Note: Descriptions are shown in the official language in which they were submitted.
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PACKAGE WITH CLOSURE, APERTURE, AND INSERT
Field of the Invention
The invention relates to packages and packaged products wherein a package
includes a closure, an aperture located on the closure, and an insert the
covers the
aperture; the package can be pressurized and certain embodiments can be
designed to
contain a dough product for refrigerated storage.
Background
Packages for commercial and consumer items come in countless varieties. Basic
package functions can be to contain a product for sale, storage, or transport,
and
sometimes to describe or display the product and contents. Some package
designs can
also be useful beyond these basic functions. Some types of consumer packages
are
designed to preserve freshness of a product (a food or a non-food product) for
an
extended period of weeks or months, to allow for easy access to the product
(easy
opening), and may allow viewing of a product within the package. Some products
undergo manufacturing or processing steps within the package, such as dough
that can
expand or "proof' within a package. In these and other ways, a product package
can go
well beyond merely containing a product for sale.
Products contained by commercial and consumer packages include food and non-
food products. Food products include dough products, sometimes packaged in a
manner
to allow storage stability and convenience to a purchaser, e.g., ease of use
of the product.
A wide variety of packaged dough products allow a user to "home bake" a dough
to
produce a desirable hot, fresh-baked item. Many such items are proofed prior
to baking,
and for consumer convenience may be partially or fully proofed prior to
purchase and
prior to use by the consumer. Such products, sold after proofing or partial
proofing, are
examples of products referred to as "pre-proofed." Examples of pre-proofed or
partially
proofed dough products include breads and bread-like products that generally
contain a
leavening ingredient and include but are not limited to loaves of bread such
as French
bread, white or whole wheat bread, bread sticks, biscuits, rolls, pizza dough,
and the like.
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Such products include dough formulations that can be, but are not necessarily,
chemically-leavenable.
Various commercial dough products, including pre-proofed or partially proofed
dough products, are sold in pressurized containers, which have a positive
internal
pressure, i.e., an internal pressure that is greater than atmospheric. One
technique for
preparing a pre-proofed dough product in a pressurized package is by placing
an
unproofed dough in a package having a fixed volume and allowing the dough to
proof
and expand within the package. Such packages are sometimes referred to as self-
sealing
packages, and include an interior space that is vented to the outside of the
package to
allow gas to be removed from the interior space by expansion of dough in the
interior
space, followed by the vent being sealed from the interior side of the package
by the
expanded dough. More specifically, after being placed in the package, the
dough
composition produces carbon dioxide and expands inside of the package. The
expanding
dough will replace gas from the space inside of the package; the gas expels
through a
vent and the expanded dough seals the vent from the inside of the package. The
dough
can continue to produce carbon dioxide and produce an internal pressure inside
the
package.
Self-sealing packages sometimes used to contain raw dough can be in the form
of
a canister formed of composite paperboard spirally wound into a cylinder. The
initial
volume of dough packed into the canister is usually less than the canister
volume and as
the dough expands by proofing within the canister, the dough volume increases
to force
the dough to expel gas from the canister, eventually causing the dough to
contact interior
surfaces of the canister as well as channels, passages, or other openings
(e.g., valves,
near ends of the container); the dough contacts the channels, passages, or
openings, to
seal the canister from the interior side.
There is continuing need for new types of packaged pre-proofed dough products
that may be refrigerator stable. Similarly, there is continuing need for new
methods of
packaging and preparing such packaged dough products.
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Summary
The described packages can be used to contain any product or material desired,
including food and non-food items. This description relates in large part to
applications
for food, in particular dough products, but other food and non-food items may
also be
contained and stored in the described packages. Other non-limiting examples of
types of
food items may include nuts (e.g., peanuts), baby food, snack foods, coffee,
milk
powders and mixes, sugar, sugar substitutes, or other foods typically sold in
small
packages and optionally under pressure.
Examples of packages as described include those having a container that
defines
an interior space, wherein the container includes an opening, and the package
includes a
closure that covers the opening. The closure includes an aperture, and an
insert covers
that aperture. Optionally the insert can be transparent to allow viewing of
the contents of
the package. Also optionally, a package can include a pressurized interior,
meaning that
the pressure at the interior is greater than ambient pressure. The insert can
be made of a
metal or a non-metal material, preferably a non-metal material such as
plastic, paper,
cardboard etc. A two-piece closure that includes a metal piece with an
aperture, and a
non-metal insert to cover the aperture, can advantageously result in reduced
cost relative
to an all-metal closure, because the non-metal insert can be less expensive
compared to
amount of metal that the non-metal insert displaces. Packages according to
the
invention can optionally and preferably be vented to allow gas contained in an
interior
space of a package to be expelled from the interior of the package to the
exterior, such as
upon expansion of a dough composition within the package. With the expansion
of a
dough composition within the package, the size (volume) of the dough can
increase to
fill the internal package volume, displacing gas at the interior of the
unfilled package.
The dough, once expanded, can then contact a vent from the interior side of
the package,
causing the dough to cover, close, or otherwise seal the vent from inside of
the package
and prevent further passage of gas through the vent in either direction. Any
further
proofing and expansion of the dough (such as due to production of carbon
dioxide within
the dough by yeast or chemical leavening agents) will cause the dough to
further
pressurize the interior of the package. A vent can be any form of vent
(including a valve)
at any location. Embodiments of vents include those in the form of a passage
(e.g.,
channel, opening, aperture, etc.) located between a cover (e.g., closure) and
a sidewall of
a package, or located between a closure and an insert.
