Note: Descriptions are shown in the official language in which they were submitted.
CA 02678312 2009-09-04
DOUGH PRODUCT, MICROWAVEABLE FROZEN BREAD PRODUCT,
AND METHOD FOR MAKING SAME
FIELD OF THE INVENTION
[0001] This disclosure relates to an improved dough and microwaveable frozen
bread
products prepared using the improved dough. More particularly, this disclosure
relates to
improved dough for making microwaveable frozen bread products having a dual
texture after
microwaving and a method for making the same. The improved dough is especially
useful for
preparing a fully baked or par baked flathread type bread product with various
toppings which
can then be prepared in a microwave oven from the frozen state
BACKGROUND
[0002] Convenience foods (i.e., products which require a minimum amount of
consumer
preparation and are quick to prepare) are in high demand to accommodate
today's busy
lifestyles. Examples range from cheese and cracker snacks and refrigerated
bagels to frozen
dinners. Typically, such products will be eaten as packaged or after a brief
heating period,
preferably by microwave heating.
[0003] Baked bread products are normally available as freshly prepared
products that are
intended to be consumed within a relatively short time period or as frozen
products which can be
stored in the frozen state for relatively long periods of time and then thawed
for consumption.
Examples of such frozen bread products include frozen pizzas and flatbreads
which are then
heated in a conventional or microwave oven. Attempts to prepare microwaveable,
conventionally-sized frozen bread products having toppings have generally not
been successful.
Consumers often complain that frozen pizza or flatbread products do not have
the desired crispy
crust. Moreover, microwave heating is generally uneven and, therefore,
promotes the rapid onset
of toughness of the cereal products, which is often perceived as staleness.
Frozen bread products
having tbppings often absorb some of the water content of the toppings during
heating, thus
resulting in the cooked bread product having less than the desired amount of
crispiness. Such
problems from heating such frozen food products in a microwave oven may be due
to inadequate
moisture control during microwave heating. Frozen bread products generally are
pre-baked or
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par-baked and use susceptors embedded in the packaging of the microwaveable
product.
Microwaveable bread or other cereal-based products present a variety of
technical hurdles that
are difficult to overcome. For example, in microwave cooking of frozen
flatbread or pizza
products, it is often difficult to obtain the crispy and brown bottom crust
desired by consumers.
Even the use of susceptors can lead to uneven heating and/or uneven crisping
of frozen pizza
crusts and flatbreads.
[0004] 'Today's standards for microwaveable bread products, such as pizza
crusts,
flatbreads, and other thin breads, are high. The marketplace desires, if not
expects,
microwaveable bread products that rival artisan bread products made in a
conventional or
masonry oven in both texture and taste. Flatbread products made in a
conventional or masonry
oven generally have a crispy outer layer while the cemainder of the product
has an airy and soft
texture: Such a dual textured flatbread product is considered highly desirable
by consumers.
Frozen flatbread products are rising in popularity and are available with a
variety of toppings but
do not have the dual texture desired by consumers.
[0005] Thus, there remains a need for frozen bread products which can be
cooked in a
microwave oven to provide a bread product having a crispy bottom surface while
the remainder
of the bread product has a soft, airy texture.
[0006] This disclosure provides a dough composition which provides a baked
bread product
that, upon heating in a microwave or conventional oven, has a crispy bottom
surface with
artisan-like brown spots, while the remainder of the bread product is airy and
soft in texture.
These and other advantages will be apparent upon consideration of the present
specification.
SUMMARY
[0007] This disclosure relates to fully baked or par baked microwaveable
frozen bread
products which, when heated in a microwave oven, have a desirable dual texture
(i.e., a crispy
bottom surface while the remainder of the bread product is airy and soft in
texture). Although
the use of microwave heating is preferred, the present frozen bread products
can also be heated
in a conventional oven and still generate the desirable dual texture.
Generally the bread products
of the present invention are generally of the flatbread type and can be
prepared with or without
toppings. The crispy bottom surface of the cooked bread product has brown
spots and general
appearance reminiscent of artisan breads.
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[0008] Preferably, the frozen bread product described herein is heated in a
microwave oven
using a tray including a susceptor having a configuration which permits
folding of the bread
product after microwaving to provide a flatbread-type sandwich without
significant cracking or
breaking along the fold line of the bread product. Although bread products
which can be folded
after microwaving are preferred, bread products without this property can be
used in the present
invention. Preferably the frozen biead product will have one or more toppings
on the upper
exterior surface of the bread product. The toppings can be, and preferably
are, placed on the
upper exterior surface during manufacture and are frozen in place on the bread
product so that
the consumer can simply open the package, place it in a microwave oven with a
suitable
susceptor, and prepare the final product without additional steps. The frozen
bread product can
also be supplied without toppings; consumers can then prepare the bread
product with or without
toppings as they desire. For purposes herein, "bread" product, "flatbread-type
bread" products,
or bread products of the "flatbread type" refer to fully-baked or par-baked
relatively thin bread
products (typical thickness of less than about 2 inches) such as, for example,
flatbread, pizza
crust, pita bread, naan, and the like.
[0009] For purposes herein, "bottom surface" or "bottom exterior surface"
refers to the
surface of the bread product which is in contact with a susceptor when cooked
in a microwave or
with a baking rack when cooked in a conventional oven. Likewise, the "top
surface" or "top
exterior surface" is opposite the bottom surface and can receive the desired
topping or toppings.
And the "interior portion" refers to the bread product between the top and
bottom surfaces.
[0010] The bread product provided herein includes a unique dough formulation
that
provides a bread product, preferably a flatbread product or pizza crust,
having a crispy bottom
surface while the remainder of the bread product has a soft and airy texture
upon cooking in a
microwave or conventional oven.
[0011] It has surprisingly been discovered that a yeast and/or chemically-
leavened dough
comprising wheat protein isolate and fat chips can be used to provide a frozen
baked bread
product that, after cooking in a microwave or conventional oven, has a crispy
bottom surface
while the remainder of the bread product has a softer and airier texture as
compared to otherwise
similar bread products prepared from leavened dough not including wheat
protein isolate and fat
chips. It is believed that the fat chips melt during the initial baking, thus
leaving voids or holes
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which are then filled by carbon dioxide produced by the leavening agent. While
not wishing to
be limited by theory, it is believed that the wheat protein isolate provides a
softer dough which
allows the generated carbon dioxide gas to expand the dough, including the
voids produced by
the melted fat, during the initial baking.while also providing sufficient
strength to the dough such
that the dough is able to maintain the porous structure formed by the gas
bubbles, thus forming a
light, airy, soft texture to the bread product.
(0012] Moreover, the crispy, but not hard or tough, bottom surface of the
baked bread
product develops brown spots reminiscent of artisan-type bread products that
are appealing and
desirable to consumers upon cooking in a microwave or conventional oven.
Again, not wishing
to be limited by theory, it appears that these desirable brown spots are
formed over voids or holes
generated near the bottom surface due to the thinness of the dough covering
such voids or holes.
(0013] Suitable leavening agents include yeast (e.g., dry yeast, compressed
yeast),
encapsulated chemical leavening agent (e.g., encapsulated sodium bicarbonate,
encapsulated
ammonium bicarbonate, encapsulated calcium bicarbonate), leavening acid (e.g.,
sodium
aluminum phosphate, monocalcium phosphate anhydrous or monohydrate, sodium
acid
pyrophosphate, sodium aluminum sulfate, monopotassium tartrate, dicalcium
phosphate
dihydrate, glucono-delta-lactone), mixtures thereof, and the like. Other
organic acids suitable for
baking may also be used, such as fumaric acid, lactic acid, tartaric acid,
malic acid, citric acid,
and the like. Preferably, a combination of compressed yeast, encapsulated
sodium bicarbonate,
and sodium aluminum phosphate is used as the leavening agent. Surprisingly, it
was found that
using both compressed yeast and encapsulated chemical leavening agent provided
a bread
product, which upon baking in a microwave or conventional oven, has an
especially crispy
bottom layer than a similar bread product where only the compressed yeast or
encapsulated
chemical leavening agent were used alone.
