WO2000078163B1

WO2000078163B1 - Puffable half-product

Info

Publication number: WO2000078163B1
Application number: PCT/US2000/016678
Authority: WO
Inventors: Lengerich Bernhard Van; Brundt William Van; James R Borek; Keith A Evenson; Thomas M Jarl
Original assignee: Gen Mills Inc; Lengerich Bernhard Van; Brundt William Van; James R Borek; Keith A Evenson; Thomas M Jarl
Priority date: 1999-06-18
Filing date: 2000-06-16
Publication date: 2001-08-09
Also published as: WO2000078163A3; WO2000078163A9; WO2000078163A2; AU5744900A

Abstract

A system and method for distributing, preparing and consuming puffable half-products is disclosed. Puffable half-products can be expanded or puffed to produce cereals, cereal-based snacks and beverages through exposure to a suitable energy source. The half-products can be shipped through various channels of trade in bulk quantities or consumer-sized packages to an intermediary or directly to the end user. These dense pieces or pellets are not fragile and have a virtually unlimited shelf life. Furthermore, unlike conventional foods that have already been puffed long before reaching the consumer, these puffable food products can be puffed shortly before consumption. As a result, the consumer is now able, for the first time, to enjoy the full flavor and crispness of finished cereals, snacks and beverages while still 'freshly puffed' and, in certain variations, while still warm and aromatic from finish preparation. By providing consumers with access to these half-products and means to puff them, and a variety of toppings and additives, every serving of cereal, cereal-based snack and beverage can now be customized to suit a particular end user's tastes and/or dietary needs.

Claims

AMENDED CLAIMS

[received by the International Bureau on 9 March 2001 (09.03.01); original claims 25-27. 29, 46, 49 and 61 amended; remaining claims unchanged (10 pages)] how to apply the toppings.

22. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: puffing at least one half-product made from a dough to produce a puffed food product; and providing the puffed food product to a consumer while the puffed food product is still freshly puffed.

23. A method of preparing, distributing and consuming a food product, comprising the steps of: providing one or more bulk containers, each containing at least one half-product, the half-product made from a dough; gathering one or more half-products from the bulk containers; puffing the half-product by exposing the half-product to a source of energy at a level and rate sufficient to cause the half-product to expand to produce a puffed food product; and serving the puffed food product to a consumer while the puffed food product is still freshly puffed.

24. The method according to claim 22 or 23 wherein the dough is at least partially cooked, is not highly worked and is formed into the half-product at a temperature of between about 40 °C and 110 °C.

25. The method according to claim 23 wherein the source of energy is a continuous puffing device or a batch puffing device, wherein the batch puffing device expands a single serving or more of the half-product, further wherein the steps of gathering, puffing and serving take less than ten minutes.

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26. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: puffing one or more half-products in bulk quantities to produce a puffed food product; displaying the puffed food product in bulk quantities; and packaging a take-out quantity of the freshly puffed food product in a food container for transport and consumption by a consumer.

27. The method according to claim 22 or 23 or 26 further comprising: providing an interactive survey to the consumer, allowing the consumer to respond to the interactive survey; analyzing answers provided by the consumer to the interactive survey; and in response to the answers provided by the consumer, recommending one or more unique formulations of puffed food products to the consumer.

28. A method of preparing, distributing and consuming a puffed food product, comprising: providing one or more bulk containers, each containing a different type of half-product; gathering one or more single servings of half-products from the bulk containers, according to a selection made by a consumer; placing the half-product in a take-out package; the consumer preparing the half-product at another location, the preparing resulting in a freshly puffed food product; and the consumer eating the freshly puffed food product at another location.

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29. A method of preparing, distributing and consuming a puffed food product, comprising: obtaining a package of one or more half-products, the package of a certain size or less; and puffing a single serving of the half-product in a hot air oven.

30. The method according to claim 22 or 23 or 26 or 28 or 29 further comprising supplying or applying food product toppings.