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In other embodiments, the invention also relates to methods of preparing a
package, a packaged food or non-food item, or a packaged dough product.
Methods
include preparing a package structure as described, including a closure and an
insert,
placing a food (e.g., dough) or non-food item into the package and closing the
package.
If the item is dough, the dough can be allowed to expand within the package.
The
package with the contained item can be stored at any desired condition, such
as at
refrigerated storage conditions.
Examples of packages can include components of previous and conventional
packages, such as conventional pressurized wound cardboard-type cans used to
contain
dough products, plastic packages that may be wound or extruded, metal packages
that
may be wound or extruded, etc. An example of a package that includes features
of such
a conventional package may include a wound cardboard hollow container, metal
endcaps
(closures), with the endcaps including an aperture and an insert as described
herein; the
package may be vented at a joint between the endcap and the sidewall, at a
location (area
of contact) between the closure (near the closure aperture) and the insert, or
elsewhere.
In alternate embodiments, particularly embodiments that place a vent at a
location between the closure aperture and the insert, a container may include
a hollow
container that is not of wound cardboard. Sidewalls may be made, for example,
of
plastic or metal that may be formed by any method, such as by extrusion
methods.
According to certain such embodiments, a package interior can be maintained at
a
relatively low pressure (e.g., below 5, 10, or 15 psig), allowing the
sidewalls to be of a
relatively reduced thickness compared to similar containers having greater
pressures.
The invention furthermore relates to methods of preparing a package from
materials that include a closure material. Certain methods involve steps of
making
multiple closures from a single piece of closure material by making a first
closure that
contains an aperture, wherein the first closure is prepared by removing a
portion of the
closure material to form a aperture. The removed portion of closure material
can then be
used to make a second closure of a dimension smaller than the dimension of the
first
closure. Optionally, a portion of closure material from the second closure can
be
removed to form a closure aperture in the second closure. That portion of
closure
material, in turn, can be used to prepare another (third) closure of a
dimension smaller
than the second closure, optionally having still another aperture. Generally,
according to
this method, a portion of closure material removed to produce a closure
aperture can be
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used to make another closure having a dimension smaller than the original
closure and
not larger than the aperture of the original closure.
In one aspect, the invention relates to a package capable of being pressurized
internally to above atmospheric pressure. The package includes: an interior
space
defined by a hollow container having sidewalls and an opening at an end of the
sidewalls; and a closure at the opening. The closure includes a perimeter that
engages
the end of the sidewalls, a surface extending between locations of the
perimeter, an
aperture in the surface, and an insert that covers the aperture.
In another aspect, the invention relates to a method of preparing a
pressurized
packaged dough product. The method includes: providing a package according to
the
description, placing dough in the interior space, placing the closure at an
end opening,
and allowing the dough to expand within the interior space such that gas vents
from the
interior space and expanded dough seals the container.
In another aspect the invention relates to a packaged dough product that
includes
dough in a self-sealed, pressurized dough package. The dough product includes:
a
package having an interior space defined by a hollow container having
sidewalls, an
opening at an end of the sidewalls, and a vent; a dough product within the
interior space;
and a closure at the opening, the closure comprising an aperture that allows
viewing of
the dough product in the interior space. The package is pressurized and the
vent is sealed
by expanded dough in the interior space.
In another aspect the invention relates to a method of preparing a pressurized
packaged dough product. The method includes: providing a hollow container
comprising an interior space, the container having sidewalls and an opening at
the end of
the sidewalls; placing dough in the interior space; placing a closure at an
opening, the
closure comprising a perimeter that engages the end of the sidewalls, an
aperture at a
location inside of the perimeter, and an insert that covers the aperture; and
allowing the
dough to expand within the interior space such that gas vents from the
container and
expanded dough seals the container.
In yet another aspect the invention relates to a method of preparing a
pressurized
packaged dough product. The method includes: providing a hollow container
comprising an interior space, the container having sidewalls and an opening at
an end of
the sidewalls; placing dough in the interior space; providing a first closure
having a
perimeter that engages the end of the sidewalls and a surface extending
between
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locations of the perimeter; removing a second closure from the surface of the
first closure to
form an aperture at the surface; providing an insert; placing dough in the
interior space;
placing the first closure at the end opening; placing the insert to cover the
aperture; and
allowing the dough to expand in the interior space such that gas is vented
from the container
and expanded dough seals a vent.
According to an embodiment, there is provided a package capable of being
pressurized internally to above atmospheric pressure, the package comprising
an interior
space defined by a hollow container having at least one sidewall and an
opening at an end of
the at least one sidewall, and a closure at the opening, the closure
comprising a perimeter that
engages the end of the at least one sidewall, an interior surface extending
between locations of
the perimeter on an interior side of the closure, an aperture in the interior
surface, an insert on
the interior side of the closure extending across and covering the aperture on
the interior side
of the closure, said insert being engaged with the closure in a plurality of
spaced locations,
and a vent created between the plurality of spaced locations to allow fluid to
pass from the
interior space to an exterior of the package through the aperture, and wherein
a perimeter of
the insert is smaller than a perimeter that engages the end of the at least
one sidewall, wherein
the package comprises a raw dough in the interior space, and the vent is
sealed by the dough
contacting the vent from within the interior space.
