WO2013141854A1

WO2013141854A1 - Food product and coating

Info

Publication number: WO2013141854A1
Application number: PCT/US2012/029889
Authority: WO
Inventors: Blanca PEREZ AGUIRRE; Donald L. JONES; Jorge Martinez; Leon Richardo VILCHIS MACEDO; Laura CASTILLO GARCIA; David LIMA LOPEZ
Original assignee: Conagra Foods Rdm, Inc.
Priority date: 2012-03-21
Filing date: 2012-03-21
Publication date: 2013-09-26

Abstract

A coating for food and a food product having the coating are disclosed. During manufacturing and processing, the coating can be formed from a binder and a flavor system adhered to the binder. The coating can be formed by one or more layers of the binder and the flavor system to help minimize food degradation of the underlying food. Upon cooling, the food product can have a crunchy texture.

Description

FOOD PRODUCT AND COATING

BACKGROUND

[0001] Coatings can be utilized with foods. Coatings can be applied to food products in several ways. Coatings can also be formulated to achieve a desired taste perception, texture and/or mouth-fee! . Yet, some taste perceptions, textures and/or mouth- feels are difficult to achieve with coa tings because of die underlying food of the coating and/or processing conditions.

SUMMARY

[0002] This Summary' is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not mtended to identify key and/or essentia! features of the claimed subject matter. Also, this Summary is not mtended to limit the scope of the claimed subject matter in any manner.

[ 0003] Aspects of the disclosure pertain to a coating for food and a food product having the coating. During manufacturing and processing, the coating ca be formed from a binder and a flavor system adhered to the binder. The coating can be formed by one or more layers of the binder and the flavor system to help minimize food degradation of the underlying food. Upon cooling, the food product can have a crunchy texture.

DRAWINGS

[0004] FIGURE 1 is an example operational flow diagram indicating example features associated with a food coating process. DETAILED DESCRIPTION

[0005] Aspects of the disclosure are described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, example features. The features can, however, be embodied in many different forms and should not be construed as limited to the combinations set forth herein; rather, these combinations are provided so that this disclosure will be thorough and complete, and will fully convey the scope. Among other t hings, the features of the disclosure can be embodied as formulations, food products, processes, processes for making food products, and processes for making formulations. The following detailed description is, therefore, not to be taken in a limiting sense.

[0006] Coatings are used on food for a variety of reasons. For example, coatings can be utilized to import certain desired organoleptic properties to the food. Such organoleptic properties can include a desired taste, texture, and mouth-feel.

[0007] Various types of foods include coatings. For example, foods that utilize coatings can include puffed food, expanded foods, popped foods, baked foods, fried foods, and/or the like. These foods can have a carbohydrate base such as a grain base, a cereal base, a bread base, a pasta base, a bean base, a potato base, a bran base, a rice base, and/or the like. Furthermore, such foods ca have several forms. Such foods can include individual food pieces, a conglomeration of individual pieces, snack bars, and the like, [0008] An exemplary type of coated food includes packaged popped popcorn.

For example, kettle corn and caramel corn utilize a coating which imparts a sweet flavor. The sweetness in such coatings is generally attributed to the ingredients found in the coating's formulation. For example, kettle com and/or caramel corn usually include non- reducing sugars, liquid and/or solid sugars, brown sugars, com syrups, caramel, and other ingredients that elevate the sweetness perception. Furthermore, such coatings for kettle corn and caramel corn are typically applied hot and allowed to transition to a glassy state upon cooling to form a candy-type coating.

[0009] As more fully set forth below, aspects of the disclosure pertain to a binder and a flavor system for producing a coating for food. The coating does not rely on a glass transition to formulate texture. The food product with the coating can then be cooked to remove moisture and to produce a crunchy food product. The crunchy texture can be facilitated by the bite perception from cooked coating along with the underlying food product.

1. BINDER FORMULATION

1, Binding Agent

[0010] The binder can include a binding agent. The binding agent ca include corn syrup, soluble corn fiber, glucose syrup and/or high-fructose corn syrup, in one aspect, the binding agent is com syrup. The corn syrup can have a dextrose equivalent that is greater than 20. In one aspect, the dextrose equivalent of the corn syrup is about 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 to about 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30. In one aspect the com syrup can be made from starch of maize. Depending on its grade, the com syrup can include varying amounts of maltose and higher oligosaccharides. The corn syrup can be added to the binder to soften the texture, add volume, prevent crystallization of sugar, enhance flavor, and/or minimize the sweetness impact of the binding agent.

[0011] The binding agent can be about 30% to about 40% by total weight of the binder. In other aspects, the binding agent can be about 32% to about 36% by total weight of the binder, in yet other aspects, the binding agent can be 30%, 31%, 32%, 33%), 34%, 35%, 36%, 37%, 38%, 39%, 40%, to about 30%, 31%, 32%», 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% by total weight of the binder.

2, Maltodextrin

[0012] The binder can include a maltodextrin. Maltodextrin is a polysaccharide that can be utilized as an additive. The maltodextrin can be produced from starch by partial hydrolysis. For example, the starch can be a wheat starch and/or a com starch, The maltodextrin can have a dextrose equivalent from about 0 to about 20. In other aspects that maltodextrin can have a dextrose equivalent from about 5 to about 15. The dextrose equivalent can be from about 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19, 20 to about 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20.