31. The method according to claim 30 further comprising supplying a set of instructions for the consumer to pick up, the instructions having information on preparing the half-product and applying the toppings, wherein the toppings include nutritional additives selected from the group consisting of vitamins, minerals, biologically active components, probiotic bacterias, herbs, colorings, fibers, anti-oxidants, nutriceuticals, dietary supplements, aromatic substances and flavorings and mixtures thereof.

32. The method according to 22 or 23 or 26 or 28 or 29 wherein the half-product can be expanded or puffed to about two (2) times to ten (10) times its original size, further wherein the half-product has a moisture content ranging from about eight (8) to 15% and a density ranging from about 0.7 to 1.5 g/cc.

33. The method according to claim 22 or 23 or 26 or 28 or 29 wherein the half-product is cooked in a batch puffing device selected from the group consisting of hot air popper, deep fat fryer, microwave oven, vacuum device, convection air oven or a device custom-designed for puffing half-products.

34. The method according to claim 33 wherein the expanded or puffed

91 food product is consumed or served within about one to three days of being expanded or puffed.

35. The method according to claim 34 wherein the expanded or puffed food product is consumed or served while still warm from being expanded or puffed.

36. The method according to claim 22 or 23 or 26 or 28 or 29 wherein the half-product is a snack pellet or cereal pellet having a substantially flat shape or a three-dimensional shape, each pellet weighing between about 0.1 to 0.5 grams.

37. The method according to claim 36 wherein the puffed or expanded food product is mixed or blended with additives in liquid or semi-liquid form to form an admixed food product, moist food product or a blended food product, wherein the liquids are selected from the group consisting of water, flavored waters, carbonated liquids, dairy products, kefirs, juices, sodas, coffees, yogurts and teas, further wherein the blended food product is a cold beverage, frozen snack, semi-solid beverage, frozen snack on a stick or a hot fluid cereal and the moist food product has a consistency ranging from a fluid to a paste and is served frozen, chilled, warm or hot.

38. The method according to claim 37 wherein the additives are flavoring additives selected from the group consisting of fats, salts, honeys, cheeses, frostings, powdered food products, nuts, nut pieces, sugars, sugar substitutes, candies, marshmallows, gelatins, spices, fresh fruits, dried fruits, fruit products, vitamins, minerals, encapsulated biologically active components, nutriceuticals, dietary supplements, anti-oxidants, fibers, probiotic bacteria sprinkles, inulin, calcium carbonate, energy additives, protein powders, powdered

92 milk fractions satiety additives, flavorings, herbs, colorings, aromatic substances, chocolates and chocolate products and combinations thereof.

39. The method according to claim 37 wherein the additives are nutritional additives selected from the group consisting of vitamins, minerals, encapsulated biologically active components, nutriceuticals, dietary supplements, anti-oxidants, fibers, probiotic bacteria sprinkles, inulin, calcium carbonate, energy additives, protein powders, powdered milk fractions, satiety additives and mixtures thereof.

40. The method according to claim 22 or 23 or 26 or 28 or 29 wherein the puffing step takes less than about 30 seconds to three (3) minutes to complete.

41. The method according to claim 40 wherein the puffed food product is a puffed cereal or snack.

42. The method according to claim 41 wherein the puffed food product is size-reduced.

43. The method according to claim 22 or 23 or 26 or 28 wherein the half-product is puffed at a food service facility, further wherein the consumer eats some or all of the puffed food product at the food service facility.

44. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: manufacturing bulk quantities of half-products at a mass production facility; packaging half-products in packages of a certain size or less; and labeling the packages with instructions for puffing one or more servings of

93 the half-products in a hot air popper, convection air oven or other home-puffing device having a puffing capacity less than a certain volume.

45. The method according to claim 44 including distributing the packages to one or more food service facilities wherein the packages are consumer- sized packages, further wherein a consumer transports one or more packages away from the food service facility and prepares the half-products in accordance with instructions on the package.

46. The method as recited in claim 44 further comprising: providing information to a consumer describing half-products and methods for contacting a distributor of half-products; receiving an order from the consumer for a bulk quantity or a consumer-sized quantity of one or more types of half-products; and shipping the order directly to the consumer or to a nearby distributor of half-products.