(0014] Fat chips (i.e., shortening flakes) used in the present invention can
be regularly
shaped particles or irregularly shaped particles. Many factors are involved in
successfully
selecting and incorporating fat chips into the dough formulation, including
the size of the fat
chips, the solid fat content of the fat chips, the temperature of the dough,
the mixing speed and
time used to incorporate the fat chips into the dough, and the like. Fat chips
suitable for use
herein are relatively hard solids at 80 F (i.e., have a minimum solid fat
content of about 50
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percent at 80 F). Fat chips in the form of hard solids at 80 F generally
provide bread products
having an airier and softer texture than bread products made with softer fat
chips (i.e., have a
solid fat content of less than about 50 percent at 80 F). The size of the fat
chips added to the
dough mixture is less important than the size of the chips after mixing of the
dough and prior to
baking the dough. Preferably, the fat chip particles after mixing and prior to
baking generally
range between about 5 mg to about 45 mg but have an average weight of about 25
to 35 mg;
assuming a spherical shape, this corresponds to effective diameters ranging
between about 0.5 to
50 mm and an average effective diameter of about 3 to about 5 mm. "Effective
diameters" are
calculated values using the spherical shape assumption. Preferably the average
effective
diameter is in the range of about 2 to 10 mm and more preferably about 3 to 5
mm. Larger fat
chips may be used so long as the size of the fat chips is reduced during
mixing or the fat chips
distributed within the dough are of a size that allows the formation of voids
upon melting of the
fat chips which provide the light and airy texture within the fully baked or
par baked bread
products of this invention. The solid fat content of the fat chips also
affects how easily the chips
are damaged during mixing (e.g., lose their "chip" shape, melt, flake off,
break up,.disintegrate,
or the like). Generally, fat chips having lower solid fat content are more
delicate and require
lower mixing speeds, shorter mixing times, and/or lower dough temperatures
during mixing to
reduce damage to and/or melting of the fat chips. Therefore, the mixing speed,
the mixing time,
and/or dough temperature during mixing should be selected in view of the solid
fat content of the
fat chips and the starting size of the fat chips and in view of the target
size of the fat chips after
mixing and before baking. For example, if the particular fat chips selected
are of the size desired
after mixing, the dough temperature can be selected so as to prevent melting
of the fat chips
during mixing and/or the mixing speed and time can be selected so as to
substantially reduce the
amount of damage caused to the fat chips. Alternatively, if the particular fat
chips selected are
larger than the size desired after mixing, more intense mixing conditions
and/or higher
temperatures of the dough may be necessary to break-up and reduce the size of
the fat chips. Fat
chips that are too small do not provide adequate voids in the dough upon
melting during baking
and, therefore, the resulting bread product is dense and does not have the
desired airy texture.
(0015] As those skilled in the art will realize, the initial size of the fat
chip particles,
hardness of the fat chips, mixing conditions, and similar parameters can be
adjusted to provide
the desired fat chip size, distribution, and thelike which will provide the
desired texture in the
CA 02678312 2009-09-04
baked or par-baked product. Adjustment of such parameters can easily be
carried out using
appropriate experimental designs or methods using laboratory or pilot plant
sized batches and
then scaling up to manufacturing plant sized batches.
[0016] In an important aspect, the yeast and/or chemically-leavened dough
described herein
includes, in baker's percentages, about 0.05 to about 5 percent wheat protein
isolate and about
0.5 to about 10 percent fat chips. Preferably, the dough described herein
includes about 0.1 to
about 0.3 percent wheat protein isolate and about 5 to about 9 percent fat
chips.
[0017] The disclosure also includes methods for making the baked or par-baked
bread
products using this bread dough for later heating in microwave or conventional
ovens. One such
method comprises (a) mixing dough ingredients comprising, in baker's
percentages, 100 percent
flour, about 55 to about 70 percent water, about 0.5 to about 7 percent
leavening agent, about
0.05 to about 5 percent wheat proteiri isolate, and about 0.5 to about 10
percent fat chips; (b)
resting the dough, such as for about 5 to about 10 minutes; (c) shaping the
dough to the desired
size and shape; (d) proofing the dough, such as atabout 80 to about 90 F for
about 24 to about
30 minutes at a relative humidity of about 50 to about 80 percent; and (e)
baking the dough to
form a baked or par-baked bread product. Of course, the conditions under which
the fat chips
are incorporated into the dough should be adjusted so that the appropriately
sized. fat chips are
contained in the dough prior to the initial baking step. The baked or par-
baked bread product
may then be topped with one or more toppings, if desired, and frozen.
Preferably, the wheat
protein isolate, flour, leavening agent, water, and any optional ingredients
are mixed together
first and then the fat chips are incorporated therein; this allows more
precise control over mixing
conditions, and thus the particle size of the fat chips, within the dough as
well as avoiding
damage the fat chips. Mixing should be controlled so that the fat chips are of
the desired weight
or size in the dough and are distributed uniformly though the dough.
[0018] In one preferred form, the bread product is a microwaveable frozen
flatbread that,
when heated on a susceptor in a microwave oven, has a crispy bottom surface
with artisan-like
brown spots while the remainder of the bread product has an airy and soft
texture. Generally, the
brown spots have a somewhat harder texture than the remainder of the bottom
surface. It is
believed that the brown spots are thin areas of dough covering voids created
from air bubbles
close to or adjacent to the bottom surface. The thin areas of the bottom
surface which cover the
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voids heat up faster than other areas of the bottom surface, thus causing
those thin areas to
darken faster and become more crispy.
[0019] In another preferred form, the bread product is a frozen pizza crust
that can be baked
in a microwave or conventional oven to provide an artisan-style pizza crust
having a crispy
bottom surface with artisan-like brown spots while the remainder of the pizza
crust has an airy
and soft texture. If the pizza crust is baked in a conventional oven and does
not include toppings,
the upper surface of the pizza crust will also become crispy while the
interior portions (i.e.,
between the lower surface and the upper surface) will have a softer, airy
texture.
[0020] If desired, the frozen bread product described herein may include a
variety of
toppings, such as, but not limited to, meat, cheeses, vegetables, tofu, soy,
soy derivatives, sauces,
dressings, spreads, gravies, condiments, spices, herbs, flavorings, colorants,
and the like, as well
as mixtures thereof.
[0021] In one aspect, a package contains the fully assembled bread product
preferably
includes one or more microwave susceptors to assist in the microwave heating;
in such case, the
opened package containing the fully assembled bread product and microwave
susceptor(s) are
directly placed in the microwave oven. Alternatively, separate microwave
susceptors can be
included in the package; in such case, the fully assembled frozen bread
product is then placed on
the susceptor and the combination placed in the microwave oven for heating. In
a preferred
form, a tray is provided comprising a susceptor surface, wherein the susceptor
surface includes
an area free of susceptor material in order to foarn a fold zone. Heating the
bread product on
such a susceptor in a microwave oven provides a bread product having a crispy
surface adjacent
the susceptor surface but a non-crispy or less crispy surface adjacent the
area free of susceptor
material in the fold zone. Such an arrangement allows the bread product (e.g.,
flatbread) to be
folded without significant cracking or damage to the fold zone of the bread
product.
[0022] The invention is related to U.S. Patent Provisional Application Serial
No.
60/ [Docket 77727] entitled "Tray For Microwave Cooking and Folding of a Food
Product," which is being filed on the same date as this application, is owned
by the same
assignee, and is hereby incorporated by reference herein in its entirety. The
present
specification is likewise incorporated by reference into the just named
specification.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. I provides a side view of a bread product having a topping
coextensive with the
upper bread surface. The bread product is provided on a tray having a
susceptor surface thereon.
[0024] FIG. 2 provides a general flow chart illustrating a general method for
the preparation
of a fully assembled frozen flatbread product of the invention.
[0025] FIG. 3 provides a more detailed flow chart illustrating another method
for preparing
a flatbread or fully assembled flatbread product of the invention.
[00261 FIG. 4 is a top perspective view of an embodiment of a tray-having an
elevated food
product support surface with a susceptor thereon;
[0027] FIG. 5 is a bottom perspective view of the tray of FIG. 4;
[0028] FIG. 6A is a top perspective view of the tray of FIG. 4 with a food
product on the
food product support surface;
[0029] FIG. 6B is a perspective view of the tray and food product of FIG. 6A
being folded;
[0030] FIG. 6C is a perspective view of the tray and food product of FIG. 6A
in a further
folded position from that of FIG. 6B;
[0031] FIG. 6D is a perspective view of the tray and food product of FIG. 6A,
showing'the
food product folded and the tray returned to its unfolded position;
[0032] FIG. 7 is a perspective view of another embodiment of a tray having an
elevated
food product support surface with a susceptor therein, and having handles
extending outwardly
from depending legs;
[0033] FIG. SA is a partial perspective view of the tray of FIG. 7, showing
one of the
handles in an unextended position;
[0034] FIG. 8B is another partial perspective view of the tray of FIG. 7,
showing one of the
handles moving to an extended position;
[0035] FIG. 9A is a partial perspective view of tray of FIG. 4, showing.detail
of perforations
for removal of a comer region;
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[0036] FIG: 9B is another partial perspective view of the tray of FIG. 4,
similar to that of
FIG. 9A, but showing the tray after removal of the corner region; and
[0037] FIG. 9C is another partial perspective view of the tray of FIG. 4,
similar to that of
FIG. 6A, but showing a corner perforation being broken to pemzit folding of
the tray.