[0013] The maltodextrin can be about 20% to about 30% by total weight of the binder. In other aspects, the maltodextrin can be about 22% to about 26% by total weight of the binder. In yet other aspects, the maltodextrin can be 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30% to about 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, by total weight of the binder.

3. Starch

[0014] The binder can also include a starch. In one aspect, the starch can be a

Tapioca starch. In other aspects, the starch can include flour, cornstarch, arrowroot, kudzu powder, lotus root powder, sago starch, sahlab rice flour and/or sweet rice flour. The starch can be added to the binder as a thickening agent.

[0015] The starch can be about 10% to about 20% by total weight of the binder.

In other aspects, the starch can be about 12%) to about 15% by total weight of the binder. In yet other aspects, the starch can be 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20% to about 10%, 1 1 %, 12%, 13%, 14%», 15%, 16%, 17%, 18%, 19%, 20% by total weight of the binder.

4. Color Component

[0016] The binder can include a color component. By use of the term "color component", what is intended is a color additive or multiple color additives that modify and/or enhance the natural color of the food product as compared to if the color component was not added. That is, the color component adds and/or enhances an effective amount of color that is discernible to the consumer of the product. For example, when a red hue is desired, a red dye can be added to the binder. Yet, various color agents can be included in the binder for coloring the food product for a variety of purposes. For example, on St. Patrick's Day, a green coloring can be used. Also, the color component can accent a seasoning. For example, a food product can have a Salsa seasoning and can be accented with a red hued color component.

[0017] The color component can be about 0.1% to about 5% by total weight of the binder. In other aspects, the color component can be less than about 1% by total weight of the binder. In yet other aspects, the color component can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.5%, 2.0%, 2.5%, 3.0%, 3.5%, 4.0%, 4.5%, 5.0% to about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%», 0.8%, 0.9%, 1.0%, 1.5%, 2.0%, 2.5%, 3,0%, 3.5%, 4.0%, 4.5%, 5.0% by total weight of the binder,

5. Water

[0018] The formulation can include water. The water can be filtered and/or deionized water. Water can be added to the other ingredients of the binder until the total binder has a Brix value of about 62°Bx to about 75°Bx. In other aspects, water can be added to the other ingredients of the binder until the total binder has a Bri value between about 65°Bx to about 70°Bx. Water can be added to the other ingredients of the binder until the total binder has a Brix value of about 62°Bx, 63°Bx, 64° Bx, 65°Bx, 66°Bx, 67°Bx, 68°Bx, 69°Bx, 70°Bx, 71°Bx, 72°Bx, 73°Bx, 74°Bx, 75°Bx to about 62°Bx, 63 Bx. 64°Bx, 65°Bx, 66°Bx, 67°Bx, 68°Bx, 69 Bx. 70°Bx, 71°Bx, 72°Bx, 73°Bx, 74°Bx, 75°Bx. It has been found that a Brix value below the range has water available to absorb into the food product to potentially deform or degrade the food product. It has been found that a Brix value above the range has a viscosity that makes it difficult to apply to the food product.

[ 0019] The water can be about 20% to about 30% by total weight of the binder.

In other aspects, the water can be about 23% to about 25% by total weight of the binder. In yet other aspects, the water can be 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30% to about 20%, 21%, 22%, 23%, 24%, 25%», 26%, 27%, 28%, 29%, 30% by total weight of the binder. [0020] The flavor system can have a seasoning. By use of the term "seasoning", what is intended is a flavor additive or multiple flavor additives that modify and/or enhance the flavor of the food compared to when the seasoning was not present. That is, the seasoning adds and/or enhances an effective amount of flavor that is discernible to the consumer of the food product. Examples of natural and artificial seasonings can include queso jalapeno, Valentina (salsa), chili with lime, and/or any type of chili or pepper. Other examples of natural and/or artificial seasonings can include, but are not limited to: butter, sugar, sweet (such as chocolate, chocolate mint, mint, chocolate banana, honey, vanilla, pineapple, coconut, peppermint), cheese (such as cheddar cheese, mild cheddar, white cheddar, blue cheese, mozzare!la, parmesan), pizza, barbeque, smoke, hickory_', appiewood or mesquite, dry roast, buffalo wing, fruit flavors (such as apple, cherry, berry, orange, banana, pineapple), vegetable flavors (such as tomato, onion, jalapeno, habaneros), pickle, spices (such as garlic, onion, chives, parsley, general herb, mustard, pepper, cinnamon), sour cream, sweet cream, honey mustard, hot mustard, and vinegar. Seasonings that provide sour flavors or spicy or hot flavors can also be used. A wide variety of other fla vors or flavor enhancers can be used and would be included as seasoning. For example, peanut flavors, yeast extracts, or similar materials are useable.

[0021] Any of these seasonings can be used as a solid material (such as a dry powder or a bead) and/or a liquid materia! (such as an oil or a solution). Some examples of solid or dry seasonings can incorporate the flavors in a protein shell. The protein shell can protect sensitive components from loss or degradation during processing (such as heating), or interaction with other food ingredients (such as oil). Release of the full flavor profile can be delivered by the shearing action of chewing.