47. The method according to claim 46 wherein the information includes descriptions of toppings, puffing devices and recipe books, further wherein the method for contacting the distributor is by wired or wireless communication including facsimile, telephone, e-mail, Internet, electronic data interchange, cable, private delivery service or regular mail.

48. A method of preparing, distributing and consuming a puffed food product, comprising the steps of: manufacturing bulk quantities of half-products at a mass production facility; shipping the half-products to a puffing facility capable of producing puffed food products in accordance with local taste preferences; and

94 transporting the puffed food products to one or more food service facilities, the one or more food service facilities close to established shipping channels.

49. The method according to claim 44 or 48 further comprising: displaying the half-products or puffed food products on display shelves in close proximity to toppings, wherein the one or more food service facilities is a grocery store.

50. The method according to claim 49 wherein the grocery store is less than about 20 km to 150 km or more from the mass-production facility and the consumer lives less than about two (2) km to 20 km or more from the grocery store.

51. A pellet puffing apparatus, comprising: a puffing chamber of a unique size for puffing one or more types of half- products at one time; and an adapter for adapting the apparatus for commercial or consumer use, wherein the puffing apparatus operates on a continuous or batch basis.

52. The apparatus according to claim 51 comprising a device selected from the group consisting of a hot air popper, a convection air oven, a frying device, a vacuum device, a microwave oven or a device custom-designed for puffing pellets, wherein the device produces a freshly puffed food product after a period of time.

53. The apparatus according to claim 52 wherein the hot air popper is a cyclonic hot air popper having a cover and the convection oven is a normal convection oven or an air impingement convection oven.

54. The apparatus of claim 52 wherein the puffing chamber in the frying device is a frying chamber for holding oil.

55. The apparatus according to claim 52 further comprising a heater connected to the puffing chamber for heating the puffing chamber to temperatures between about 120 °C to 315 °C wherein the puffing chamber holds at least one half-product to about 50 kg of the half-product.

56. A puffing apparatus comprising a puffing chamber, the puffing chamber comprising a dryer for drying and puffing a half-product to produce puffed cereal, a toaster for toasting the puffed cereal to produce toasted puffed cereal, and an enrober for coating the toasted puffed cereal to produce coated toasted puffed cereal.

57. A pellet-puffing apparatus, comprising: one or more bins of one or more types of half-products; a puffing chamber for expanding a predetermined quantity of the half- product to produce a freshly puffed food product; a fee collector for collecting a fee from a consumer using the machine; and a dispenser for dispensing the freshly puffed food product.

58. The apparatus according to claim 57 wherein the time period from the fee collecting to the freshly puffed food product dispensing is less than about 30 seconds to about four (4) minutes or more.

59. An apparatus for puffing one or more half-products to produce a freshly puffed food product comprising a puffing chamber and a heater, the puffing chamber comprising a vacuum chamber maintained at a pressure less than about

96 one (1) Torr, and the heater heats the half-product to its glass transition temperature.

60. The apparatus according to claim 52 or 56 or 57 or 59 wherein toppings and oil are admixed with the freshly puffed food product or coated toasted puffed cereal.

61. The apparatus according to claim 60 further comprising a grinder for grinding the coated toasted puffed cereal to produce ground food product, further wherein the ground food product can be used in beverages, frozen food products or toppings.

62. The apparatus according to claim 52 or 56 or 57 or 59 further comprising: a half-product moving device located inside the puffing chamber for periodically moving the half-product during puffing for a total of about 15 seconds to about three (3) minutes; a half-product dispenser connected to the puffing chamber for dispensing a predetermined amount of the half-product into the puffing chamber; a timer, thermometer and controller connected to the puffing chamber; and a toppings dispenser connected to the puffing chamber for dispensing a predetermined amount of toppings.

63. The apparatus according to claim 62 wherein a time period beginning with dispensing the half-product and ending with delivering the freshly puffed food product to a consumer is between about 15 seconds up to about two (2) days or more.

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64. The apparatus according to claim 63 further comprising a computer control system having instructions for storing, displaying and processing recipe information necessary to operate the apparatus.

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