[0038] FIG. 10 is a diagram of the template used to test the firmness of the
inventive
flatbread according to the Example.
[0039] FIG. 11 is a diagram of the template used to test the firmness of the
Lean Cuisine
Flatbread Melt according to the Example.
[0040] FIG. 12 is a bar graph shoiving firmness measured via a TA-TX2 Texture
Analyzer
for inventive flatbreads made using dough incorporating fat chips and wheat
protein isolate as
compared to commercially available Lean Cuisine'? Flatbread Melts of the
Example.
DETAILED DESCRIPTION
[0041] This disclosure relates to improved dough and microwaveable frozen
bread products,
preferably a microwaveable flatbread product, although other thin bread
products, including
pizza crusts, pita bread, naan, and the like, are also contemplated. Such
bread products, when
heated in a microwave or conventional oven, have a crispy bottom surface while
the remainder
of the bread product has a soft, airy texture. The dual texture provided in
the bread products
described herein is very desirable to consumers and has not been achieved in
microwaveable
bread products prior to the invention described herein. If desired, the bread
product may include
toppings on the upper surface. This disclosure further relates to method of
making the dough
and microwaveable frozen bread products.
[0042] FIG. I illustrates a fully assembled frozen bread product I having an
upper surface 2,
a bottom surface 3, an interior portion 4, and topping 5. Topping 5 may be
provided on the
upper surface 2 of the bread product 1. In one aspect, the bread product I may
include a topping
5, which may include, if desired, meat or vegetables in the form of chunks,
lumps, or diced
shapes 6. The topping may be substantially coextensive with the upper surface
2 (as illustrated)
but is not required. In a preferred aspect, the bread product is cooked in a
microwave oven on a
tray 7 having a susceptor surface 8. The bottom surface 3 of the bread product
1 is in contact
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with the susceptor surface 8 during cooking. The bottom surface 3 becomes
crispy during final
heating and develops brown spots reminiscent of artisan breads.
[0043] Dough Formulation. The following descriptions refer to preparation and
use of
bread dough for purposes of the provided non-limiting illustrations, but it
will be appreciated that
the concepts of the disclosure are considered to be generally applicable to a
variety of fully-
baked or par-baked thin bread products, including flatbread, pizza crust, pita
bread, naan, and the
like. It will also be appreciated that, while the disclosure herein generally
focuses on frozen
microwaveable bread products, the frozen bread products described herein are
also suitable for
baking in conventional ovens to provide a dual textured bread product.
Generally, bread
products without toppings which are cooked in a conventional oven will have a
crispy upper
surface, as well as a crispy lower surface, and the area interior to the upper
and lower surfaces
will have a soft, airy texture, whereas the same untopped frozen bread product
cooked in a
microwave oven will generally not have a crispy upper surface without using a
susceptor
adjacent to that upper surface.
[0044] The bread dough described herein comprises a unique formulation which
provides
the desirable dual texture on the top and bottom surface and an airy intemal
texture or structure
upon heating in a microwave or conventional oven. The bread dough comprises a
leavened
mixture comprising a major portion of flour and water and a minor portion of
wheat protein
isolate and fat chips. The bread dough may be yeast and/or chemically
leavened. It has
surprisingly been discovered that incorporation of wheat protein isolate and
fat chips in yeast
and/or chemically-leavened dough provides a bread product which, after cooking
in a microwave
or conventional oven, has a crispier bottom surface while the remainder of the
bread product has
a softer and airier texture as compared to otherwise similar baked products
prepared from
leavened dough without wheat protein isolate and fat chips. Moreover, the
crispy, but not hard
or tough, bottom surface is provided with brown spots reminiscent of artisan-
type bread
products.
[0045] It is believed that the fat chips melt during initial baking, thus
leaving voids which
can be filled, and expanded, by carbon dioxide gas produced by the leavening
agent. The melted
fat appears to be absorbed by the surrounding dough. While not wishing to be
limited by theory,
it is believed that the wheat protein isolate provides a softer dough that
allows the carbon dioxide
CA 02678312 2009-09-04
gas to expand the dough, as well as the voids produced from the melting fat,
while also providing
sufficient strength such that the dough is able to maintain the porous
structure formed by the gas
bubbles, thus forming the highly desirable light, airy, soft texture. During
final heating in the
microwave or oven, the susceptor in the microwave oven rapidly increases in
temperature.
Therefore, the areas of the bottom surface of the bread product in contact
with the susceptor also
become hot more rapidly. The thin areas of the bottom surface covering voids
created by air
bubbles heat up faster than other areas of the bottom surface, thus causing
those thin areas to
darken faster and become crispier than sutrounding areas, thus forming the
brown spots.
[00461 The dough comprises, in baker's percentages, about 0.5 to about 10
percent fat chips
and about 0.05 to about 5 percent wheat protein isolate. Preferably, the dough
comprises, in
baker's percentages, about 5 to about 9 percent fat chips and about 0.1 to
about 0.3 wheat protein
isolate.
[0047] An illustrative and preferred recipe (in baker's percentages) for dough
prepared
according to an embodiment of the invention is provided in the table below.
Ingredient Illustrative Recipe Preferred Recipe
% flour basis (% flour basis)
Flour 100 100
Compressed east 0.5-5 2-3
Encapsulated chemical 0-2 0.1-0.5
leavening agent
Leavening acid 0-1 0.1-0.5
Salt 0-4 t-3
Sweetener 0.5-6 0.5-1.5
Wheat protein isolate 0.05-5 0.1-0.3
Fat chips 0.5-10 5~9
Vital wheat gluten 0-8 1-3
Water 55-70 58-60
Oil 0-8 3-5
[0048] Suitable leavening agents include yeast (e.g., dry yeast, compressed
yeast),
encapsulated chemical leavening agent (e.g., encapsulated sodium bicarbonate,
encapsulated
ammonium bicarbonate, encapsulated calcium bicarbonate), leavening acid (e.g.,
sodium
aluminum phosphate, monocalcium phosphate anhydrous or monohydrate, sodium
acid
pyrophosphate, sodium aluminum sulfate, monopotassium tartrate, dicalcium
phosphate
dihydrate, glucono-delta-lactone), mixtures thereof, and the like. Other
organics acids suitable
for baking may also be used, such as fumaric acid, lactic acid, tartaric acid,
malic acid, citric
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acid, and the like. Preferably, a combination of compressed yeast,
encapsulated chemical
leavening agent, and leavening acid is used. More preferably, compressed
yeast, encapsulated
sodium bicarbonate, and sodium aluminum phosphate are used as the leavening
agent. It was
surprisingly found that using a leavening agent comprising compressed yeast,
encapsulated
chemical leavening agent, and acid leavening agent provided a bread product,
which upon
baking in a microwave or conventional oven, has a crispier outer layer than a
similar bread
product where either the compressed yeast or encapsulated chemical leavening
agent (with
leavening acid) was used without the other. Generally, a bread product made
with compressed
yeast but without chemical leavening agent provides a slightly denser product.
Generally, about
0.5 to about 5 percent compressed yeast is used, preferably about 2 to about 3
percent
compressed yeast. When the leavening agent comprises yeast, encapsulated
chemical leavening
agent, and leavening acid, about 0.5 to about 5 percent compressed yeast,
about 0 to about 2
percent chemical leavening agent, and about 0 to about 1 percent leavening
acid are used;
preferably about 2 to about 3 percent compressed yeast, about 0.1 to about 0.5
percent chemical
leavening agent, and about 0.1 to about 0.5 percent leavening acid are used.
Dry yeast may be
substituted for the compressed yeast. If dry yeast is used, the baker's
percentage or weight is
adjusted to account for the water content of the compressed yeast; likewise,
the amount of water
added may be increased to account for the water content of the compressed
yeast.
[0049] Fat chips (i.e., shortening flakes) are generally regularly shaped or
irregularly shaped
particles; the actual shape of these fat chips or flakes does not appear to be
especially important
so long as suitable sized voids are produced in the dough after the fat chips
or flakes melt. Many
factors are involved in successfully incorporating fat chips into the dough
formulation, including
the size of the fat chips, the solid fat content of the fat chips, the
temperature of the dough, the
mixing speed, and mixing time. Fat chips suitable for use herein are generally
hard solids at 80
F (i.e., have a minimum solid fat content of about 45 percent at 80 F and
preferably 50 percent
at 80 F). Fat chips which are hard solids at 80 F provide bread products
having an airier and
softer texture than bread products made with fat chips that are softer (i.e.,
have a solid fat content
of less than about 40 percent at 80 F). The initial size of the fat chips
added to the dough
mixture is less important than the size of the chips after mixing of the dough
and prior to baking
the dough. Preferably, the fat chips after mixing and prior to baking
generally range between
about 5 mg to about 45 mg but have an average weight of about 30 mg. The solid
fat content or
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firmness of the fat chips will affects how easily the chips are reduced in
size or are damaged
during mixing (e.g., lose their "chip" shape, melt, flake off, break up,
disintegrate, or the like).