[0022] The seasoning can be about 10% to about 20% by weight of the total flavor system, In other aspects, the seasoning can be about 12% to about 16% by weight of the total flavor system. The seasoning can be about 10%, 1 1 %, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, to about 10%, 1 1%, 12%», 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20% by weight of the total flavor system,

2. Salt

[0023] The flavor system can include a salt. The salt can include sodium chloride, potassium chloride and/or any other type of food grade salt. The salt can be about 0.01 % to about 1.00% by weight of the total flavor system. The salt can be about 0.01 % to about 0.10% by weight of the total flavor system. The salt can be about 0.01%, 0.02%, 0.04%, 0.06%, 0.08%. 0.10%, 0.12%, 0.14%, 0.16%,, 0.18%, 0.20%, 0.30%», 0.40%, 0.50%, 0.60,% 0.70%, 0.80%, 0.90%, 1.00% to about 0.01%, 0.02%, 0,04%, 0.06%, 0.08%, 0.10%, 0.12%, 0.14%, 0.16%, 0.18%, 0.20%, 0.30%, 0.40%, 0.50%, 0.60,% 0,70%,, 0.80%, 0.90%, 1 ,00% by weight of the total flavor system

3. Food Grade Add

[0024] The flavor system can include a food grade acid. For example, the food grade acid can include citric acid. In other examples, the food grade acid can include acetic acid and/or lactic acid. The food grade acid facilitates a flavor profile for savory ingredients and stimulates saliva production. The food grade acid can be about 0,01% to about 1.0% by total weight of the flavor system. In other aspects, the food grade acid can be about 0.02% to about 0.06% by total weight of the flavor system. The food grade acid can be about 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.20%, 0.30%, 0.40%, 0.50%,, 0.60%, 0.70%, 0,80%, 0.90%, 1.00% to about 0,01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.20%, 0.30%, 0.40%, 0.50%», 0.60%, 0.70%, 0,80%, 0.90%», 1.00% by weight of the total flavor system. [0025] The flavor system can include a leavening agent. For example, the leavening agent can include baking powder. In other aspects, the leavening agent can include baking soda. In one aspect, the leavening agent is less than about 0.1.0% by total weight of the flavor system. In another aspect, the leavening agent is less than about 0.01% by total weight of the flavor system. The leavening agent can be less than about 0.10%, 0.09%, 0.08%, 0.07%, 0.06%, 0.05%, 0.04%, 0.03%, 0.02%», and 0.01% by weight of the total flavor system.

5. Food Starch

[0026] The flavor system can include a food starch. The food starch can be a pregelatinized, modified food starch that is based on waxy maize. The function of the food starch can be to draw the moisture of the binder away from the underlying food product. When in its hydrated state, the food starch forms a structure. After drying, the structure remains with cavities formed therein that help facilitate the crunchy texture of the product, The food starch can be from about 5% to about 15% by total weight of the flavor system, In other aspects, the food starch can be from about 7% to about 10% by total weight, of the flavor system. In still other aspects the food starch can be less than about 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1% by total weight of the flavor system.

6, Flour

[0027] The flavor system can include flour. In one aspect, the flour can have a protein content from about 8.5%· - 9.0%¾ to facility a crunchy texture and a contrast with the underlying food product. As the protein content increases above 10%, the texture of the flavor system becomes harder and the texture of the underlymg food product is masked by the texture of the flavor component, The protein content is not. meant to be restrictive, it is fully contemplated that the flour can have any protein content, including protein contents below 8.5% and greater than 10%. The flour can be enriched flour, in one aspect, the flour is wheat flour. The flour ca be from about 5% to about 15% by total weight of the flavor system. In other aspects, the flour can be from about 7% to about 10% by total weight of the flavor system. In still other aspects, the flour can be less than about 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1 % by total weight of the flavor system.

7. Cora Starch

[0028] The flavor system can include corn starch, in one aspect, the corn starch is a modified com starch. The corn starch ca function to maintain expanded textured after the food product is baked or cooked. The corn starch can have adhesion properties that minimize breakage. Also, the com starch can draw the moisture of the binder away from the underlying food product. When in its hydrated state, the corn starch can help form a structure. After drying, the structure can remain with ca vities formed therein and help facilitate the crunchy texture of the product. In one aspect, the com starch can be XPANDER manufactured by Tate & Lyle of the United Kingdom. The corn starch can be about 25% to about 80% by total weight of the flavor system. In other aspects, the com starch can be about 60%» to about 80% by total weight of the flavor system. The com starch can be about 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80% to about 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80% by total weight of the flavor system.

8. Other Ingredients

[0029] The flavor system can include other ingredients. For example, the other ingredients can include a flavor enhancing component, texture component, a nutrient component, a color component, and/or an aromatic component. For example, the other ingredient can include a color component. By use of the term "col or component", what is intended is a color additive or multiple color additives that modify and/or enhance the natural color of the food product as compared to if the color component was not added. That is, the color component adds and or enhances an effective amount of color that is discernible to the consumer of the product.

