raisin muffins.

The foregoing Example Ill demonstrates a set solid layer comprising food bits (e.g., raisins) that are agglomerated together by a bonding medium, and which can be first separated out and then subdivided by hand. Such an agglomerated set layer can be separated by the consumer and used in various ways, such as to provide a topping, or to provide a material to be mixed with ingredients like fat and sugar and thereafter deposited in a pan ahead of the batter as an upside down cake.

EXAMPLE IV.

The same procedure was followed as in Example lll. However, the bags employed were of the type which shrinks when heat is applied. After packaging and sealing, the bag was heated to about 120 F. to cause both shrinkage of the film and setting of the layer of raisins.

EXAMPLE V.

This example demonstrates a product which is adapted to be marketed in refrigerated or frozen condition. Likewise, in this instance a shortening content is used as a bonding medium and is subsequently used to provide shortening in the dough batter.

A dry discrete fruit cake mix was prepared having the following formulation:

Flour 33.00% Sugar 32.00% Salt 1.50% Flavor dry powder 1.00% Shortening 32.50%

Total: 100.00%

The dry ingredients of the above formula were blended together. The shortening was separately prepared by chilling to a temperature of the order of 0 F. and followed by subdividing to a particle size of about 10 mesh.

A fruit mix was prepared having a formulation as follows:

Candied Orange Diced Peel 15% Candied Grapefruit Diced Peel 5% Candied Pineapple Diced Peel 15% Candied Citron Diced Peel 5% Candied Cherries Whole 20% Candied Fruit Totai: 60% Raisins 40% Total: 100% The candied fruit used in the above formula was first treated to remove excess syrup by heating it to about 140 F. and then centrifuging off the excess syrup content. After centrifuging and with the fruit at about 120 F the raisins at ambient temperature were added whereby the mix assumed a resulting temperature of about 120 F. Ground Myvacet at a temperature of about 10 F. and in an amount corresponding to 3 percent by weight of the fruit-raisin mix, was added to the mix with agitation to distribute it over the surfaces of the fruit and raisins, after which the mix was spread on a tray and permitted to cool to ambient. During this time it was occasionally agitated to maintain free-flowing properties. This discrete fruit mix at ambient temperature was first introduced into the bags in the amount of 1 lb. of the fruit mix for each bag. A 5 oz. quantity of the discrete shortening (softening point above 60 F.) was then added upon the top of the fruit layer, and the bag vibrated to effect settling. An 1 1 oz. quantity of the dry cake mix was then added upon top of the shortening, making a total bag weight of about 2 lbs. The bags were then held at ambient room temperature of about to F. until it was observed that the shortening had softened and compacted without, however, becoming a liquid. The bags were then cooled to a refrigerated temperature of 38 F. and held for marketing. After being stored at 38 F. for about 2 months, the bags were opened and it was found that the cake mix was in discrete condition and could be readily poured from the bag, leaving practically no cake mix in contact with the shortening and fruit layer. The bag was then slit and it was found that the shortening was a distinct mass which could be readily separated from the fruit mix requiring separate processing. The fruit mix was also found to be a self-retaining mass due to interbonding between pieces of fruit by the Myvacet. However, this mass could be readily crumbled by hand into individual pieces or clusters of the fruit. The materials thus removed from the bag were processed in the usual manner to make a fruit cake. This involved addition of the shortening to the discrete cake mix,

mtmr Ma and with the addition of the fruit before baking. However, before the fruit was added to the dough it was first soaked in hot water 20 minutes, after which excess hot water was removed by screening.

in the foregoing example, the shortening forms a distinct layer within the bag, and it is added as a separate material in discrete form. After being added to the bag it is caused to congeal or soften whereby there is some bonding between particles of the shortening, thus forming a solid layer which divides and maintains the dry cake mix separate from both the discrete cake mix content and the bottom layer of fruit. Also the dividing material is one which is a normal ingredient of the cake mix. Its use in a separate dividing layer makes possible an adequate quantity separate from the flour. Dispersion of shortening in a flour mix is undesirable in certain premixes. It tends to promot deterioration of the shortening during storage, and at the higher levels required for some cakes it tends to cause clumping.

EXAMPLE V1.

The purpose of this example was to demonstrate application of the invention to a non-bakery product, particularly a gel dessert of the type referred to as a pudding or pie filling.