Generally, fat chips having lower solid fat content are more delicate and may
require more gentle
mixing conditions (i.e., lower mixing speeds, shorter mixing times, and/or
lower dough
temperatures) during mixing to reduce damage to and/or melting of the fat
chips. Therefore, the
mixing speed, the mixing time, and/or dough temperature during mixing should
be selected in
view of the solid fat content of the fat chips and the starting size of the
fat chips and in view of
the target size of the fat chips after mixing and before baking. For example,
if the particular fat
chips selected are of the size desired after mixing, the dough temperature can
be selected so as to
prevent melting of the fat chips during mixing and/or the mixing speed and
time can be selected
so as to substantially reduce the amount of damage caused to the fat chips.
Alternatively, if the
particular fat chips selected are larger than the size desired after mixing,
faster mixing speeds
and/or higher temperatures of the dough may be used to reduce the size of the
fat chips to the
desired range. Fat chips that are too small do not provide adequate voids in
the dough upon
melting during baking and, therefore, the resulting bread product is dense and
does not have the
desired airy texture. As noted above, initial size and firmness of the fat
chips and the mixing
conditions can be adjusted to provide a dough having properly sized fat chips
uniformly
distributed within the dough, which can then be baked or pare baked to provide
a bread product
with dual texture on the top and bottom surfaces and an airy texture
intemally.
[0050] Wheat protein isolate is prepared by removing starch from wheat flour.
While not
wishing to be limited by theory, it is believed that the wheat protein isolate
provides a soft dough
which allows the carbon dioxide gas to expand the dough while also providing
sufficient strength
to the dough such that the dough is able to maintain the porous structure
formed by ihe gas, thus
forming a light, airy, soft texture to the bread product. Suitable commercial
wheat protein isolate
products include, for example, Arise 5000 from MGP Ingredients, Inc. and
Prolite 100 from
ADM. Arise 5000 includes about 90 percent wheat protein. Bread products
prepared without
wheat protein isolate are generally very dense and do not have the desired
soft, airy texture.
[0051] Exemplary of the flour component or farinaceous materials which may be
used, for
example, are whole grain or refined wheat flour. Hard or soft wheat flours,
red or white wheat
flours, winter or spring, and blends thereof, all purpose flours, and so forth
may be used. The
flour may be bleached or unbleached. Wheat flour or mixtures of wheat flour
with other grain
13
CA 02678312 2009-09-04
flours are preferred. For pizza crust applications, high gluten flours are
particularly desirable.
High gluten flours include, for example, flours made from milled hard wheat
grain (e.g., hard red
winter wheat, hard white wheat, and hard white spring wheat), or spelt. Vital
wheat gluten or
other wheat protein fractions, including those of gliadin or glutenin, may be
added to the flours
as a protein source or functional agent. For example, lower gluten content
flours, such as
triticale, can be used with vital wheat gluten added to increase gluten
content.
[0052] The bread dough also may contain minor amounts of other functional and
flavoring
additives commonly used in bread dough, such as oil, protein source,
sweetener, preservative,
emulsifier, salt, dough conditioners, chemical leavening agent, herbs,
seasonings, spices, and the
like, as long as the additional ingredients do not adversely affect formation
of the dual textured
product with the light, airy interior. If desired, the dough can be fortified
with macronutrients
and/or micronutrients, such as iron preparations, bioavailable calcium
sources, vitamins,
minerals, amino acids, and'other nutraceuticals. Vitamin and vitamin-like
nutritional
fortification can be obtained using Vitamin C, Vitamin E sources, Vitamin D
sources, beta
carotene sources, and so forth. Vitamin C also may be used as a functional
additive in a
conventional manner for gluten strengthening, and other performance quality
enhancements and
benefits.
[0053] Suitable oils include vegetable oils, shortening, hydrogenated oil, and
the like.
Prefen-ed vegetable oils are corn, canola, sunflower seed, cottonseed and
soybean oils, or
mixtures thereof, with soybean oil and corn oil being the most preferred. The
oil may have a
butter flavoring agent. Fat substitutes may also be used, if desired.
Altematively, a butter
flavoring agent or other flavoring agent may be added to the recipe in an
amount known to those
skilled in the art or in accordance with the flavor manufacturer's
'recommendations.
[0054] The dough also may include sweeteners. These include sugars such as
sucrose,
fructose, glucose, high fructose corn syrup, or other sweet mono- or
disaccharides commonly
used in baking materials. The total sugar solids content of the dough of the
present invention
may range from 0.5 up to about 6 percent by weight, depending on the product.
For bread dough,
the total sugar content generally may range between 0.5 to about 6 percent by
weight,
particularly between about 0.5 to about 1.5 percent. All or a portion of the
natural sweetener
content can be substituted by or augmented with artificial sweetener,
nonnutritive sweetener,
14
CA 02678312 2009-09-04
high intensity sweetener, sugar alcohol materials, and the like. Of course, if
used, the levels of
such other sweeteners should be adjusted to provide the desired level of
sweetness and, if
appropriate (i.e., if corn syrup is used), the level of water may be adjusted
to account for water
added with the sweetener.
[0055] If desired, emulsifiers may be included in effective, emulsifying
amounts in the
dough of the disclosure. Exemplary emulsifiers which may be used include, mono-
and di-
glycerides, polyoxyethylene sorbitan fatty acid esters, DATEM (di-acetyl
tartaric acid esters of
mono- and diglycerides), lecithin,.stearoyl lactylates, and mixtures thereof.
Exemplary of the
polyoxyethylene sorbitan fatty acid esters which may be used are water-soluble
polysorbates
such as polyoxyethylene (20) sorbitan monostearate (polysorbate 60),
polyoxyethylene (20)
sorbitan monooleate (polysorbate 80), and mixtures thereof. Examples of
natural lecithins which
may be used include those derived from plants such as soybean, rapeseed,
sunflower, or corn,
and those derived from animal sources such as egg yolk. Soybean-oil-derived
lecithins are
preferred. Exemplary of the stearoyl lactylates are alkali and alkaline-earth
stearoyl lactylates
such as sodium stearoyl lactylate, calcium stearoyl lactylate, and mixtures
thereof. Exemplary
amounts of the emulsifier which may-be used range up to about 3 percent by
weight of the
dough.
[0056] Since the baked or par baked bread of this invention will generally be
distributed in a
frozen form, preservatives may not be required. Nevertheless, the dough of the
disclosure may
include antimycotics or preservatives, such as calcium propionate, potassium
sorbate, sorbic
acid, sodium benzoate, nisin, and the like, singly or in combinations thereof,
if desired.
Exemplary amounts -may range up to about 1 percent by weight of the dough, to
assure microbial
shelf-stability.
[0057] Flavorings and/or spices may be used in the manufacture of the
flatbread dough, if
desired. The flavorings may include, for example, olive oil, rosemary, garlic,
butter, salt and the
like. Other flavorings or combinations of flavorings may be used, if desired.
[0058] The bread fonmulations of this disclosure are designed to provide good
organoleptic
properties and a crisp bottom layer while the remainder of the bread product
has a soft, airy
texture after microwaving or baking in a conventional oven by the consumer.
Thus, the bread
formulations provided herein have better organoleptic properties as compared
to similar
CA 02678312 2009-09-04
microwaveable products prepared with conventional dough formulations,
including conventional
dough formulations used in microwaveable products currently available in the
marketplace.
Although the dough formulations described herein are especially designed for
use in flatbread
food products, the dough formutations can be used to advantage in other bread
products,
including those intended to be heated in microwave ovens and conventional
ovens, such as pizza
crust, pita bread, naan, and the like.
[0059] Dough Mixing and Dough Products. The dough formulations of the
disclosure can
be formed into a useful bread product using a variety of techniques. The dough
is mixed, rested,
shaped, proofed, and baked before freezing. The bread product may be topped
before or after
freezing, if desired. The sequence of the other operations is not particularly
limited and may be
varied. It is important, as noted above, that the initial size and hardness of
the fat chips, as well
as the conditions under which they are incorporated into the dough, be
adjusted to obtain the
desired size and homogenous distribution of the fat chips in the dough before
baking so that the
desired textural characteristics are obtained.
[0060] FIG. 2 illustrates a preferred general method of preparing fully
assembled frozen
bread products of the disclosure. As those skilled in the art will recognize,
the order of steps
shown in FIG. 2 can be modified if desired; for example, freezing can occur
before or after
adding a topping. The dough is first prepared by mixing dough ingredients
comprising, in
baker's percentages, 100 percent flour, about 55 to about 70 percent water,
about 0.5 to about 7
percent leavening agent, about 0.05 to about 5 percent wheat protein isolate,
and about 0.5 to
about 10 percent fat chips. Other ingredients may be added if desired.