[0030] As another example, the other ingredient can include a nutrient component. By use of the term "n utrient component", what is intended is a nutrient additive or multiple nutrient additives for facilitating a discernible or indiscernible health effect. Such nutrient components can include fatty acids such as omega-3 fatty acids, omega-6 fatty acids, saturated fatty acids, and monounsaturated fatty acids. Other nutrient components ca include amino acids such as Isoleucine, Leucine, Lysine, Methionine, Phenylalanine, Threonine, Tryptophan, Valine, Histidine, Tyrosine, and Selenocysteine. Other amino acids can include Alanine, Arginine, Aspartate, Cysteine, Giutamate, Glutamine, Glycine, Proline, Serine, Asparagine, and Pyrrolysine. Other nutrient components can include vitamins such as retinol, choline, thiamin, riboflavin, vitamin G, niacin, vitamin P, vitamin PP, adenine, epileptic biotin, pantothenic acid, pyridoxine, pyridoxamine, pyridoxal, biotin, vitamin H, folic acid, folate, vitamin M, cobalamin, ascorbic acid, ergocalciferol, cholecalciferol, tocopherol, and

naphthoquinoids. Yet another "nutrient component" can include dietary minerals such as calcium, chloride, chromium, cobalt, copper, iodine, iron, magnesium, manganese, molybdenum, nickel, phosphorus, potassium, selenium sodium sulfur, and zinc,

[0031] As another example, the other ingredient can include an aromatic component. By use of the term "aromatic component", what is intended is an aromatic additive or multiple aromatic additives that modify and/or enhance the natural aroma of the food product compared to if the aromatic component was not added. That is, the aromatic component adds an effective amount of aroma that is discernible to the consumer of the product. An aromatic component can allow for a controlled release of a desired aroma from the food product. In one aspect, the aromatic component can be configured to compliment a flavor component and/or color component, In some aspects, the aromatic component is configured to not taste. The aromatic component may be released by multiple mechanisms, including time, heat, and/or physical manipulation. Some example aromatic components, which are not meant to be limiting can include: Aldehyde C- 16, Aldehyde C-18, Aldehyde C-19, Aldehyde C-20, Aldehyde C-8,

Aldehyde C-9, Aldron, Ally! Arnyl Glycolate, Alpha Amy 1 Cmnamic, Aldehyde, Alpha Damascon, Alpha lonone, Cumarin, Cyclogalbanate, Cyclosrose, Dep (Di Etyl Phthalate), DHM (Di, Hydro Mercenol), Di Hydro Iso Jasmone, DMHQ (Dimethyl Hydro Quinone), DMO (Di Methyl Octonol), Ethyl Maltoi, Ethyl Vanilline, Eucalyptol, Neroiine

Bromalia, Nopyl Acetate, Orange Oil P.E.M.E., Para Cresyl Acetate, Para Cresyl Phenyl Acetate, Patcholi, Petit Grain, Phenyl Acetic Acid, and Phenyl Ethyl Alcohol.

[0032] The other ingredients can he about 0.1% to about 10.0% by total weight of the flavor system. The other ingredients ca be 0.1%, 0.2%, 0.4%, 0.6%, 0.8%, 1.0%, 1.5%, 2.0%, 2.5%, 3.0%, 3.5%, 4.0%, 4.5%», 5.0%, 5.5%, 6.0%, 6.5%, 7.0%, 7.5%, 8.0%», 8.5%, 9.0%, 9.5%, 10.0% to about 0.1%, 0.2%, 0.4%, 0.6%, 0.8%, 1.0%, 1.5%, 2.0%, 2.5%, 3.0%, 3.5%, 4.0%, 4.5%, 5.0%, 5.5%, 6.0%, 6.5%, 7.0%, 7.5%, 8.0%, 8.5%, 9.0%, 9.5%, 10.0% by total weight of the flavor system.

ΙΠ. FOOD PRODUCT

[0033] Food products can include a coating having the binder adhering the flavor system to the food. The coating can include a single layer of the binder and flavor system. In other aspects, the coating can include multiple layers that include the binder and flavor system. The food product can have a pre-cooked state and a post-cooked state. The examples utilized herein primarily discuss popped popcorn as the food. However, the food can include other foods beside popcorn. For example, the food can be a food for forming a snack food, a low moisture food product, a shelf stable food product, a carbohydrate based food product, and combinations thereof. As an example, the food can include an individual food, an aggregated food, and/or a formed food. As an example, the individual food can include puffed foods, extruded puffed foods, cracker type foods, pretzel type foods, chip type foods, and/or the like. In other aspects, an individual food can include partial or whole grains, seeds, and cereal. An aggregated food can include an aggregate of more than one individual food. For example, an aggregated food can include a popcorn ball. Formed foods can include snack bars, nutrition bars, health bars, and the like.

1. Pre-cooked State

[0034] The food product can have a pre-cooked state. The pre-cooked state can include the state of the food product after the binder and the flavor system have been applied to form the coating but before the food product has been cooked (e.g. baked, heated, and/or dried) to remove the moisture from the coating and form the crunchy structural matrix of the coating. In the pre-cooked state, the generally hydrophilic flavor system has been applied to the moist surface of the binder. The generally hydrophilic flavor system draws the moisture from the binder away from the food and at least partially hydrates the flavor system to cause the flavor system to expand and begin forming the structure of the coating. By drawing the moisture from the binder and away from the food, any s tmctural degradation of the food is minimized from the moisture of the binder.

[0035] The food product can include about 30% to about 40% popped popcorn by total weight of the food product in its pre-cooked state. In another aspect, the food product can include about 30%> to about 35% popped popcorn by total weight of the food product in its pre-cooked state. The food product can include about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% to about 30%, 31%, 32%, 33%, 34%, 35%, 36%), 37%, 38%), 39%, 40% popped popcorn by total weight of the food product in its pre-cooked state.