According to another embodiment, there is provided a method of preparing a
pressurized packaged dough product, the method comprising providing a package
as
described herein, placing dough in the interior space, placing the closure at
an end opening,
and allowing the dough to expand within the interior space such that gas vents
from the
interior space and expanded dough seals the container.
According to another embodiment, there is provided a packaged dough product
comprising dough in a self-sealed, pressurized dough package, the product
comprising a
package comprising an interior space defined by a hollow container having at
least one
sidewall, an opening at an end of the at least one sidewall, a closure at the
opening, an insert
on an interior side of the closure extending across and covering an aperture
on the interior side
of the closure, said insert being engaged with the closure in a plurality of
spaced locations,
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and a vent created between the plurality of spaced locations to allow fluid to
pass from the
interior space to an exterior of the package through the aperture, and wherein
a perimeter of
the insert is smaller than a perimeter that engages the end of the at least
one sidewall, a dough
product within the interior space, the closure comprising an aperture that
allows viewing of
the dough product in the interior space, wherein the package is pressurized
and the vent is
sealed by expanded dough in the interior space.
According to another embodiment, there is provided a method of preparing a
pressurized packaged dough product, the method comprising providing a hollow
container
comprising an interior space, the container having at least one sidewall and
an opening at the
end of the at least one sidewall, placing dough in the interior space, placing
a closure at the
opening, the closure comprising a perimeter that engages the end of the at
least one sidewall,
an aperture at a location inside of the perimeter, and an insert extending
across and covering
the aperture, said insert being engaged with the closure in a plurality of
spaced locations,
allowing the dough to expand within the interior space, such that gas vents
from the container
through a vent created between the plurality of spaced locations from the
interior space to an
exterior of the package through the aperture, and wherein a perimeter of the
insert is smaller
than a perimeter that engages end of the at least one sidewall and expanded
dough seals the
container.
According to another embodiment, there is provided a method of preparing a
pressurized packaged dough product, the method comprising providing a hollow
container
comprising an interior space, the container having sidewalls and an opening at
an end of the
sidewalls, placing dough in the interior space, providing a first closure
comprising a perimeter
that engages the end of the sidewalls and a surface extending between
locations of the
perimeter on an interior side of the first closure, removing a second closure
from the surface
of the first closure to form an aperture at the surface, providing an insert,
placing dough in the
interior space, placing the first closure at the end opening, placing the
insert on the interior
side of the first closure and extending the insert across the interior side of
the first closure to
cover the aperture, said insert being engaged with the first closure in a
plurality of spaced
locations, and allowing the dough to expand in the interior space such that
gas is vented from
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the container and expanded dough seals a vent created between the plurality of
spaced
locations to allow fluid to pass from the interior space to an exterior of the
package through
the aperture, and wherein a perimeter of the insert is smaller than a
perimeter that engages the
end of the sidewalls.
According to another embodiment, there is provided a packaged dough
composition as described herein, wherein the dough comprises from 30 to 50
weight percent
flour, from 15 to 40 weight percent water, and less than 20 weight percent
fat, based on the
total weight of dough composition.
According to another embodiment, there is provided a package capable of
being pressurized internally to above atmospheric pressure, the package
comprising: an
interior space defined by a hollow container comprising a first end and a
second opposing
end, at least one sidewall extending between the first and second ends, and a
closure adjacent
to at least one of the first and second ends, wherein at least one closure
comprises: a perimeter
that matches a perimeter of the end to which it is adjacent; an inner surface
facing toward the
interior space; an outer surface opposite the inner surface; an aperture
extending through the
closure from the inner surface to the outer surface; an insert covering the
aperture and
adjacent to the inner surface of the closure, said insert being engaged with
the closure in a
plurality of spaced locations; and a vent created between the plurality of
spaced locations to
allow fluid to pass from the interior space to an exterior of the package
through the aperture,
and wherein a perimeter of the insert is smaller than a perimeter that engages
the end of the at
least one sidewall, wherein: the package comprises a raw dough in the interior
space, and the
vent is sealed by the dough contacting the vent from within the interior
space.
Brief Description of the Drawings
Figures 1 A and 1B illustrate embodiments of containers useful in exemplary
embodiments of described packages.
Figures 2A, 2B, 2C, and 2D illustrate embodiments of closures useful in
exemplary embodiments of described packages.
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Figures 3A and 3B illustrate embodiments of closures useful in exemplary
embodiments of described packages.
Figures 4A and 4B illustrate embodiments of described packages.
Figure 5 is a cross-sectional illustration of an embodiment of a package
having
an anaconda fold.
Figure 6 is a cross-sectional illustration of an embodiment of a package
excluding an anaconda fold.
Detailed Description
The invention involves packages that are capable of containing a non-food item
or a food item (e.g., a dough), optionally under pressure. The package
includes an interior
space within a hollow container defined at least in part by a sidewall, and
containing an
opening, e.g., at an end of the sidewall. A closure covers the opening. The
closure includes a
closure aperture (or simply "aperture") that is in turn covered by an insert.