Preferably, the dough
ingredients are first mixed before adding the fat chips. Then the fat chips
are added and mixed
under conditions to provide the desired size and distribution of the fat chips
in the dough. The
mixing speed, the mixing time, and/or dough temperature during mixing should
be selected in
view of the solid fat content of the fat chips and the starting size of the
fat chips to achieve the
desired size and distribution of the fat chips after mixing and before baking.
For example, if the
particular fat chips selected are close to the size desired after mixing, the
dough temperature can
be selected so as to prevent melting of the fat chips during mixing and/or the
mixing speed and
time can be selected so as not to substantially reduce the size of the fat
chips or otherwise
damage them. Alternatively, if the particular fat chips selected are larger
than the size desired
16
CA 02678312 2009-09-04
after mixing, mixing conditions can be modified to achieve the desired size
and distribution of
the fat chips in the dough prior to baking.
[0061] The resulting dough mixture is rested for about 5 to about 10 minutes
and then
shaped to the desired size and shape. The dough is the proofed the dough, such
as at about 80 to
about 90 F for about 24 to about 30 minutes at a relative humidity of about
50 to about 80
percent. The proofed dough is then baked to form a baked or par-baked bread
product. The
bread product may then be topped with one or more toppings, if desired. The
bread product and
any toppings that have been added are then frozen.
[0062] Preferably, the wheat protein isolate, flour, leavening agent, water,
and any optional
ingredients are mixed prior to the addition of the fat chips in order to allow
better control of the
size and distribution of the fat chips in the dough. If desired, the process
may include an optional
pressing step with or without heat to better shape the dough. The dough is
then baked. As noted
above, the fat chips will melt to form voids or holes within the dough which
can then be
expanded by the generated gas during baking. Of course, some melting of the
fat chips adjacent
to the external surfaces may occur during the optional pressing stage (if heat
is used); such early
melting (if it does occur) appears to allow the desired formation of the voids
or holes in the
baked product.
[0063] As those skilled in the art will realize, the baking conditions will
largely depend on
the type of oven used and the size/weight of the dough. For example, a dough
piece (about 85 to
91 grams) in the shape of a square or circular could be baked in an
impingement-type oven at
about 550 to about 650 F for about I to about 2 minutes. As one of ordinary
skill in the art will
readily recognize, the precise baking temperatures and baking time will vary
depending on the
type of oven used and the type of bread product being made.
[0064] FIG. 3 provides a detailed flow chart illustrating methods of preparing
dough
products comprising fat chips and wheat protein isolate. As those skilled in
the art will realize,
the various steps of the process shown in FIG. 3 (as well as the more general
process shown in
FIG. 2) can be modified, re-ordered, eliminated, and/or incorporated into one
or more of the
other processes described, depending on the type of bread product being made,
the equipment
available, desired optional steps, and other considerations in the baking
industry. The dough is
first prepared by dry blending flour, leavening agent, wheat protein isolate,
and water. Optional
17
CA 02678312 2009-09-04
ingredients may be added, if desired. The dough mixture is mixed, such as on
high speed for
about 6 minutes or until the dough has developed viscoelasticity. The fat
chips are then added
and mixed into the dough to form a homogenous distribution of properly sized
fat chips. The
dough mixture is then subjected to a chunker/divider to obtain the desired
amount of dough. The
dough is then formed into an appropriate sheet by extrusion, such as into
dough pieces of about
3.17 to about 3.87 ounces, and cut into the desired shape and size. The cut
dough is then placed
in individual pans of the appropriate size and shape and then proofed (about
80 to about 90 F
for about 24 to about 30 minutes at a relative humidity of about 50 to about
80 percent) to allow
the dough to relax prior to molding. The dough compositions can be optionally
treated with
presses to form the shape, such as about 5 to about 10 seconds. The pressed
dough products are
then depanned and baked. For example, a dough piece (about 85 to 91 grams) in
the shape of a
square or circle could be baked in an impingement-type oven at about 550 to
about 650 F for
about 1 to about 2 minutes. The baked crusts are frozen before or after adding
a topping (if
used). If a topping is added to the frozen crusts, the resulting product
should then be frozen as a
unit.
[0065) Bread products of conventional and non-conventional shapes can be
formed. Such
conventional shapes include, for example, a generally circular, oval square,
rectangular
(rectangular with one or more rounded ends), and the like, although other
shapes may be
prepared, if desired. Although the dimensions can vary, the bread product
generally has a
thickness of about 1/6 inch to about 2 inches thick depending on the actual
intended use;
preferably the thickness is less that about 1 inch and more preferably less
than about'/. of a inch.
For pizza crusts, the baked crust is preferably about 1/16=inch to about 1/2
inch thick. For
flatbreads, the baked flatbread is preferably about 1/8 inch to about 1/2 inch
thick.
(00661 The raw dough may be directly used in baking operations or,
altematively, it may be
stored under refrigerated or frozen conditions as a chilled product until used
later. The dough
may be topped to provide a composite dough product that can be subsequently
baked.
Depending on the product, the dough may be pre-shaped, baked or par-baked, and
topped. The
bread product and/or topped bread product may be packaged in any suitable
conventional
manner for storage and handling.
18
CA 02678312 2009-09-04
[00671 Preferably, the bread product is frozen after baking. The bread
products described
herein may be frozen for long term storage. Such bread products are stable at
freezing
temperatures for at least about 4 months, preferably at least about 12 months.
[0068] If desired, the bread product may be provided with one or more toppings
thereon.
Generally, the topping is placed on the top of the flatbread using any
suitable automatic,
semiautomatic, or manual technique. Suitable toppings include, for example,
meats (e.g.,
chicken, turkey, beef, ham, and the like), cheeses, vegetables, tofu, soy, soy
derivatives, and the
like as well as combinations thereof. Such toppings may also include sauces,
dressings, spreads,
gravies, condiments, spices, flavorings, colorants, and the like as well as
combinations thereof.
Preferably, meat and/or vegetables in the topping are in the form of lumps or
diced shapes
(generally less than about 2 inches in the longest dimension).
[0069] The meat may be in a shaved, sliced, shredded, chopped, or other
convenient form.
The type of meat that may be used is not particularly limited. The meat may be
beef (e.g., roast
beef, barbecued beef, steak, hamburger, etc.); poultry (e.g., chicken breast,
barbecued chicken,
turkey breast, turkey burger, chicken salad, etc.); pork (e.g., ham, barbecued
pork, ham salad,
etc.); and fish (e.g., tuna, tuna salad, lox, etc.). The meat topping also may
be processed meats
like bacon, sausage, bologna, olive loaf, pepperoni, salami, corned beef,
pastrami, liverwurst,
and so forth. Combinations of such meat products may be used if desired. Soy
or soy derivative
meat substitutes may be used as a protein source in combination with the meat
filling, or
altematively in place thereof in the sandwich filling. The water content and
water activity of the
meat topping may vary greatly depending on the type of meat selected. For
instance, leaner cuts
of meat generally contain less water content than less lean cuts.
[0070] The type of cheese that may be used is not particularly limited. The
cheese may be
in form of shredded, sliced, shaved, flaked, powdered, crumbled, slabbed,
creamed, and so forth;
preferably, the cheese is in the form of cheese shreds. The cheese type, for
example, may be
process cheese, cheddar cheese, Swiss cheese, American cheese, Provolone
cheese, mozzarelta
cheese, Parmesan cheese, blue cheese, Monterey Jack cheese, Romano cheese,
cream cheese,
Havarti cheese, Gouda cheese, Muenster cheese, Asiago cheese, feta cheese,
Gorgonzola cheese,
and combinations thereof. Of course, other cheeses may be used if desired.
19
CA 02678312 2009-09-04
[00711 Vegetables suitable for use in the filling include, for example,
onions, tomato,
peppers, garlic, bean sprouts, cucumber, zucchini, potato, kale, basil, and
the like as well as
combinations thereof. Of course, other vegetables may be used if desired.
[0072] Both the bread portion and the topping can be seasoned, such as with
salt, pepper,
oregano, hot pepper flakes or spreads, onion powder, garlic powder, sesame
seeds, poppy.seeds,
cinnamon, and the like as well as combinations thereof. Food additives, such
as preservatives,
flavorings, colors, emulsifiers, soy flour, and so forth, also can be included
in or applied to the
dough and/or topping.
[0073] All or some of the ingredients in the topping may be premixed if
desired;
altematively, all or some of the ingredients may be individually placed on the
bread product. All
or some of the ingredients in the topping may be frozen or thawed when placed
on the bread
product. Indeed the entire topping may be prepared and then frozen into the
appropriate size and
shape (i.e., puck or other shape) and then placed frozen on the bread product.