[0036] As another example, the food product can include about 20% to about 30% of the flavor system by total weight of the food product in its pre-cooked state, in another aspect, the food product can include about 25% to about 28%) of the flavor system by total weight of the food product in its pre-cooked state. The food product can include about 20%, 21 %, 22%, 23%, 24%», 25%, 26%, 27%, 28%, 29%, 30% to about 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30% of the fla vor system by total weight of the food product in its pre-cooked state. [0037] As a further example, the food product can include about 30% to about

40% of the binder by total weight of the food product in its pre-cooked state. In another aspect, the food product can include less than about 40% binder by total weight of the food product in its pre-cooked state. In another aspect, the food product can include about 35% to about 40% of the binder by total weight of the food product in its precooked state. The food product can include about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% to about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% of the binder by total weight of the food product in its pre-cooked state.

2. Post-cooked State

[0038] The food product can also have a post-cooked state (also referred to herein as a final food product). The post-cooked state can include the state of the food product after the coating (e.g. binder and the flavor system) have been applied and after the food product has been cooked (e.g. baked, heated, and/or dried) to remove the moisture from the coating and form the crunchy structural matrix of the coating. In the post-cooked state, moisture is removed from the coating. The remaining structure is generally honeycombed with a plurality of cavities. The remaining structures form the crunchy texture as a consumer bites through the coating into the popcorn.

[0039] The food product can include about 30% to about 40% popped popcorn by total weight of the food product in its post-cooked state. In another aspect, the food product can include about 35% to about 38%> popped popcorn by total weight of die food product in its post-cooked state. The food product can include about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% to about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% popped popcorn by total weight of the food product in its post-cooked state. In another aspect, the percentage of the popped popcorn by total weight of the food product can increase from about 1% to about 5% between the precooked state and the post-cook state. The increase can be about 1%, 2%, 3%, 4%, 5% to about 1 %, 2%, 3%, 4%, 5%. [0040] As another example, the food product can include about 25% to about 35% of the flavor system by total weight of the food product in its post-cooked state. In another aspect, the food product can include about 27% to about 30% of the flavor system by total weight of the food product in its post-cooked state. The food product can include about 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35% to about 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35% of the flavor system by total weight of the food product in its post-cooked state. In another aspect, the percentage of the flavor system by total weight of the food product can increase from about 1%» to about 5% between the pre-cooked state and the post-cooked state. The increase can be about 1 %, 2%, 3%», 4%, 5% to about 1%, 2%, 3%, 4%», 5%.

[0041] As a further example, the food product can include about 30% to about

40% of the binder by total weight of the food product in its post-cooked state, in another aspect, the food product can include about 33% to about 38%> of the binder by total weight of the food product in its post-cooked state. The food product can include about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% to about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% of the binder by total weight of the food product in its post-cooked state. In another aspect, the percentage of the binder by total weight of the food product can decrease about 1% to about 5% between the pre-cooked state and the post-cooked state. The decrease can be about 1%, 2%, 3%», 4%, 5% to about 1%, 2%, 3%, 4%, 5%.

[0042] The food product in its post-cooked state have about 7°/» to about 10% less moisture than the food product in its pre-cooked state . The moisture content of the post- cooked state can be about 7°/», 8%, 9%, 10% to about 7%, 8%, 9%, 10% less than the moisture content in the pre-cooked state . The total moisture content of the food product in its post-cooked state can be less than about 6%. In other aspects, the total moisture content of the food product in its post-cooked state can be about 2% to about 6%. The total moisture content can be about 2.0%, 2.5%, 3.0%, 4.0%, 4.5%, 5.0%, 5.5%, 6.0% to about 2.0%, 2.5%, 3.0%, 4.0%, 4.5%,, 5.0%, 5.5%, 6.0% by total weight of the food product in its post-cooked state. [0043] The final food product can have a water activity of about 030 to about

0.40. In other aspects, the water activity can be about 0.36 to about 0.37. The water activity can be about 0.30, 0.31 , 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40 to about 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40.

[0044] The final food product can have a protein content of about 5% to about

10%. The final food product can have a protein content of about 5%, 6%, 7%, 8%, 9%, 10% to about 5%, 6%, 7%, 8%, 9%, 10%.

[0045] The final food product can have a total fat content of about 1% to about

5%, The final food product can ha ve a protein content of about 1%, 2%, 3%, 4%, 5%, to about 1%», 2%, 3%, 4%, 5%.

[0046] The final food product can ha ve a saturated fat content of about 0%. In other aspects, the saturated fat content can be about 0% to about 3%. The saturated fat content can be about 0%, 1%, 2%, 3% to about 0%, 1%, 2%, 3%.

[0047] The final food product can have a trans fat content of about 0%. In other aspects, the trans fat content can be about 0% to about 3%. The trans fa content can be about 0%, 1%, 2%, 3% to about 0%, 1%, 2%, 3%.

[0048] The final food product can have a monounsaturated fat content of about

0%, In other aspects, the monounsaturated fat content can be about 0% to about 3%, The monounsaturated fat content can be about 0%, 1%, 2%, 3% to about 0%, 1%, 2%, 3%.

[0049] The final food product can ha ve a polyunsaturated fat content of about 0%,

In other aspects, the polyunsaturated fat content can be about 0% to about 5%. The polyunsaturated fat content can be about 0%, 1%, 2%, 3%, 4%, 5% to about 0%, 1%, 2%, 3%, 4%, 5%.

[0050] The final food product can ha ve a cholesterol content of about 0%. In other aspects, the cholesterol content can be about 0% to about 3%. The cholesterol content can be about 0%, 1%, 2%, 3% to about 0%, 1%, 2%, 3%.

