WO2008005704A1

WO2008005704A1 - Revealing printing on reheatable dough products

Info

Publication number: WO2008005704A1
Application number: PCT/US2007/071858
Authority: WO
Inventors: Barrie R. Froseth; Thomas Martin; Cynthia M. Schramm
Original assignee: General Mills Marketing, Inc.
Priority date: 2006-06-30
Filing date: 2007-06-22
Publication date: 2008-01-10

Abstract

A pre-cooked dough product having an image applied to an exterior portion of the dough product that is generally non- visible prior to a reheating step and that becomes visible during and subsequent to the reheating step. The pre-cooked dough product can comprise a shelf-stable cooked dough product, a frozen pre-cooked dough product or a refrigerated, pre-cooked dough product. As heat is applied during the reheating process, the imaging composition undergoes a reaction wherein the previously non-visible image becomes visible to the unassisted eye and remains visible following the reheating step.

Description

REVEALING PRINTING ON REHEAT ABLE DOUGH PRODUCTS

FIELD OF THE DISCLOSURE

The present disclosure relates to pre-cooked dough products requiring a reheating step prior to consumption. More specifically, the present disclosure relates to a reheatable dough product having an exterior image applied subsequent to an initial cooking step such that the exterior image is generally non-visible until exposed to heat during a reheating step.

BACKGROUND OF THEDISCLOSURE

Due to the stress and time constraints imposed by modern life, an increasing number of food products are being marketed to consumers that require only a single reheating step prior to eating. Generally, these food products are completely prepared and cooked using high volume production equipment, wherein the cooked food products are subsequently frozen for transportation to and storage prior to purchase by the consumer.

These food products are available in a variety of formats including complete meals, main courses, side items and appetizers.

One especially popular group of food products that can be provided in a precooked, format are dough based products. These can include breakfast products, such as, pancakes, waffles and filled pastries, such as, Toaster Strudel™ brand frozen pastries available from the Pillsbury Division of General Mills, Inc. of Golden Valley, MN or Pop- Tarts® brand toaster pastries available from the Kellogg Company of Battle Creek, MI. These types of breakfast food products are especially convenient in that the typical method of reheating the food product involves nothing more than toasting the dough products in a conventional toaster or toaster oven. With the resistive heating elements within the bread toaster, a hot, fresh tasting dough product can be prepared in minutes without any additional consumer effort making them ideal for use by children and time burdened adults.

While reheatable, dough products are well known, it would be advantageous to include additional features that make the preparation and consumption of these products more desirable. SUMMARY OF THE DISCLOURE

The present disclosure is directed to a pre-cooked dough product having an image applied to an exterior portion of the dough product that is generally non-visible prior to a reheating step and that becomes visible during and subsequent to the reheating step. The pre-cooked dough product can be cooked prior to freezing using any of a variety of suitable cooking methods, such as, for example, baking and/or frying. Following the cooking step, the cooked dough product can have an image applied to an exterior portion of the cooked dough product using a suitable image application process, such as, for example, spraying or printing the image. The image is applied with a suitable imaging composition that is essentially non-visible when applied to the cooked dough product. The cooked dough product is then packaged for storage and shipment. In some embodiments, the cooked dough product can comprise a shelf-stable cooked dough product while in other alternative embodiments, the cooked dough product can comprise a frozen or refrigerated cooked dough product. Prior to consumption by a consumer, the pre-cooked dough product is reheated using a suitable heating appliance, such as, for example, a bread toaster, a toaster oven or a conventional oven. In microwave applications, the pre-cooked dough product can be packaged along with suitable microwave susceptor packaging in order to achieve desired temperatures. As heat is applied during the reheating process, the imaging composition undergoes a reaction wherein the previously non-visible image becomes visible to the unassisted eye and remains visible following the reheating step.

In one aspect, the present disclosure relates to a pre-cooked dough product that has a non-visible exterior image that becomes visible during a reheating step prior to consumption of the dough product. The dough product can comprise products generally consumed during breakfast, lunch, dinner or as a between meal snack. In one representative embodiment, the dough product can comprise a fried breakfast product that is reheated using a conventional bread toaster or other appliances mentioned above. The dough product can comprise a frozen, refrigerated or shelf-stable dough product.