The bread product
may also be pre-ffozen. The bread product may be frozen before or after the
addition of
toppings, if used. Conventional freezing techniques are used to freeze the
bread product.
[0074] The assembled bread product is packaged, preferably using modified
atmosphere
techniques, frozen (if not already frozen), and then stored under suitable
conditions. Susceptors,
if used, may be included in the same package as the assembled bread product or
may be
separately contained in the kit. In one aspect, the bread product is provided
as a fully assembled
flatbread with toppings thereon and contained in a package that can be opened
and then heated
directly in a microwave oven or conventional oven.
[0075] Alternatively, the frozen bread product and toppings can be provided in
a single
serve package having separate compartments or pouches for the frozen bread
product and
various toppings. The pouches preferably are sealed under an inert atmosphere
to increase the
shelf life of the product or kit.
[0076] Frozen bread products may be cooked in a microwave oven or conventional
oven.
Generally, the bread products can be microwaved from the frozen state (without
thawing) for
about 2 minutes, 45 seconds at full power on a susceptor in an 1100 watt
microwave or in a
conventional oven for about 13 to 15 minutes at about 400 to about 450 F if
the product is
topped or for about 10 minutes if untopped. As one of ordinary skill in the
art will readily
CA 02678312 2009-09-04
recognize, the precise cooking conditions will vary depending on the type of
oven used and the
type of bread product being made.
[00771 As noted, the package containing the bread product preferably includes
one or more
microwave susceptors to assist in the microwave heating; in such case, the
opened package containing the fully assembled food product and microwave
susceptor(s) are directly placed in
the microwave oven. Alternatively, separate microwave susceptors can be
included in the
package; in such case, the bread product is then placed on the susceptor and
the combination
placed in the microwave oven for heating. Preferably, the frozen bread product
is supplied with
an appropriately sized and.shaped susceptor to assist in the microwave heating
process. Various
types and forms of susceptors are known in the art and can be provided for use
with the bread
products described herein. For example, the susceptor may be a film having a
layer of metal
deposited thereon. In addition, the susceptor may have different thicknesses
to assist in
concentrating heat energy at select portions of the fully assembled food
product. The susceptor
may be an integral part of the packaging of the frozen bread product or may be
a separate
componerit upon which the frozen bread product is placed before microwave
heating.
[00781 Particularly preferred susceptors are described in greater detail
herein. The use of
the microwave susceptors described herein provides a bread product having a
crispy outer layer
while the remainder of the bread product has a soft, airy texture. During
microwave heating, the
susceptor positioned on the tray assists in regulating the moisture content of
the flatbread such
that the bottom surface has less moisture than the soft, airy center.
[0079] Raised platforms having susceptor material for micro-wave cooking of a
foldable
food product and methods of use are described herein and illustrated in FIGS.
4-10. The raised
platform has legs that extend to elevate a food product support surface having
the susceptor
material, and thus the food product, above the floor of the microwave dtiring
the cooking cycle to
provide more even microwave cooking. The susceptor material is disposed on the
raised
platform in a configuration facilitating folding of the cooked food product
with reduced cracking
or breaking.
[00801 The raised platforrn 10 has a food product surface 12 for supporting a
food product
14 at least partially on a susceptor surface 16. The susceptor surface 16
provides for conductive
heating of portions of the bread product 14 in contact therewith. After
cooking, the surface 12
21
CA 02678312 2009-09-04
may be folded about a fold region 18 which is free from susceptor material. A
fold zone of the
food product immediately adjacent to the fold region 18 of the food product
surface 12 does not
experience the same degree of conductive heating and thus is more flexible.
This facilitates
folding of the bread product about the fold zone with the end result being
less cracking or
breaking of the food product in the fold zone.
10081] The food product surface 12 includes depending legs 20 to support the
food product
surface 12 in an elevated position, such as above the floor of a microwave
oven. The legs 20
depend from a periphery 22 of the food product surface, as il lu$trated in
FIG. 4. The legs 20
may be a series of segments that form a continuous sidewal124 that extending
partially or
completely around the periphery 22 of the food product surface. In the
illustrated example of a
generally rectangular food product surface 12 having outer periphery edges 47,
a first segment
28 may extend and connect to an adjacent second segment 30 which connects to
an adjacent third
segment 32 which connects to an adjacent fourth segment 34 to form the
sidewall 24. Each
segment has a longitudinal edge 31 connected to the food product support
surface and a pair of
transverse edges 33, each of which is attached to the adjacent segment to form
a corner 36.
[0082] The food product surface 12 includes areas of susceptor material 46 on
both sides of
an area free of susceptor material 48. The area free of susceptor material 48
coincides with the
fold region 18 which bisects the food product surface 12. The fold region 18
may extend from
an edge 50 to an opposite edge 52 of the food product surface 12. In the
example of FIG. 4, the
fold region 18 extends from a corner region 66 to an opposite coraer region 68
along a diagonal
70 of the food product surface 12. The fold region 18 includes a fold line or
area, preferably but
not necessarily weakened line 40, extending parallel to an outer edge 55 and
opposite outer edge
57 of the fold region 18 and at least along a substantial length of the fold
region 18 sufficient to
facilitate folding. The weakened line 40 may extend within the fold region 18
in the area free
from susceptor material 48 at a location spaced an equal distance away on both
sides from the
area containing susceptor material 46. By free of susceptor material, what is
meant is that this
region will have less conductive heating than the adjacent portions having the
susceptor material
46. This includes a region entirely free of susceptor material, as well as a
region that has less
than the adjacent susceptor material 46. The objective is to crisp the fold
zone of the food
product to a lesser degree than the adjacent portions of the food product. The
weakened line 40
may include perforations 44, or creases, scores or other areas of weakness
that facilitate the
22
CA 02678312 2009-09-04
folding of the food product surface 12 about the fold region 18. The fold
region of the food
product surface may altematively include at least two weakened lines that
extend parallel to one
another and extend the length of the fold region. The two weakened lines may
include
perforations, or a crease, scores, or other areas of weakness that facilitate
folding along the
weakened lines. Folding along the at least two weakened lines can allow the
food product
surface to fold a thicker food product that is ih contact with the food
product surface.
Furthermore, there can be a pair of spaced apart susceptor free zones on the
food product surface
with susceptor material therebetween, each having its own fold line of
weakness.
[0083] The food product surface 12 can be used to fold the food product 14
thereon by
moving the surface 12 from an initial open position, suitable for cooking; to
a folded position;
and back to the initial open position, leaving the folded food product on one
half of the surface
12. In FIG. 6A, a first portion 74 and a second portion 76 ofthe food product
surface 12 are
separated by the weakened line 40 and the food product 14 rests on both the
first portion 74 and
the second portion 76 of the food product surface 12. In FIG. 6B and FIG. 6C,
the first portion
74 contacts a portion of the food product 15 and can be folded about the
weakened line 40 into
close proximity with the second portion 76, which causes the portion of the
food product 15 to
move and position the food product 14 into a folded position. If necessary,
and depending on the
thickness of the food product 14, the first portion 74 may be folded to a
position nearly parallel
to the second portion 76 to position the food product 14 in the folded
position. As illustrated in
FIG. 6D, the first portion 74 of the food product surface is folded back to
its initial position and
the food product 14 is left in the folded position.
[0084] The continuous sidewall 24 is initially configured to provide stability
to the food
product surface 12 during cooking and to prevent folding of the food product
surface 12. This
permits the food product surface 12 to support the food product 14 in an
elevated position while
cooking and handling during removal from the microwave oven following
cooking,without
collapsing under the weight of the food product 14 resting thereon. After
cooking is completed,
the food product surface 12 may be configured to permit folding by breaking
portions of the
sidewall 24. In one configuration, the corners adjacent a diagonally extending
line of weakness
may be removed, as illustrated in FIG. 9B. In another configuration, suitable
for both diagonally
extending and side-to-side lines of weakness, the adjacent portions of the
sidewall may be
broken, as illustrated in FIG. 9C. Furthermore, these two configurations can
be combined in one
23
CA 02678312 2009-09-04
raised platform 10, as illustrated in FIG. 9A. While these two eonfigurations
are discussed
herein with reference to being combined, they could also be provided
separately.
[00851 One way of breaking the sidewall 24 to permit folding of the food
product surface 12
along its weakened fold line 40 is to separate the sidewall 24 along a pair of
weakened lines 38
formed therein and aligned with the weakened fold line 40, as illustrated in
FIGS. 9A and 9C. In
the illustrated example having a diagonally-extending weakened fold line 40,
the weakened lines
38 are positioned in the sidewal124 adjacent each comer adjacent to each end
of the weakened
fold line 40. The weakened lines 38 may contain perforations 44, or creases,
scores, or other
areas of weakness that will allow breaking or tearing of the weakened line 38
in order to permit
the sidewall 24 to be broken into two or more portions, which in tum permits
folding of the food
product surface 12 along its weakened fold line 40.