[0051] The final food product can have a total carbohydrate content of about 70% to about 80%. In other aspects, the total carbohydrate content can be about 70%, 71%, 72%, 73%, 74%, 75%,76%, 77%, 78%, 79%, 80% to about 70%, 71%, 72%, 73%, 74%, 75%,76%, 77%, 78%, 79%, 80%. [0052] The final food product can have a sugar content of about 10% to about

20%, In other aspects, the total carbohydrate content can be about 10%, 1 1 %, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20% to about 10%, 1 1%, 12%, 13%, 14%, 15%,16%,

17%, 18%, 19%, 20%.

[0053] The final food product can have a dietary fiber content of about 2% to about 10%. In other aspects, the dietary fiber content can be about 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10% to about 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%.

[0054] The final food product can have a sodium content of about 0.1 % to about

3,0%. In other aspects, the sodium content can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1 .2%, 1.4%, 1.6%, 1.8%, 2.0%, 2.2%, 2.4%, 2.6%, 2.8%, 3.0% to about 0.1 %, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.2%, 1.4%, 1 .6%, 1 .8%, 2.0%, 2.2%, 2.4%, 2.6%, 2.8%, 3.0%.

IV. COATING PROCESSES AND FOOD PRODUCT

[0055] FIGURE 1 indicates several exemplary operations associated with coating processes and the food product. Even though FIGURE 1 indicates a start operation and an end operation, the operations associated with FIGURE 1 should not be read as being mutually exclusive or an ultimate start or ultimate end to the overall elements described herein. Also, FIGURE 1 is utilized to describe components of the formulation of the coating, properties of the coating, and steps in the process for producing the food product. Operational flow 100 should not be read as requiring a dependency between the formulation, operational steps, and/or properties of the coating or food product.

Furthermore, the operational flow 100 utilizes popped popcorn as an example food product that receives the coating (e.g. binder and flavor system). Yet, operational flo 100 is not limited to popped popcorn.

[0056] FIGURE 1 is an example operational flow diagram indicating example features associated with the food product and processes for making the food product. Operational flow 100 begins at start operation 102 and continues to operation 104, At operation 104, the popcorn is prepared. The popcorn can be prepared by popping the popcorn. In one aspect, the popcorn can be popped in a hot air popper in the absence of oil n other aspects, the popcorn can be prepackaged popped popcorn. The popping of the popcorn can be facilitated in a batch system, a continuous system, or a system that is partial batch processing and partial continuous processing.

[0057] Operational flow 100 continues to operation 106 where the binder is premixed. For example, the binder can be premixed with one or more of the ingredients and at one or more of the ratios indicated in Section I of this Specification. In one aspect, the binder is mixed in a batch kettle at about room temperature. The temperature can be about 50°F to about 110°F. In one aspect, the binder is unhealed during the mixing. The premixing of the binder can be facilitated in a batch system, a continuous system, or a system that is partial batch processing and partial continuous processing.

[0058] Operational flow 100 continues to operation 108 where the flavor system is premixed. For example, the flavor system can be premixed with one or more of the ingredients and at one or more of the ratios indicated in Section Π of this Specification. The premixing of the flavor system can be facilitated in a ba tch system, a continuous system, or a system that is partial batch processing and partial continuous processing, [0059] Operations 104, 106, and 108 are indicated within block 110. Block 1 10 indicates that operations 104, 106, and 108 can occur in any order or they can occur simultaneously.

[0060] Operational flow 100 continues to operation 112. At operation 112, the binder is applied to the popped popcorn. In one aspect, the binder is applied to the popped popcorn in a continuous system. In other aspects, the binder is applied to the popped popcorn in a batch system. For example, popped popcorn can enter a coating pan and the binder can be ladled onto the popped popcorn. The popped popcorn and the binder can be tumbled in the coating pan at about 27 rpm to about 30 rpm. The revolutions can be higher or lower depending on the appearance of breakage during the tumbling. In other aspects, the binder can be sprayed or dripped into the tumbler until the popped popcorn is coated with the binder.

[0061] From operation 112, operational flow 100 continues to operation 114 where the flavor system is applied to the popped popcorn having the binder. In one aspect, the flavor system can be applied in a continuous system. In other aspects, the flavor system is applied in a batch system. For example, the flavor system ca be dusted, sprayed, ladled, scattered, shaken and/or otherwise applied to the popcorn in coating pan. When the generally hydrophilic flavor system impacts the tacky surface of the binder of the popped popcorn, the moisture in the binder is drawn away from the popcorn and the flavor system at least partially hydrates to at least partially form the coating of the food product.

[0062] From operation 114, operational flow 100 continues to decision operation

1 16, where it is decided whether another cycle is desired to form another layer. Another cycle may be desired to achieve a proper flavor impact and texture without destroying the internal structure of the popcorn from the moisture of the binder. As an example, if a large initial quantity of binder is applied to the popped popcorn, the structural matrix of the popped popcorn can begin to dissolve from the moisture of the binder. Accordingly, it may be desirable to use several coating cycles so that the moisture impact to the popcorn can be minimized by incrementally adding the flavor system to draw the moisture away from the popped popcorn. As an example, the popped popcorn can undergo about 1 to about 15 cycles. In other aspects, the popped popcorn can undergo about 4 to about 8 cycles. The popped popcorn can undergo about 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 to about 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 cycles. As indicated in FIGURE 1, where another cycle is desired, operational flow 100 loops back up to operation 1 12. In the situation where another cycle is not desired, operational flow 100 continues to operation 116.