The "insert" may
be placed on either side of the closure to cover the aperture, i.e., either on
an exterior side
(away from the interior space) or on the interior side (the same side as the
interior space), or
may be otherwise placed or incorporated into the closure. Optionally and
preferably a package
can be vented. According to particular embodiments of packages for containing
a dough
product, an optional vent can allow a dough composition to expand within the
interior space,
causing gas to be expelled through the vent, and allowing the expanding dough
to seal the
package from the interior of the package by covering and closing the vent.
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The hollow container can be any hollow container that definer a suitable
interior
space, e.g., suitable for atefrigerated.dough product A hollow container may
be of any
useful material, including a flexible, rigid, or semi-rigid material, e.g.,
capable of
containing a pressurized dough product. Various packaging materials useful for
a hollow
container are known in the food and dough packaging arts, and include metals
(e.g.,
altuninurn, steel, tit' i), cardboard (e.g., wound.eardboatd), paper,
polymeric or,plasrie
materials (e.g., films, which may be wound, extruded as a sheet or tubular or
cylindrical:
container, or otherwise formed into a hollow.container), etc.
Hollow wound paperboard (cardboard, paper, optionally including a barrier
material or metalized layer, etc.) containers are welt known and are
described, for
example, in the following United States Patent documents :
5,084,284; 6,190,485.(see, e.g., Figure 5 and related text of the
6,190,485 patent); 6,234,386; 6,378,763; 6,510,674;
Described in these listed patents, and well known in the art of food and
paperboard packaging, is an optional feature of a wound package seal known as
an
"anaconda fold." An anaconda fold is a fold at tat edge of an inner layer of a
package
material that has been wound into a wound canister. The fold.of the inner
layer is at one
edge of the inner layer, at which a short.(e.g., 0.2 to 1.0 centimeter, such
as from 0.3 to
0.7 centimeter) piece of then inner layeris folded back to meet an underside
surface of
the inner layer, The folded portion is then used. to form a seal with, an
adjacent edge of
the paperboard upon winding. The folded edge is spirallywotmd against an
unfolded
edge, with the fblded edge overlappinga surface of the adjacent unwound edge.
A feature of an anaconda fold can be-an ability of the fold to function as a
channel that can. facilitate venting of a package having this type of fold. It
is believed
that the structure of the fold, winding along the inner suffice of the package
and
teludnating at the two opposed end openings of the tubular canister, creates a
space or
"channel" extending helically along the inner Surface. During expansion of a
dough
product -within the package, the dough can increase -in volume to fill the
interior space
and match the volume of the Interior.. When this happens the dough contacts
and places
internal pressure upon the inner surface.of the container-. which, inhibit
continued passage
of gaseous fluid from locations at the interior of the package, to ends of the
package
where the gaseous 'fluid can be vented, An anaconda fold. atthe inner surface
of the
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package can function as a channel that leads from the interior of the package
to the ends,
to allow venting.
As described in the Background section of U.S. patent 6,190,485, an example of
an anaconda fold structure can be prepared from a wound multi-layer (e.g.,
laminated)
package material that includes a body ply layer and a liner layer (an inner
layer). The
material is wound in a fashion by which the inner liner ply is sealed to
itself along a
helical seam, which is typically slightly offset from the helical seam of the
body ply.
The liner ply seam is formed with an "anaconda" fold, wherein the overlying
edge of the
liner ply is folded back on itself and adhered to the underlying (unfolded)
edge.
According to embodiments of packages as described, a wound package may
include an anaconda fold. Alternately, according to other embodiments, a wound
or
otherwise-formed package may avoid the need for an anaconda fold, and the
package
may exclude an anaconda fold. For example, a wound paperboard (e.g., multi-
layer
laminated fibrous package material) package can be wound and sealed without
the
presence of an anaconda fold; an inner liner may be sealed to itself without a
folded
edge. Alternately, a wound package may be made of wound plastic or other
material that
includes a helical seal that excludes an anaconda fold structure.
Figure 5 shows an example of a helically-wound package as described herein,
including an anaconda fold. Package 100 includes multi-layer package material
102,
which includes paperboard layer 104 and inner (e.g., liner) layer 106. A
helical seal
includes un-folded edges of paperboard 104 abutted at seam 110. Inner layer
106 is
folded at seam 108 to include an anaconda fold 112, whereby the edge of inner
layer 106
is folded to place edge 114 beneath a surface of the edge of inner layer 106;
fold 112 is
then wound against the opposing edge 116 of inner layer 106, with fold 112
overlapping
a surface of edge 116.
Figure 6 shows an example of a helically-wound package as described herein,
which includes a multi-layer package material 102, without an anaconda fold.
Package
100 includes multi-layer package material 102, which includes paperboard layer
104 and
inner (e.g., liner) layer 106. A helical seal includes un-folded edges of
paperboard 104
abutted at seam 110. Edge 114 of inner layer 106 abuts edge 116 of inner layer
106,
without either edge being folded. Edges 114 and 116 do not include any
overlapping
surfaces, but one surface could optionally overlap the other, without either
surface being
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folded. Additional layers may also be included, such as an outer printed
layer, but are
not shown at figure 5.
Exemplary hollow containers for dough compositions such as sweet rolls,
breads,
rolls, buns, biscuits, and others, may have exemplary dimensions that include
an interior
space volume in the range from 50 to 800 cubic centimeters, e.g., from 200 to
500 cubic
centimeters. Stated differently, a hollow container may be sized and shaped to
contain a
desired volume (e.g., based on number or portions) of dough product, for
example, for
some retail-sale products, to contain from 1 to 10 chemically leavened
biscuits dough
pucks; volumes outside of this range may also be useful for biscuit or other
dough
products.