In another aspect, the present disclosure relates to a method of preparing a pre- cooked dough product having an exterior image that is generally non-visible until the dough product is reheated prior to consumption. A dough product is initially prepared and fully cooked. A generally non-visible image is applied to an exterior portion of the cooked dough product using a suitable application process, such as, for example, spraying or printing. The cooked dough product having the generally non-visible image is then frozen for shipment and storage for ultimate use by the consumer. Prior to consumption, the pre-cooked dough product is reheated using a conventional heating appliance, such as, for example, a bread toaster, a toaster oven, a conventional oven or a microwave oven, wherein the image becomes visible and remains visible during consumption.

In another aspect, the present disclosure relates to a dough product kit that includes a pre-cooked dough product, one or more decoration applicators for use in decorating an exterior surface of the pre-cooked dough product and suitable packaging. The pre-cooked dough product includes an image that is generally non-visible prior to the consumer reheating the pre-cooked dough product prior to consumption. Following reheating, the image is visible and can display an outline, picture, logo, design, symbol and the like suitable for decoration by the consumer with the one or more decoration applicators. The packaging can comprise suitable packaging for use with either frozen, refrigerated or shelf-stable dough products.

In another aspect, the present disclosure relates to a pre-cooked dough product having an imaging composition applied to an exterior portion of the dough product after baking. Upon initial application, the imaging composition is essentially nonvisible. Immediately prior to consumption, the pre-cooked dough product is reheated wherein the imaging composition reacts with the heat energy and becomes visible to the unassisted eye. In one representative embodiment, the imaging composition can comprise an aqueous, semi-aqueous or dry composition having an effective amount of hydroxy acetaldehyde that undergoes a browning reaction on the exterior portion of the dough product when exposed to heat energy during reheating. The pre-cooked dough product can be presented to a consumer in either a frozen, refrigerated or shelf-stable configuration.

The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the invention. The figures in the detailed description that follows more particularly exemplify these embodiments. BRIEF DESCRIPTION OF THE FIGURES

These as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings of which:

Figure 1 is a perspective view of an embodiment of a pre-cooked dough product of the prior art.

Figure 2 is a process flow diagram for making a reheated dough product having a visible image according to the present disclosure.

Figure 3 is a plan view of an embodiment of a pre-cooked dough product having a generally non-visible image according to the present disclosure.

Figure 4 is a perspective, partial cut-away view of an embodiment of a packaging kit for a pre-cooked dough product.

Figure 5 is a plan view of an embodiment of a reheated dough product having a visible image according to the present disclosure.

DETAILED DESCRIPTION OF THE FIGURES

As illustrated in Figure 1, a pre-cooked dough product 100 of the prior art can comprise a first major surface 102 and a second major surface 104 defined by a pair of ends 106a, 106b, a pair of sides 108a, 108b and set apart by a product thickness 110. In a preferred embodiment, first major surface 102 and second major surface 104 are substantially flat and reside generally in parallel planes. Pre-cooked dough product 100 can comprise a variety of configurations including, for example, frozen, refrigerated or shelf-stable pre-cooked dough products. One representative example of a frozen, precooked dough product includes the products previously identified as Toaster Strudel as described in U.S. Patent Nos. 4,612,198 and 4,623,542, each of which is herein incorporated by reference, and which are available from General Mills, Inc. of Golden Valley, MN. In another alternative embodiment, a representative dough product of the invention can comprise a shelf-stable dough product such as, for example, Pop-Tarts® available from Kelloggs of Batlle Creek, Michigan.

Pre-cooked dough product 100 generally comprises a representative dough suitable for use with refrigerated and/or frozen products. Dough suitable for use in preparing the pre-cooked dough product 100 generally comprises a grain constituent that contributes to the structure of the dough. Typically, flour is the most common grain constituent and is typically the primary dough ingredient. A variety of different flours can be utilized to make dough suitable for use in preparing pre-cooked dough product 100 including whole and refined grain flour. In addition, dough can comprise water, a fat source, a leavening agent and a variety of other ingredients providing desirable taste, appearance, processing and storage qualities.

In making dough for use in preparing the pre-cooked dough product 100, the various dough ingredients are generally combined in a mixing step 200 as illustrated in Figure 2. In mixing step 200, the dough ingredients can be mixed together using a suitable mixer, such as, for example, a Hobart mixer available from the Hobart Corporation of Troy, OH. During mixing step 200, the dough ingredients are mixed such that a protein network is formed giving the dough a viscoelastic structure. Once the dough is formed, the dough can be formed into a dough product intermediate in a forming step 202. The dough product intermediate can be formed by a suitable dough forming process, such as, for example, through extrusion or sheeting of the dough to form the desired dough product intermediate. In the forming step 202, an edible filling can be placed between layers of dough to form a filled dough product intermediate. The dough product intermediate can then be fully cooked in a cooking step 204 utilizing a suitable cooking process to form a cooked dough product intermediate. In one preferred embodiment, cooking step 204 comprises a frying step such that the cooked dough product intermediate has an oil layer present on the exterior of the cooked dough product.