[0063] One example related to coating cycles and the layers formed by the coating cycles is indicated in TABLE A.

TABLE A

0 4000 100.00% 0 0.00% 0 0.00%

1 4000 76.92% 700 13.46% 500 9.62%

2 4000 62.50% 1400 21.88% 1000 15.63%

3 4000 52.63% 2100 27.63% 1500 19.74%

4 4000 45.45% 2800 31.82% 2000 22.73%

5 4000 40.00% 3500 35.00% 2500 25.00%

6 4000 35.71% 4200 37.50% 3000 26.79%

[0064] TABLE A is just one example of cycles. The incremental amount of binder and flavor system added during each cycle can vary depending on the tumbling speed, the amount of popped popcorn in the coating pan, the number of desired cycles and/or the like.

[0065] At operation 116, the coated popped popcorn can be cooked in a hot room for about 30 to about 40 minutes at a temperature of about 180°F to about 200°F. The coated popped popcorn can be cooked to have a moisture reduction and/or moisture content indicated above in Section ΙΠ of this Specification.

[0066] Operational flow 100 continues to decision operation 120 where it is determined whether the moisture content is acceptable. If it is not acceptable, operational flow 100 loops back up for further cooking. If the moisture is acceptable, operational flow 100 continues to operation 122.

[0067] At operation 122, the popped popcorn product can be cooled to a packaging temperature. For example, the packaging temperature can be less than about 110 °F. At decision operation 124, it is determined whether the packaging temperature has been obtained. If not, operational flow^r 100 loops back, If the packaging temperature has been obtained, operational flow 100 can continue to operation 126, where the popped popcorn product can undergo a sifting process and/or a process to remove fines and broken particulates. From operation 126, operational flow continues to operation 128 where the popped popcorn product can be packaged. The popped popcorn product can be packaged to have a modified atmosphere with reduced oxygen levels to increase the time before expiration. The package can contain about 5% oxygen. The package can contain about 0%, about 1%, about 2%, about 3%, about 4%, or about 5% oxygen.

During packaging, a gas flush and/or oxygen scavengers can be utilized to reduce the oxygen level. In one aspect, the gas flush can include aromatics to provide a desirable aroma to the packaged product. The packaged product can be equilibrated prior to shipping. Operational flow 100 then ends at end operation 130.

V. EXAMPLES

1, Moisture Content and Water Activity

[0068] Samples were prepared according to the methods indicated above. The seasoning included Queso jalapeno and Valentina. The samples were tested for moisture content and water activity via standard test methods. The results are indicated below in TABLE 1.

TABLE I

Moisture g of water/1 OOg of wet sample

2, Texture

[0069] Samples were prepared according to the methods indicated above. The seasoning included Queso jalapeno and Velentina. A TA-XT2 device from Texture Technologies Corp. of Scardale, NY, U SA was used during the testing. Samples of each were prepared and allowed to cool for 15 minutes. Fifteen grams of each sample were placed into a one liter beaker. A cell of 12 cm long and 10 cm in diameter was used to handle the pre and post test of 1 and 10 mm . The speed of the device was 6 mm/s and the distance was 40 mm. 15 repetitions were conducted for each seasoning type. The principle of the texture measurement system was to deform the sample in a controlled manner and measure its response. Forces created during the test were set to mimic a typical bite. The results are indicated below in TABLE 2.

TABLE 2

3. Nutritional Composition

[0070] Samples were prepared according to the methods indicated above, seasoning included Queso jalapeno and Valentina. The samples were tested for nutritional composition via standard test methods. The results are indicated below

TABLE 3. TABLE 3

Cholesterol 0 0.0% 0 0.0%

Total

23 76.7% 23 76.7%

Carbohydrates

Sugars 4 13.3% 4 13.3%

Dietary Fiber 2 6.7% 2 6.7%

Sodium 0.387 1.3% 0.515 1.7%

CONCLUSION

[0071] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.

Claims

Claims:

1. A popped popcorn product, the popped popcorn product comprising: popped popcorn;

a coating cooked on the popped popcorn, wherein the coating includes a binder and a flavor system adhered to the binder,

wherein the binder includes a binding agent, maltodextrin and a starch, wherein the fla vor system includes a seasoning and at least one member of a group consisting of: a flour and a starch.

2. The popped popcorn product of claim 1, wherem the binding agent includes corn syrup, wherein the corn syrup is about 30% to about 40% by total weight of the binder,

3. The popped popcorn product of claim 1, wherein the maltodextrin is about 20% to about 30% by total weight of the binder.

4. The popped popcorn product of claim 1 , wherein the starch of the binder includes Tapioca starch, wherein the Tapioca starch is about 10% to about 20% by total weight of the binder,

5. The popped popcorn product of claim 1 , wherein the binder further includes a color component, wherem the color component is about 0.1%» to about 5.0%) by total weight of the binder.

6. The popped popcorn product of claim 1 , wherein the seasoning is about 1.0% to about 20% by total w ei ght of the flavor system.

7. The popped popcorn product of claim 1, wherein, the flour of the flavor system includes a wheat flour, wherein the wheat flour is about 5% to about 15% by total weight of the flavor system.