A hollow container may be of any three-dimensional shape, defined by sidewalls
and at least one opening, such as a cylinder (e.g., tube), a cube with one or
more open
end, a rectangular container with one or more open end, or any other three-
dimensional
shape or form having sidewalls and an opening. For a cylinder, tube, can, or
canister, or
similar cylinder-like shape (e.g., with a non-circular cross section), such as
for a retail-
type product, an exemplary length-wise dimension may be in the range of from 2
to 10
inches (from 5 to 25 centimeters), e.g., from 4 to 8 inches (from10 to about
20
centimeters), and a diameter (for a round cross section), width (for non-round
cross
section), or other cross-sectional dimension, also optionally the dimension of
an opening
of the hollow container, may be in the range from about 1 to about 5 inches
(from about
2.5 to about 12.5 centimeters), e.g., from about 2 to about 4 inches (from 5
to about 10
centimeters).
One typical style of package for pressurized dough products includes a hollow
container in the form of a can or canister having rigid or semi-rigid
materials that define
a sidewall, such as paper, cardboard (e.g., wound cardboard), or a polymeric
material
(e.g. wound, extruded, etc.). A material considered to be "rigid" can be a
material that is
self-supporting and potentially flexible, but not necessarily able to be
substantially
stretched (i.e., is inelastic); examples include cardboard, wound cardboard,
similarly-stiff
plastics, and the like. A material considered to be "flexible" can be a
material that is able
to bend and change shape without stretching, such as paper, thin inelastic
polymeric
films, cardboard, wound cardboard, similarly-stiff plastics, and the like.
Certain specific examples of sidewall materials include cardboard and
paperboard
including 25# ream, 25# bleached kraft, and papers and cardboards of similar
strength
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and thickness, as well as various polymers including polyolefins such as
polyethylene,
high density polyethylene, low density polyethylene, and polypropylene; nylon;
and the
like. A sidewall material may be formed of a single material or layer or
multiple
materials or layers. A paper or polymeric base layer may be treated with a
coating or
film such as a metal foil layer, a plastic barrier or sealer layer added to a
paper or
cardboard (e.g., nylon, ethylene vinyl alcohol, polyethylene, polyvinyl
chloride,
polyvinylidene chloride, polypropylene, etc.), an adhesive or adhesive layer
(e.g.,
thermoplastic polyolefin), a liner ply, tie-layer, or other functional layers
or features. In
certain preferred embodiments a sidewall material may be recyclable. As used
herein, a
recyclable material may be a recyclable metal, plastic, or a recyclable paper.
A
recyclable paper may be a paper or cardboard material that having a non-paper
content
that does not exceed 5 percent by weight.
Sidewalls can be designed to have strength (based, e.g., on thickness) that is
sufficient to accommodate a desired pressure. According to certain embodiments
of
packages used for relatively low interior pressure (e.g., below 5, 10, or 15
psig),
sidewalls can be selected to have a relatively reduced thickness compared to
sidewalls
designed for packages required to maintain a relatively higher pressure (e.g.,
20, 25, or
30 psig. Non-limiting examples of polymeric materials that can be used for
packages
designed for relatively low interior pressure reduced (e.g., below 5, 10, or
15 psig)
include polymeric materials that include the following polymers and optionally
additives
or copolymers: polyethylene terephthalate (PET) having a wall thickness of
from 10-13
mil, high density polyethylene (HDPE) from 25-35 mil, and polypropylene (PP)
from
20-25 mil. Examples of non-polymeric materials that can be used for packages
designed
for relatively low interior pressure (e.g., below 5, 10, or 15 psig) include
paper or
cardboard materials alone or in multi-layer sidewall materials.
Exemplary hollow containers that can be useful according to the present
description, forming a can or canister (sometimes referred to collectively
herein as
"can") can have a fixed interior space volume, can be in the form of a tube or
cylindrical,
and can be vented to allow a contained dough composition to expand within the
package
to expel gas, to seal the package from within, and to optionally build a
desired interior
pressure. A "can" can define sidewalls and two opposing ends, the ends being
closed
with a cap or other closure (see below) secured to the cylinder (e.g., at
sidewalls) by any
useful technique such as heat sealing, adhesive, a mechanical engagement
(e.g.,
81616495
crimping), or the like. With expansion of a dough composition inside of the
hollow
container (can), after a closure Is placed over an opening, the dough volume
can increase
to fill the entire volume of the interior space, and upon any further proofing
the pressure
inside the container can increase and, (according to certain embodiments of
packages)
the expanded dough can scat vents from the inside of the package.
A canister can be formed from any of a selection of useful materials such as
paper, cardboard, plastic, and multilayer composites that include one or more
of these
materials optionally additionally including additional layers such as a metal
layer or
other barrier layer. A canister may be formed as desired. For example, a
plastic canister
may be formed by molding, e.g., blow molding, injection molding, winding, etc.