A dry dessert mix was prepared with a formula as follows:

Sugar 80.00% Non Fat Dry Milk Powder 7.00% Cornstarch 4.50% Cocoa 5.00% Agar,powdered 2.00% Salt 1.00% Dry Flavors (Vanillin,etc.) 0.50%

Total: 100.00%

A confectionary mix was then prepared having a formula as follows:

Granulated Sugar 12.00%

Corn Syrup 35.00%

Sweetened Condensed Milk 25.00%

Cream (20% fat) 21.00%

Cocoanut 011 7.00%

Total: 100.00%

Salt to Taste The ingredients of the latter formula were intermixed and the resulting dispersion concentrated by boiling to such an extent that it became brittle upon cooling. It was then deposited on a cooling slab to produce a layer about three-eights inch thick. Before the sheet was completely cool it was surfaced with almond nut bits and melted milk chocolate. After cooling and hardening, this layer was sliced into pieces of such size that they would pass a inch mesh screen but would remain on a No. 12 screen. Polyethylene bags were then filled commencing with 1 oz. of the divided confection, followed by introduction of 7 oz. of the dessert powder. The bags were then sealed and heated to a temperature slightly over 100 F (e.g., about 105 F.) after which they were cooled to about 80 F. Cooling was carried out relatively rapidly and immediately after heating to avoid discoloration of the chocolate. It was observed that the confection layer was set as a self-retaining layer, due partly to the sticky surface characteristics of the confection pieces, but primarily because of fusion of the free chocolate present. After storage for 2 weeks at ambient temperature, the top of the bag was opened, and it was found that the dessert powder was discrete and free-flowing and could be readily poured into a receptacle. It was also found that although the confection layer was set and self-retaining, it could be readily crumbled by hand in the bag and then poured out into a receptacle. Also after removal of this material from the bag, it was found that the larger clusters could be readily subdivided by hand. The dessert mix was then processed to form a gel, and the confection used as a topping.

0 EXAMPLE V11.

The following example illustrates how the invention can be used to produce a package having three difierent and separate materials. Also in this instance a separate packet was inserted in the main container to enclose an ingredient which was not premixed with the other materials, namely dry yeast.

A pizza dough dry mix was prepared in accordance with the following formula:

Flour 86% Shortening 7% (No Emulsifier) Sugar 4% (Granulated) Corn Sugar 1% Milk Solids 1% Salt 1% Total:

Packet of Active Dry Yeast A pizza topping dry mix was then prepared in accordance with the following formula:

Dried, Granulated Onions 6% Dried, Granulated Sweet peppers 3% Dried, Granulated Celery 2% Dried, Powdered Garlic 1% Dried, Powdered Oregano 1% Dried, Powdered Rosemary /4% Agar 2% Salt 1 Black pepper Starch 57 Dried Non Fat Milk Powder 5% Coarse Brown Sugar 73% Total: 100% Plus: Powdered Beeswax 8% of above mix All of the ingredients of the last named mix except the beeswax were first intimately intermixed. The beeswax which had a melting point of about 144 to 149 F. was chilled to 20 F. and then ground to sufficient fineness to pass a 16 mesh screen. The beeswax (8% of the mix) was then added and intermixed with the topping dry mix formula. A grated cheese was provided consisting of separately grated parmesan and romano cheeses, blended together with proportions of one part parmesan to three parts romano cheese. A 1- /2 oz. quantity of this grated cheese was first introduced in each of the bags. The topping mix was heated to a temperature of about to F. and then added to the bags upon the top of the cheese, a 2 oz. quantity of such mix being introduced into each bag. A 6- /2 02. quantity of the dry dough mix was then added to each bag upon the top of the topping mix, and a packet of dry yeast inserted before sealing. The bags were then cooled to ambient room temperature and stored. When inspected after 2 days storage it was found that the middle layer of topping mix was relatively firm and served as a solid dividing mass. After 2 months storage, the bags were opened and it was found that the dough mix remained in free-flowing discrete form and could be poured out into a container. Only a very minor portion of this mix remained upon the central layer. By slitting the bag the central layer could be readily removed bodily from the bag and could be crumbled by hand to facilitate processing. The lower layer of cheese could also be readily removed, and could be readily separated by hand into clusters to facilitate its use. The separate package of yeast which was removed with the dough mix was used in the processing of this mix to fonn a proper pizza dough. Processing of the various materials involved preparing the pizza dough by the addition of water and with proofing, kneading and sheeting operations, thereby providing a dough sheet in a baking pan. The topping mix was processed in a frying pan together with olive oil and added tomato paste and water. The topping mix was added upon the dough layer and then the cheese sprinkled on the topping.

In addition to the various embodiments described in the above examples and specifications, in some instances it may be desirable to provide two solid layers of materials with an intervening layer of discrete material. For such packages the three separate materials are introduced into the package in discrete form, after which the first and third materials are set in the form of solids by the procedures previously described. In this manner the two resulting solid layers effectively trap a layer of discrete material between the same.

In the foregoing I have referred to one or more layers of materials in discrete form. It is desirable to avoid very find particle sizes (e.g., 200 mesh), since such materials may tend to sift between the package walls and solid layers or into pores or interstices of an adjacent solid layer. Thus I prefer that the discrete materials which remain as such be of substantial particle size. If fine particle sized material is used (e.g., non-fat dry milk) the same should be processed to form aggregates or granules of substantially larger particle size.