The cooked dough product intermediate can then be processed in an image application step 206 in which an image 112 is applied on one or both of first major surface 102 and second major surface 104 so as to form an imaged cooked dough product 113 as illustrated in Figure 3. Image 1 12 is illustrated in Figure 3 in dashed lines as being essentially non-visible to the unassisted eye when applied to the cooked dough product intermediate during image application step 206. Image 112 can comprise any suitable image, such as, for example, a logo, a symbol, numbers, letters, pictures and combinations thereof.

Image 112 can be applied during image application step 206 using any suitable application process including spraying, stamping and/or printing, such as, for example, ink-jet printing. Image 112 is defined by applying an edible composition 114 to either or both of the first major surface 102 and the second major surface 104. Edible composition 1 14 can comprise a heat activated browning agent, such as, for example, a composition comprising hydroxyacetaldehyde. One representative composition comprising hydroxyacetaldehyde is Maillose® available from Red Arrow Products Company, Inc. of Manitowoc, WI. Specific processing and compositional information regarding hydroxyacetaldehyde and Mailose® can be on the web-site www.redarrowusa.com as well as in U.S. Patents 5,252,188 to Stradal et al., 5,393,542 to Stradal et al., 5,397,582 to Underwood et al., 5,756,140 to Shoop et al., 6,261,612 to Ballard et al. and 6,884,446 to Underwood et al., all of which are herein incorporated by reference in their entirety. In some embodiments, image application step 206 can further include the addition of protein or hydrolyzed protein derivatives to the first major surface 102 and/or the second major surface 104 to promote and/or accentuate the browning characteristics of edible composition 1 14.

Following application of image 112 to the cooked dough intermediate, the imaged cooked dough product 113 can be frozen prior to packaging, shipment and storage in a freezing step 208 when pre-cooked dough product 100 is provided in a frozen format such as the previously identified Toaster Strudel™. In some instances, it may prove advantageous to reverse the order of image application step 206 and freezing step 208 such that the edible composition 1 14 is applied to a frozen first major surface 102 and/or a frozen second major surface 104. Once the image application step has been accomplished, the imaged cooked dough product 1 13 can be individually packaged or bulk packaged in suitable packaging 1 15 such that a plurality of dough intermediates are contained within a single package as illustrated in Figure 4. Packaging 115 can comprise packaging suitable for frozen products, refrigerated products or shelf-stable products. In addition, an edible decorating element 116, such as, frosting, icing, jelly, jam, particulate sprinkles and the like can be packaged in a serving packet 117 along with the frozen, pre-cooked dough product 100. One representative edible decorating element 116 is disclosed in U.S. Patent No. 4,379,176, which is herein incorporated by references. Edible decorating element 116 can be applied by a consumer for enhancing or decorating the image 112.

Prior to consumption by a consumer, the imaged cooked dough product 113 must be reheated using a suitable heating appliance. In one preferred embodiment, imaged cooked dough product 113 is reheated within a conventional bread toaster. Alternatively, other suitable heating appliances, such as, for example, a conventional oven, a toaster oven or a microwave oven can be utilized as well.

During reheating of the imaged cooked dough product 113, the heat energy supplied by the heating appliance causes edible composition 114 to undergo a Maillard browing reaction on either or both of the first major surface 102 and the second major surface 104. During the Maillard browning reaction, the hydroxyacetaldehyde reacts within proteins such as, for example, existing proteins present in the dough and/or exogenous protein or protein derivatives deliberately applied in combination with hydroxyacetaldehyde or applied as a separate solution or film to form brown shades such that the edible composition 114, and consequently the image 112 become visible to the unassisted eye. In the instance wherein the cooked dough product intermediate was prepared with a frying step, the external oil layer serves as a barrier layer to prevent interaction between the edible composition 114 and proteins within the dough until activated by heat energy during reheating of the frozen imaged cooked dough product 113. Depending upon the format of the imaged cooked dough product 113, for example, frozen, refrigerated or shelf-stable, as well as the type of heating appliance used to supply heat energy, the amount of time necessary for the Maillard browning reaction to occur can vary. Preferably, the Maillard browning reaction can be accomplished in a period of 10 minutes or less.