A
canister may be spirally wound into a cylinder, from plastic, paper,
cardboard, etc., or
from another type of rigid, semi-rigid, or flexible material capable of being
so formed
and then sealed to contain a dough composition. This "can" embodiment is
discussed in
terms of a cylindrical package, but other shapes con also be useful and are
contemplated
according to the present description, such shapes including "tube"-type hollow
containers having non-circular cross section, such as an elongate container
having
sidewalls of square, hexagonal, oval, octagonal, rhombus, rectangle, or other
shape cross
section, The can may be rigid or semi-rigid in an elongate direction and
sealed at one or
more ends with one or more closure as described.
As described, the package can optionally be vented. A useful vent can be any
type of vent that allows gas to be expelled from the interior, optionally also
being
capable of being closed or covered from the interior, such as by a food (e.g.,
dough)
product expanding within the interior space. Examples of vents that can be
incorporated
into a package of the present description include those described in
Assignee's
copending Patent Application Publication No. 2008/0286420.
A vent can be located at any desired location,
including at a perimeter of a closure, at a perimeter of an Insert, or
elsewhere. A vent
can be of any size or design, including micravents (see, e.g., Patent
Application
Publication No. 2010/0021591.
Figures IA and IB illustrate examples of hollow container structures.
Refetring
to figure 1A, hollow container 2 includes sidewalls 4, sidewall ends 6, and
openings 8 at
opposing ends of sidewalls 4; these collectively define internal space 10.
Hollow
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container 2 is in the form of a hollow cylinder, or "tube," having dimensions
to contain a
dough product. Sidewalls 4 can be made of any suitable material, such as
paper, wound
cardboard, plastic film, another type of extruded or wound plastic material,
or other
plastic, polymeric, or non-polymeric materials. Sidewalls 4 can be made of a
single
layer (e.g., of plastic, paper, or cardboard) or can be of a multi-layer
material that may
include combinations of materials such as paper or cardboard optionally coated
with or
laminated to one or more additional layer of paper, metal, plastic or metal
foil,
thermoplastic, cardboard, or polymer. Figure 1B shows a similar hollow
container with
having a rectangular or square cross section.
A package as described herein includes a closure to cover an opening of the
hollow container, e.g., by engaging sidewalls of the hollow container. The
closure can
be any structure that can engage the hollow container, e.g. at ends of a
sidewall structure,
to close an opening of the hollow container by covering the opening
(optionally allowing
for venting). A closure can be of any desired material such as metal, plastic,
cardboard,
or another polymeric or non-polymeric material capable of combining with a
hollow
container as described to contain a pressurized dough product. The size and
shape of the
closure can correspond to a size and shape of an opening of a hollow
container, such as
an end of a hollow structure defined by ends of a sidewall structure. The
closure can be
flat (e.g., planar, two-dimensional) or curved, and can be of a shape that
corresponds to a
shape of an opening of the hollow container, e.g., a cross section of a hollow
container.
Certain exemplary closures for use with a cylindrical or tube-like hollow
container can have features of relatively flat (planar), rigid, metal or
polymeric discs in
the form of "caps" or "end-caps" sometimes used to seal ends of pressurized
(wound
cardboard, polymeric, etc.) packages used to contain dough products. These
closures,
e.g. at a perimeter of the closure, can engage ends of sidewalls of the hollow
container,
with optional venting, by being crimped or otherwise mechanically secured to
ends of
the sidewalls. Other types of closures can be plastic and can engage sidewalls
by
alternate engagements such as adhesive or other mechanical engagements.
A closure can be formed from any of a selection of useful materials such as
metal, paper, cardboard (e.g., wound, flat, convolute, etc.), plastic, and
multilayer
composites that include one or more of these materials optionally additionally
including
additional layers such as a metal layer or other barrier layer. Examples of
materials
include metal, plastic such as polyethylene terephthalate, polyethylene
naphthalate,
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polyolefin such as polypropylene and polyethylene, and the like. A closure can
be a
recyclable metal, plastic, or paper. A closure can include a perimeter
designed to engage
an opening of a hollow container, e.g., at a sidewall, and the closure can be
of any useful
form such as mechanical (e.g., vented) or adhesive.
According to the invention, a closure includes an aperture, and the aperture
is in
turn covered by an insert in a manner that can result in a closed or sealed
package. The
aperture can be any size or shape, and preferably is sufficiently large to
allow for visual
access to the interior space (and contents) of the package, having a dimension
(e.g.,
diameter) that is at least about 1 centimeter.
An aperture can preferably be contained within (i.e., bounded by) a surface of
the
closure, defined by aperture boundaries that do not extend to edges at the
outer perimeter
of the closure; the aperture can be defmed by a surface or edge of the closure
internal to
the outer edge or perimeter of the closure so that an inner edge or border of
the closure
fully defines a perimeter or outer edge or border of the aperture.
Dimensions of an aperture of a closure of any particular package can be based
on
factors such as the size of the package, and particularly the size of the
closure (which in
turn can relate to the size of the package) and a desired dimension for a
closure surface.