I claim:

1. In a method for the manufacture of a consumer food package, the steps of separately and successively introducing at least two food materials in the form of dry discrete particles into a single container, one of the materials having a bonding medium dispersed between the particles of the same, whereby the layers of the two materials thereby formed in the container are in direct interface contact, and causing the particles of said one material to be bonded together by said bonding medium after introduction into the container thereby forming a dry solid layer.

2. A method as in claim 1 in which the bonding medium is in the form of a powder having a softening point above the temperature level at which the product is marketed and mixed with the particles of said one material before introducing the same into the package, the bonding being effected by heating the one material and the bonding medium to a temperature sufficient to soften said bonding material and then reducing the temperature of said one material and the bonding medium below said softening point.

3. A method as in claim 1 in which the bonding medium has a softening point above the temperature level at which the product is to be marketed, and in which said one material and the bonding medium are heated to a temperature above the softening point of the bonding medium prior to cooling of the same, the heating being carried out before the particles of said one material and the bonding medium are introduced into the container.

4. A method as in claim 1 in which the bonding medium is a fat or wax.

5. A method as in claim 1 in which the bonding medium is a synthetic wax.

6. A method as in claim 1 in which the bonding medium has a softening point above the temperature level at which the product has to be marketed, the amount by weight of said medium being a minor percentage of said one material, the particles of the one material being bonded together by heating the one material and the bonding medium to a temperature to soften the bonding medium and then cooling the one material and the bonding medium to a temperature below said softening point, with heating and cooling being carried out while the one material is within the package.

7. A method as in claim 6 in which the bonding medium is chilled and ground while chilled to form a discrete material and thereafter mixed with said one material.

8. A method as in claim 6 in which the container comprises walls of heat shrinkable film material that are shrunk upon the materials during said heating and cooling.

9. A method as in claim 6 in which the portion of the container surrounding the one material is placed in a mold and retained in said mold during said heating and cooling.

10. A method as in claim 9 in which compression is applied to the one material during molding.

11. In a method for the manufacture of a consumer food package, the steps of separately and successively introducing at least two food materials each in the form of dry discrete particles into a single container, a bonding medium in the form of a chilled powder intermixed with the particles of one of said materials before introduction of the same into the contamer, said powder being formed by chilling the medium and grinding the same while chilled, the bonding medium having a softening point above the temperature level at which the product is to be marketed, the two discrete food materials by virtue of successive introduction into the package being caused to form two layers of materials in direct interface contact, and causing the dry particles of said one material to be bonded together by heating the material to a temperature sufficient to soften the bonding medium and thereafter booling the material to a temperature below said softening point, the heating and cooling being carried out while both of the materials are within the package.

Claims

2. A method as in claim 1 in which the bonding medium is in the form of a powder having a softening point above the temperature level at which the product is marketed and mixed with the particles of said one material before introducing the same into the package, the bonding being effected by heating the one material and the bonding medium to a temperature sufficient to soften said bonding material and then reducing the temperature of said one material and the bonding medium below said softening point.
3. A method as in claim 1 in which the bonding medium has a softening point above the temperature level at which the product is to be marketed, and in which said one material and the bonding medium are heated to a temperature above the softening point of the bonding medium prior to cooling of the same, the heating being carried out before the particles of said one material and the bonding medium are introduced into the container.
4. A method as in claim 1 in which the bonding medium is a fat or wax.
5. A method as in claim 1 in which the bonding medium is a synthetic wax.
6. A method as in claim 1 in which the bonding medium has a softening point above the temperature level at which the product has to be marketed, the amount by weight of said medium being a minor percentage of said one material, the particles of the one material being bonded together by heating the one material and the bonding medium to a temperature to soften the bonding medium and then cooling the one material and the bonding medium to a temperature below said softening point, with heating and cooling being carried out while the one material is within the package.
7. A method as in claim 6 in which the bonding medium is chilled and ground while chilled to form a discrete material and thereafter mixed with said one material.
8. A method as in claim 6 in which the container comprises walls of heat shrinkable film material that are shrunk upon the materials during said heating and cooling.
9. A method as in claim 6 in which the portion of the container surrounding the one material is placed in a mold and retained in said mold during said heating and cooling.
10. A method as in claim 9 in which compression is applied to the one material during molding.
11. In a method for the manufacture of a consumer food package, the steps of separately and successively introducing at least two food materials each in the form of dry discrete particles into a single container, a bonding medium in the form of a chilled powder intermixed with the particles of one of said materials before introduction of the same into the container, said powder being formed by chilling the medium and grinding the same while chilled, the bonding medium having a softening point above the temperature level at which the product is to be marketed, the two discrete food materials by virtue of successive introduction into the package being caused to form two layers of materials in direct interface contact, and causing the dry particles of said one material to be bonded together by heating the material to a temperature sufficient to soften the bonding medium and thereafter booling the material to a temperature below said softening point, the heating and cooling being carried out while both of the materials are within the package.