[0086] Another way of breaking the sidewall 24 to permit folding of the food
product
support surface 12 along its weakened fold line 40 is to remove the comer
regions adjacent each
end of the diagonally-extending weakened fold line 40. The corner regions are
initially joined
to the remainder of the raised platform 10 via a weakened corner line 42,
which may contain
perforations 44, or creases, scores, or other areas of weakness that will
enable a user to break the
weakened line 42. More specifically, the weakened corner line 42 includes
surface line 118
extending between periphery edges of the food product surface 12 and generally
orthogonal
relative to the weakened fold line 40. An aligned weakened sidewall line 116
extends in one of
the sidewall segments 28 from the surface line 118 at the periphery edge of
the food product
support surface 12 to the opposite longitudinal edge of the segment 28.
Although not required,
the weakened sidewall line 116 may extend at an inclined angle away from the
comer 36. A
similar weakened sidewall line 120 is located in the adjacent segment 34. This
same structure of
the weakened comer line 42 is also at the opposite corner at the opposite end
of the diagonally-
extending weakened fold line 40. Removal of the comer regions along the
weakened corner
lines 42 permits the sidewall 24 to be broken into two or more portions, which
in turn allows the
food product surface 12 to be folded along its weakened fold line 40.
[0087] Handling features may optionally be associated with the food product
surface 12 to
allow a user to fold the food product surface 12, and the food product 14
thereon after cooking
without contacting the susceptor material 46. For instance, the food product
surface may include
24
CA 02678312 2009-09-04
susceptor free areas 98 that an individual can grasp to fold the food product
surface 12, as well as
any food product thereon. The susceptor free areas 98 may be located at corner
regions of the
food product surface 12 and at a position spaced from the fold region 18 by
the susceptor
material 46. The susceptor free areas 98 may be generally triangular in shape
with a first side
bordering a portion of a first outer periphery edge 124 and a second side
bordering a portion of a
second outer periphery edge 126 of the food product surface 12 and a third
side 128 bordering
the susceptor materia146. The individual may grasp at least one of the
susceptor free areas 98 to
fold the food product surface 12 about the weakened line 40. By not having
susceptor material
in the susceptor free areas 98, those areas 98 will not be as hot as other
areas along susceptor
material following microwave heating.
[0088] Additionally, portions of the sidewall 24 in FIGS. 7-8 may extend
outward to allow
an individual to grasp and fold the food product surface 12 without contacting
the suscepter
material 46. A flat portion 102 may be disposed on a segment 26 and include a
series of
connected weakened lines 104 or, alternatively, die cuts that require no or
minimal breaking.
The weakened lines 104 may include perforations 44, or creases, scores, or
other areas of
weakness that allow the weakened lines 104 to be folded or broken apart. The
weakened lines
104 may be broken apart and folded such that an individual can grasp the flat
portion 102 as a
handle 106 to fold the food product surface 12. Specifically, the weakened
lines 104 may
include transverse line 108, opposite transverse line 110, a top line 112, and
bottom line 114.
Transverse line 108 and opposite transverse line 110 may be located on the
segment 26 and
extend in a direction that is generally transverse to the longitudinal edge 31
of the segment. Top
line 112 and bottom line 114 may be located on the segment 26 and extend in a
direction that is
generally parallel to one another as well as the longitudinal edge 31 of the
segment. In one
example, transverse line 108, opposite transverse line 110, and the bottom
line 114 in FIGS. 8A-
8B are broken and separated so as to detach a section of the flat portion 102
from the segment
26. The top line 112 may remain attached and connected to the segment 26. The
flat portion
102 is then folded about the top line 112 until the flat portion 102 extends
outwardly from the
segment 26 to a position generally parallel to the food product surface 12.
Preferably, an
opposite segment or adjacent segment will contain a similar flat portion
capable of being folded
outward from the segment and used as a handle 106. This enables the individual
to grasp the
handles and fold the food product surface 12 without contacting the susceptor
material 46.
CA 02678312 2009-09-04
[0089] Tuming to one example of the construction of the raised platform 10,
opposite
segments 30 and 34 each have flaps 37 and 39, respectively, at each of their
transverse edges 33
that can be folded and adhered to inner surfaces of the other segments 28 and
32. Specifically,
the second segment 30 has a pair of flaps 37 at each transverse edge 33. Both
of the flaps 37 are
folded inwardly, and one is adhered or otherwise affixed to the inner surface
of the first segment
28 and the other is likewise adhered or otherwise affixed to the inner surface
of the third segment
32. The fourth segment 34 has a pair of flaps 39 at each transverse edge 33.
Both of the flaps 39
are folded inwardly, and one is adhered or otherwise affixed to ihe'inner
surface of the first
segment 28 and the other is likewise adhered or otherwise affixed to the inner
surface of the third
segment 32, at opposite end portions from where the flaps 37 are attached.
[0090] Vents may be disposed at locations throughout the food product surface
12 to
provide air flow and allow moisture to vent during microwaving and to provide
the optimal
environment for cooking and heating of the food product 14. Some of the vents
may be disposed
on the area free of susceptor material 48. Vents 60 in FIG. 4 and FIG. 5 may
be generally
circular and of varying sizes and may be disposed within the fold region 18.
The vents 60 may
be positioned towards the center of the fold region 18 and may be equally
spaced on each side
from the susceptor material 46. Moreover, susceptor vents 62 and slit vents 64
may be disposed
on the susceptor material 46. Susceptor vents 62 are generally circular and
may be positioned
toward the outer periphery edge 47 of the food product surface. Slit vents 64
are generally
rectangular and may form narrow slits that ext end parallel to the fold region
18. Other vent
patterns and shapes can be equally suitable.
[0091] The food product surface 12 is configured to be used for cooking and
then folding of
a food product 14 by folding the food product about a flexible fold zone
located on the food
product. In one example, the user may place the food product 14 on the food
product surface 12
of the raised platform 10 and place the platform 10 vvith the food product 14
thereon in a
microwave oven for heating or cooking. The food product 14 is crisped or
browned in response
to the heating or cooking in the microwave oven in areas that are in contact
with the susceptor
material disposed on the food product surface 12. However, the food product 14
is not crisped or
browned in area's where it is not in contact with the susceptor material 46.
In one example, the
food product surface 12 includes an area free from susceptor material along a
fold region 18 that
allows the food product 14 to experience a lesser degree of conductive heating
within a fold zone
26
CA 02678312 2009-09-04
of the food product 14 and therefore more flexible for folding along the fold
zone. After
cooking, the user may remove the raised platform 10 and the food product 14
from the
microwave oven. The user may break weakened lines 38 disposed on the legs 20
and separate
adjacent segments of the sidewall to allow the folding of the food product
surface 12 and the
food product 14. Alternatively, the user may break the weakened corner line 42
to remove the
corners which extend at the opposite edges of the fold region 1 S. This
configuration allows the
food product surface 12, and the food product 14, thereon to be folded.
Handling features are
provided that allow the user to fold the food product surface 12 and the food
product 14 without
contacting the susceptor material. In one example, optional susceptor free
corners are available
for the user to grasp to fold the food product surface 12 and the food product
14. In addition or
in the alternative, a user may grasp optional handles that extend outwardly
from a flat portion
located on the sidewall segments to fold the food product surface 12 and the
food product 14.
The user may grasp these handling features to fold the food product surface 12
and the food
product 14 and position the food product 14 in a folded position, such as
illustrated in FIG. 7.
[0092] In one example of a raised platform 10, the food product surface 12 may
be generally
rectangular and about 6.5 -inches long by about 6.5 inches wide, and the legs
20 may have a
height of about 1 inch. By way of example, food products that can be cooked
using the raised
platfonn 10 include a flat-bread product, pizza crust, pita bread, naan, gyro,
taco, and the like,
having a bread or dough formulated bottom with toppings thereon. The susceptor
material 46
can provide browning or crisping of the bottom of the food product during
microwave heating,
with the exception discussed herein of the fold zone. After heating, the food
product surface 12
can be folded to fold the food product and place the toppings on top of each
other.
[0093] Although preferred packaging and/or cooking arrangements are described
in detail
above (as well as in the related provisional application incorporated by
reference above), those
skilled the art will realize that many different packaging and/or cooking
arrangements can be
used.
[0094] The examples that follow are intended to illustrate the invention and
not to limit it.
All percentages used herein are by weight unless otherwise indicated. All
patents, patent
applications, and literature references cited herein are hereby incorporated
by reference in their
entirety.