For certain closure designs, a minimum size of a closure surface may
correspond to a
distance between a closure aperture and a closure perimeter of at least 1/4 or
1/8 of an inch
(from 0.6 to about 0.3 centimeters). A dimension of a closure aperture is
smaller than a
dimension (e.g., diameter) of the closure measured at a closure perimeter. An
area of a
closure surface (calculated as the area of the closure within a perimeter,
excluding the
size (area) of the closure aperture) can vary depending on the size of the
closure
perimeter and the closure aperture. Examples of useful areas of a closure
surface may be
up to 85 or 90 percent of a total area within a perimeter of the closure,
e.g., up to 65
percent of the area within a perimeter of the closure, or up to 50 percent of
the area
within a perimeter of the closure. For a substantially circular and planar
closure, a
diameter of a closure aperture may be less than 75 percent of the diameter of
the closure
perimeter, e.g., less than 65 percent of the diameter of the closure aperture,
or less than
50 percent of the diameter of the closure perimeter.
In terms of specific dimensions, for a round (e.g., circular) closure, an
outer
diameter of a closure perimeter can be a size to engage and close an opening
on the
hollow container, with examples of useful diameters being the same as
diameters of a
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tubular container, e.g., in the range from 1 to 5 inches (from 2.5 to 12.5
centimeters),
e.g., from 2 to 4 inches (from 5 to about 10 centimeters). For a non-round
closure, such
as one that covers a non-round opening of a hollow container that has a round
or non-
round form, these dimensions can relate to a diameter or other dimension of
such an
opening. A size (e.g., diameter) of an aperture of a closure of a size in this
range can be
as indicated, with specific examples as follows: for a round or non-round
closure having
a diameter or dimension of about 3 inches (about 7.5 centimeters), a diameter
or
dimension of an aperture can be from about 0.3 to about 2.75 inches (from 0.75
to 6.9
centimeters); for a round or non-round closure having a diameter or dimension
of about
2.25 inches (about 5.7 centimeters), a diameter or dimension of an aperture
can be from
about 0.3 to about 2 inches (from about 0.75 to about 5 centimeters); for a
round or non-
round closure having a diameter or dimension of about 1.75 inches (about 4.4
centimeters), a diameter or dimension of an aperture can be from about 0.3 to
about 1.5
inches (from about 0.75 to about 3.8 centimeters).
Figures 2A, 2B, 2C, and 2D illustrate examples of closures that include
apertures.
(Figures 2A and 2C are side-perspective views, and figures 2B and 2D are top
views.)
Referring to figure 2A, closure 12 includes aperture 14, outer edge or
perimeter 16, inner
edge 18 (which is also the outer edge of perimeter 16), and surface 20.
Closure 12 is in
the form of a planar (substantially two dimensional) round disc having round
aperture
14. Aperture 14 is the open space or area removed or absent from the round
disc
forming closure 12. The size (area and diameter) of aperture 14 is smaller
than closure
12 (i.e., is smaller than perimeter 16), and the outer boundary of aperture
14, which
consists of a continuous perimeter, is co-extensive with the inner boundary of
surface 20.
As illustrated, aperture 14 and perimeter 16 are concentric circles;
alternately, aperture
14 may be of a different shape than perimeter 16, may have a different center
(or central
location), or both.
According to the invention, the package includes an insert that covers the
aperture of the closure. The insert can be any size and shape that will allow
the insert to
cover an aperture in a closure, and may be rigid or flexible, can be flat
(planar) or
optionally curved in three dimensions, and can have a shape that corresponds
to a
closure, an aperture, or both. Exemplary inserts can have a shape that
corresponds to an
aperture (e.g., a circular insert to work with a circular aperture) and can
have a diameter
(or other dimension) that is slightly greater than a diameter (or other
dimension) of the
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aperture, to optionally allow coverage of the aperture, as well as contact
between a
peripheral surface of the insert and a surface of the closure adjacent to the
aperture. For
example, a diameter (or other dimension) of an insert may be greater than a
diameter (or
other dimension) of a cover aperture by at least 0.25 inch (allowing 0.125
inch of overlap
between surfaces of the insert and the closure, on opposite sides of the
insert), such as at
least 0.5 inch (allowing 0.25 inch of overlap on opposite sides of the
insert), or at least
0.8 inch (allowing 0.4 inch of overlap on opposite sides of the insert).
The insert can be of any material, such as any of those mentioned above for
other
components of the package, including any types of metal, polymer, plastic,
paper,
cardboard, etc. An insert can be relatively rigid (self-supporting and
optionally inelastic)
such as in the form of a rigid metal or plastic, or may be more flexible (self-
supporting
but bendable and optionally inelastic) such as in the form of a bendable
paper, cardboard,
or polymer, or flaccid (limp and optionally inelastic) such as in the form of
a thin paper,
foil, or polymer film. An insert can be of sufficient strength and
inelasticity to maintain
an internal pressure in a package, when the insert covers an aperture, but
rigidity is not
necessarily required so an insert may be of an inelastic and flaccid material
having a
relatively low thickness, such as paper, foil, or a thin polymeric film.
Certain specific
examples of materials useful for an insert include metal, plastic such as
polyethylene
terephthalate (e.g., 25 mil thick, transparent), polyethylene naphthalate,
polyolefin such
as polypropylene and polyethylene, and the like. An insert can include a
surface
designed to engage a surface of the closure to produce a seal or a vent. An
insert can be
plain, colored, transparent or translucent, and may optionally be decorated
and may
contain printing. An insert can be shaped to match a shape of a closure
aperture or a
cross-section of a sidewall, or can have a shape that is different from a
closure aperture
or a cross-section of a sidewall of a package that includes the insert.