After the reheating process is complete, a reheated dough product 118 is ready for consumption by a consumer. As illustrated in Figure 5, image 112 is now visible to the unassisted eye. In the event that edible decorating item 1 16 accompanied the pre-cooked dough product 100, the edible decoration item 1 16 can be applied to either or both of the first major surface 102 and the second major surface 104 to essentially "color" the image 112. In some instances, multiple colors or styles of edible decoration item 116 can be included. Such image 112 can be customized or "colored by number" as desired by the consumer. Although embodiments of the disclosure have been described above, it is not limited thereto, and it will be apparent to persons skilled in the art that numerous modifications and variations form part of the present disclosure insofar as they do not depart from the spirit, nature, and scope of the claimed and described disclosure.

Claims

Claims:

1. A pre-cooked dough product having a generally non-visible image applied to at least one major surface and whereupon said non-visible image reacts to become a visible image upon exposure to heat energy within a heating appliance.

2. The pre-cooked dough product of claim 1, wherein the pre-cooked dough product is presented in a configuration selected from the group consisting of: a frozen, precooked dough product, a refrigerated pre-cooked dough product and a shelf-stable precooked dough product.

3. The pre-cooked dough product of claim 1, wherein the non-visible image comprises a heat activated browning agent including hydroxyacetaldehyde.

4. The pre-cooked dough product of claim 3, where the heat activated browning agent is Maillose®.

5. The pre-cooked dough product of claim 1, wherein the visible image is selected from the group consisting of: a logo, a symbol, numbers, letters, pictures and combinations thereof.

6. The pre-cooked dough product of claim 1, wherein the at least one major surface includes an external oil layer to prevent interaction between the non-visible image and proteins within the pre-cooked dough product until activated by heat energy supplied by the heating appliance.

7. The pre-cooked dough product of claim 1 , wherein an edible decorating element os applied to the visible image.

8. The pre-cooked dough product of claim 7, wherein the edible decorating element is selected from the group consisting of: frosting, icing, jelly, jam, particulate sprinkles and combinations thereof.

9. The pre-cooked dough product of claim 1, wherein a second generally non- visible image is applied to a second major surface and whereupon said second generally non-visible image reacts to become a second visible image upon exposure to heat energy within the heating appliance.

10. A method for forming a visible image on a pre-cooked dough product comprising:

cooking a dough product having at least one major surface;

applying a generally non-visible image to the at least one major surface;

packaging the dough product; and

reheating the dough product in a heating appliance wherein heat energy supplied by the heating appliance causes the generally non-visible image to react and transition into a visible image.

11. The method of claim 10, further comprising:

freezing the dough product to form a frozen, pre-cooked dough product.

12. The method of claim 10, wherein applying the generally non-visible image comprises applying a second non-visible image to a second major surface.

13. The method of claim 10, further comprising:

decorating the visible image with an edible decorating element.

14. The method of claim 10, wherein cooking the dough product comprises frying the dough product in an oil such that an oil layer is formed on the at least one major surface, and wherein the oil layer isolates the generally non-visible image from proteins in the dough product prior to reheating of the dough product.

15. The method of claim 10, wherein applying the generally non-visible image to the dough product comprises applying a heat activated browning agent to define the non-visible image.

16. The method of claim 15, wherein the heat activated browning agent undergoes a Maillard browning reaction when exposed to heat energy during the reheating step.

17. A reheatable dough product kit comprising:

a pre-cooked dough product having at least one major surface, wherein a generally non-visible image is defined on the at least one major surface;

an edible decorating element; and

a package for retaining the pre-cooked dough product and the edible decorating element prior to consumption,

wherein the generally non-visible image reacts and transitions to become a visible image when the pre-cooked dough product is exposed to heat energy from a heating appliance during a reheating process, and

wherein the edible decorating element is utilized to decorate the visible image.

18. The reheatable dough product kit of claim 17, wherein the pre-cooked dough product, the edible decorating element and the package are supplied in a kit configuration selected from the group consisting of: a frozen kit configuration, a refrigerated kit configuration and a shelf-stable kit configuration.

19. The reheatable dough product kit of claim 17, wherein the generally non- visible image comprises a heat activated browning agent and wherein the heat activated browning agent undergoes a Maillard browning reaction to form the visible image.

20. The reheatable dough product kit of claim 19, wherein the heat activated browning agent comprises hydroxyacetaldehyde.