8. The popped popcorn product of claim 1, wherein the starch of the flavor system includes a modified food starch and a corn starch.

9. The popped popcorn product of claim 8, wherein the modified food starch is about 5% to about 15% by total weight of the flavor system.

10. The popped popcorn product of claim 8, wherein the com starc is about 25% to about 80% by total weight of the flavor system,

11. The popped popcorn product of claim 1, wherein the flavor system further includes salt, wherein the salt is about 0.01% to about 1.00% by total weight of the flavor system.

12. The popped popcorn product of claim 1, wherein the flavor system further includes a food grade acid, wherein the food grade acid is about 0.01% to about 1.00% by total weight of the flavor system.

13. The popped popcorn product of claim 1, wherein the flavor system further includes a leavening agent, wherein the leavening agent is less than about 0.10% by total weight of the fla vor system.

14. The popped popcorn product of claim 1 , wherein the popped popcorn is about 30% to about 40% by total weight of the popped popcorn product.

1 . The popped popcorn product of claim 1 , wherein the binder is about 30% to about 40% by total weight of the popped popcorn product.

The popped popcorn product of claim 1, wherein the flavor system is about 25% to about 35% by total weight of the popped popcorn product.

17. The popped popcorn product of claim 1, wherein the binder and the flavor system of the coating forms a first layer.

18. The popped popcorn product of claim 17, wherein the coating includes multiple s layers of the binder and the flavor system.

19. A popped popcorn product, the popped popcorn product comprising: popped popcorn;

a coating cooked on the popped popcorn, wherein the coating includes multiple layers, wherein each layer is formed from a flavor system and a binder,

wherein the popped popcorn product has a moisture content of about 2% to about 6% by total weight of the popped popcorn product.

20. A popped popcorn product, the popped popcorn product comprising: popped popcorn;

a coating baked on the popped popcorn, wherein the coating includes multiple layers, wherein each layer is formed from an expanded hydrophilic flavor system and a binder,

wherein the popped popcorn product has a moisture content less than about 6% and a water activity less than about 0.4.

21. A process for making a popped popcorn product, the process comprising: applying a quantity of a binder to a surface of popped popcorn to form a tacky surface on the popped popcorn;

applying a quantity of a flavor system to the tacky surface to cause moisture in the binder to at least partially hydrate the flavor system; and

drying the popped popcorn product to a moisture content less than about 6% by total weight of the popped popcorn product.

22. The process of claim 21 , wherein the binder and the flavor system form a first layer of a coating.

23. The process of claim 22, wherein the coating includes another layer formed by:

applying another quantity of the binder to the first l ayer of the coating to form a tacky surface on the first layer; and

applying another quantity of the fla vor system to the tacky surface on the first layer to cause moisture in the another quantity of the binder to at least partially hydrate the another quantity of the flavor system.

24. The process of claim 22, wherein the coating includes at least one subsequent layer of the binder and the fl avor sy stem formed on the first layer of the coating.

25. The process of claim 22 , wherein the coating includes a plurality of consecutive layers of the binder and the flavor system.

26. The process of claim 25, wherein the coating is about 55% to about 75% by total weight of the popped popcorn product.

27. The process of claim 26, wherein the binder is about 30% to about 40% by total weight of the popped popcorn product.

28. The process of claim 26 wherein the flavor system is about 25% to about 35 > by total weight of the popped popcorn product.

29. The process of claim 21 , wherein drying the popped popcorn product includes baking the popped popcorn product.

30. The process of claim 21 , wherein the binder includes a binding agent, maltodextrin and a starch.

31 . The process of claim 30, wherein the binding agent includes at least one member of a group consisting of: com syrup, soluble com fiber, glucose syrup and high- fructose corn syrup.

32. The process of claim 30, wherein the starch includes at least one member of a group consisting of: tapioca starch, flour, corn starch, arrow root, kudzu powder, lotus root powder, sago starch, sahlab rice flour and sweet rice flower.

33. The process of claim 21, wherein the flavor system includes a seasoning and at least one member of a group consisting of: a flour and a starch.

34. The process of claim 33, wherein the starch of the flavor system includes at least one member of a group consisting of: a modified food starch and a corn starch.

35. The process of claim 33, wherein the flavor system further includes at least one member of a group consisting of: a food grade acid and a leavening agent,

36. A process for making a popped popcorn product, the process comprising: forming a coating on a surface of popped popcorn, wherein the coat includes multiple layers, wherein each layer is formed by:

applying a binder to the popped popcorn to form a tacky surface on the popped popcorn, and

applying a flavor system to the tacky surface to cause moisture in the binder to at least partially hydrate the flavor system, and

drying the popped popcorn product to a reduced moisture content.

37. The process of claim 36, wherein the multiple layers are consecutive.

38. The process of claim 36, wherein the coating is about 55% to about 75% by total weight of the popped popcorn product .

39. A process for making a popped popcorn product, the process comprising: forming a coating on a surface of popped popcorn, wherein the coating includes multiple layers, wherem each layer is formed by:

applying a binder to the popped popcorn, wherein the binder has a brix value of about 62°Bx to about 75°Bx , and

applying a quantity of a hydrophiiic flavor system to cause moisture in the binder to at least partially hydrate the flavor system; and

baking the popped popcorn produc t to a reduced moisture content.

40. The process of claim 39, wherein the multiple layers are consecutive.