27
CA 02678312 2009-09-04
EXAMPLES
[0095j Example 1. This example demonstrates a quantitative difference in the
crispness of
the top and bottom of a flatbread product made with dough incorporating fat
chips and wheat
protein isolate in accordance with the invention in comparison with Lean
Cuisine'sQD Flatbread
Melts.
[0096] Inventive Flatbread. Inventive flatbreads were prepared according to
the following
method. The ingredierits listed below in Table 2, excluding the fat chips,
were combined and
mixed at about 30-50 rpm in a horizontal mixture until the ingredients were
blended
(approximately 1 minute). The dough was then mixed at about 70-100 rpm for
about 6 minutes
and tested for development (i.e., viscoelasticity). Then the fat chips were
added and the dough
was mixed for an additional 1 minute at 70-100 rpm; it was necessary to reduce
the dough
temperature to about 65-70 P to prevent melting of the fat chips during
mixing. Although this
reduction of the dough temperature allowed this softer fat chip to be used,
harder fat chips are
preferable used (see Example 2 below).
[0097] The dough was then rested for about 10 minutes while covered. Then the
dough was
sheeted using a conventional sheeting line and then cut to squares of about 85
to 91 grams. After
proofing for 24 minutes at 80 F and 25% relative humidity, the dough was
pressed using die for
about 5 seconds (bottom temperature of about 400 F). The pressed dough was
then depanned
and baked in a dual zone oven (zone 2 at about 660 F and zone at about 600
F) with a dwell
time of about 70 to 75 seconds. The baked dough was then frozen. A topping
containing honey
mustard sauce, chicken, bacon, tomato, Monterey jack cheese, and mozzarella
cheese was then
added and the completed product was frozen. The bread was about 1/4 to 3/8
inches thick and
the topping ranged from about 1/4 to 1/2 inch thick.
28
CA 02678312 2009-09-04
Table 2.
In ient Amount (% Aonr bas4
Wheat flour 100
Conpressed east 2.5
Salt 1.5
Su 1.0
Wheat protein isolate (Arise 5000) from MGP 0.20
In ients
Vital wheat luten 2.0
Water 58
Corn oil 4.0
Fat chips (Palm chips from Golden Brand 7.0
[0098] Twenty inventive flatbreads with toppings were prepared as described
above. Ten of
the samples were and used to test the texture of the top of the flatbread
(e.g., the side of the
flathread from which the food toppings were removed) and ten were used to test
the texture of
the bottom of the flatbread (e.g., the side of the flatbread against the
susceptor). Six
measurements were performed per sample using a calibrated TA-XT2 Texture
Analyzer from
Texture Technologies Corp., Westchester County, NY, equipped with a 2 mm
probe.
[0099] As shown in FIG. 10, a six by six inch transparent template was used to
replicate
testing .positions across all tests. The numbers on the template represent the
number and order of
the tests. Test positions 1, 3, 5, and 6 are inset 1 inch from the conmer of
the template and 2.75
inches from the center of the template. Test positions 2 and 4 are inset 2
inches from the
respective nearest conrners and 1.18 inches from the center of the template.
[00100] The tests were conducted by laying the template on top of the
flatbread and aligning
the hole of the template with the position of the probe. The peak force of
compnession was
recorded at the point when the probe punetures the surface of the flatbread
(typically the first
peak on the graph).
[00101] The flatbread was microwaved from frozen state (e.g., without prior
thawing) for 2
minutes, 45 seconds using on a tray having a susceptor surface in a 1100 watt
microwave. The
flatbread and susceptor was then removed from the microwave and placed on the
countertop
without removing the susceptor.. A rubber spatula was used to remove the
toppings from the
surface of the flatbread.
29
CA 02678312 2009-09-04
[001021 The flatbread was then removed from the susceptor and placed on the
stage of the
texture analyzer with either the top or bottom of the flathread facing up. The
template was then
placed on the surface of the flatbread; one of the test positions indicated by
the template was
aligned with the texture probe. The compression force was then measured using
the texture
analyzer (pretest speed: 1.0 mm/sec; test speed: 1.7 mm/sec; post test speed:
10 mm/sec;
distance: 70% of measure; and load cell: 5 kg). The flatbread was then
repositioned so that all
test positions were measured in turn; all measurements were made within 5
minutes of removing
the flatbread from the microwave.
[00103) Comparison Product: Lean CuisinO Flatbread Melt. A commercially
available
"Chicken Ranch Club" flatbread melt from Lean Cuisine was used for comparison
purposes.
The crust was about 0.25 inch thick and the topping was about 1/8 to 1/4 inch
thick, depending
on the location of measurement. The product was circular with about a 6 to
6.25 inch diameter.
The topping included chicken, tomato, bacon, cheddar, mozzarella, and ninch
sauce. The
product was cooked in a similar microwave oven as above according to the
cooking instructions
printed on the packaging and then prepared for testing as above.
[001041 A 6.5 inch diameter transparent template (see FIG. 11) was used to
determine testing
positions across all tests. The numbers on the template represent the number
and order of the
tests. All test locations were 2.36 inches from the center of the template and
about 1 inch from
the perimeter of the plate. Tests were carried out in the same manner as
described above.
[00105] The results obtained from positions 2 and 4 of the inventive flatbread
differed
considerably from the positions closer to the edge of the flatbread; this is
thought to occur
because the bread at positions 1, 3, 5, and 6 had considerably more brown
spots than at positions
2 and 4. The averages for the inventive flatbread were compiled from a total
of 40 replicated
tests per location. The averages for the Lean Cuisine Flatbread Melts were
compiled from a
total of 12 replicated tests per location.
(00106] The average results of the tests are provided in the table below and
in FIG. 12:
Product - Test Average Force (g) Standard Deviation Change trom
To ottom
Inventive flatbread Bottom surface 541.48 310.212
Top surface 153.24 163.89 388.24
Lean Cliisine Bottom surface 99.11 31.88
ttatbrcad To surface 50,56 11.33 48.55
CA 02678312 2009-09-04
[00107] The texture analyzer results indicate a significant and
distinguishable difference in
texture and crispiness between the top and bottom crusts of the inventive
flatbread. The average
change in compression force between the bottom and top of the inventive
flatbread was almost
400 grams. The average change in compression force between the bottom and top
surfaces
provides an indication of the degree of dual texture obtained in the present
invention. Generally,
this average change in compression force between the bottom and top surfaces
for the inventive
product is at least about 100 grams and preferably at least about 200 grams.
[00108] The Lean Cuisinem Flatbread Melts had a much smaller difference in
texture and
crispness for the top and bottom surfaces of was not found. In fact, the
average change in
compression force between top and bottom of the Lean Cuisineo Flatbread Melts
was only about
50 grams.
[00109] The average change in crispiness resulting from the inventive
susceptor technology
and dough formulation resulted was nearly eight times greater than the Lean
Cuisinem Flatbread
Melt.
[00110] Example 2. This example illustrates the preparation of flatbread
products using fat
chips from various suppliers. The fat chips varied in both size and finnness.
The resulting
flatbrr.ad products were evaluated for mouthfeel, crispness of the bottom
surface (i.e., the surface
of the flatbread contacting the susceptor during microwave cooking) and
airiness of the
remainder of the flatbread. The flatbread products were prepared according to
Example I with
the exception that the dough temperature was controlled to 70-75 F for butter
chips and 65-70
F for palm chips to prevent melting of the fat chips during mixing. The
results are shown in the
following table.
31
CA 02678312 2009-09-04
~` ... = =g
E
ag
an
v N vf
rt
~ 'O
=~ E E 3114
=
i N C_ v'l r+1 vt
0~'' ~ 2 1 < < f ~ N e'~i
~'S 3
Y v =~'
> w
C6..
~ ~, N d d z ~
w N !- m
oo en
.30 N c v a
ti
'^ a
9 ~ {t
a
ei. U e U e o~ ~ s ~
I
~ U~oo v~ ~ .~U S~ eo
a
r+ N N1 Y1
CA 02678312 2009-09-04
[00111] Samples 1, 2, 3, and 6 provided acceptable results with Sample I being
the best.
These fat chip types have a solid fat content of at least 45 percent at 80 F.
These fat chips also
stay intact after pressing with finger at room temperature. Thus, the fat
chips in these samples,
when incorporated into the dough, desired the desired size. Sample 4 was too
soft and was either
reduced to a smaller than desired size or otherwise damaged during
incorporation. The fat chips
of Sample 5 were too hard, thereby resulting in poor organoleptic properties.
[00112] While the invention has been particularly described with specific
reference to
particular process and product embodiments, it will be appreciated that
various alterations,
modifications, and adaptations may be based on the present disclosure, and are
intended to be
within the spirit and scope of the invention as defined by the following
claims.
33