Optionally an insert can be transparent to allow viewing of contents contained
in
the package through the insert and aperture. As desired, the insert can be
located on an
interior or exterior side of the closure. Optionally, an adhesive or other
securing
mechanism can be used to maintain the position of the insert to cover the
aperture. Also
optionally, the placement of the insert at a surface of the closure can create
or maintain a
vent (e.g., space, channel, slot, opening, etc.) between the closure and the
insert;
preferably a vent can be closed or sealed from the interior side of the
package by the
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expansion of dough contained in the interior space, the expanded dough
covering the
vent to prevent subsequent passage of gas through the vent.
In particular embodiments an adhesive can be placed adjacent to a vent, e.g.,
between a surface of the insert and a surface of the closure, such as a
pressure-activated
adhesive coating. A pressure-activated adhesive coating can be useful to
maintain a
position of an insert relative to a closure. As used herein, a pressure-
activated adhesive
coating is a coating that contains an adhesive (e.g., a pressure sensitive
adhesive), where
the coating as a practical matter does not exhibit properties of a pressure
sensitive
adhesive (e.g., tack, adhesion (shear or peel)) but that can be caused to
exhibit adhesive
properties by application of a pressure, such as a minimum amount of pressure
referred
to as a "threshold pressure." A threshold pressure can be an amount of
pressure that
causes a pressure-activated adhesive coating to display properties of a
pressure-sensitive
adhesive, such as tack, shear adhesion, peel adhesion, etc., and may be an
amount of
pressure that disrupts, fractures, or breaks a feature or structure of the
coating that then
releases or exposes pressure-sensitive adhesive. Such feature or structure may
be, e.g., a
polymeric sphere (e.g., "microsphere"), a polymeric coating, a glass sphere
(e.g., "glass
bead"), non-spherical matrix, etc.
Prior to being the exposed to a threshold pressure to activate the adhesive, a
pressure-activated adhesive coating does not function as a pressure-sensitive
adhesive;
subsequent to being exposed to a threshold pressure, the pressure-activated
adhesive
coating behaves as a pressure-sensitive adhesive. The activation by exposure
of the
adhesive coating to pressure may be accomplished by known methods, such as by
use of
coatings that contain polymeric beads or microspheres, glass beads, or other
matrixes,
wherein the beads or matrixes may contain adhesive or components of adhesive
(e.g.,
different components of a reactive adhesive such as an epoxy). Upon exposure
of the
beads, spheres, coating, microspheres, or matrix to pressure (e.g., a
threshold pressure),
the beads, spheres, coating, microspheres, or matrix become disrupted and
release or
expose the adhesive.
A pressure-activated adhesive coating can be any useful pressure-activated
adhesive coating, and for use in a package for containing food can preferably
be
"generally recognized as safe" (GRAS). In an "unactivated" condition, prior to
a
threshold pressure being applied to a pressure-activated adhesive coating, one
or more
properties of tack, peel adhesion, and shear adhesion can be below values for
a pressure-
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sensitive adhesive, e.g.: for example, an unactivated pressure-activated
adhesive coating
can exhibit substantially no adhesive property measured as tack (measured by
AS TM-
D3121-06); peel adhesion (measured by ASTM-D1876-08); or shear adhesion
(measured
by ASTM-D3654 or Adhesion D-3330). Upon activation by application of a
threshold
pressure, the pressure-activated adhesive coating can exhibit one or more
property of a
pressure-sensitive adhesive, such as a useful level of tack (measured by ASTM-
D3121-
06); a property of peel adhesion (measured by ASTM-D1876-08) of at least 80
gm/in; or
a property of shear adhesion (measured by ASTM-D-3330) of at least 2.0 N/10
mm.
An adhesive contained in a pressure-activated adhesive coating can be any
adhesive or adhesive component, such as any adhesive known within adhesive
arts as
"pressure-sensitive adhesives" or "PSA." Pressure-sensitive adhesives are
known
compositions that exhibit one or more adhesive properties of tack, peel
adhesion, shear
adhesion, etc., that can adhere to an adherend surface based on contact and
without the
requirement of solvent, water, or heat to activate the adhesive. Examples
include
polyolefins (e.g., poly-alpha olefms), polyacrylates, polystyrene and
polystyrene block
copolymers, vinyl ethers, ethylene-vinyl acetate, butyl rubber, nitriles,
natural rubber,
and the like.
A pressure-activated adhesive coating may be applied to a substrate by known
methods, such as coating from solvent (e.g., organic or aqueous), hot-melt
coating, etc.,
as desired. The amount can be an amount to provide desired adhesive properties
before
and after application of a threshold pressure.
Examples of inserts useful to cover an aperture of a closure are illustrated
at
figures 3A and 3B. Referring to figure 3A, an end of a package 30 includes
closure 32
and insert 34. Closure 32 includes outer perimeter 36, aperture 38, surface
40, and inner
edge 42 adjacent to surface 40. Inner edge 42 also defines the outer boundary
of aperture
38. Closure 32 may be made out of any material, such as a metal (e.g., steel,
tin,
polymer (e.g., polyolefin, PET, polyamide)). Insert 34 includes outer diameter
44
(dashed lines) and surface 46, which as illustrated is an exterior surface
facing away
from an interior space of package 30. Insert 34 can be made of any single or
composite
material the can be formed to the illustrated shape and capable of covering
aperture 38 to
close aperture 38 and retain a dough composition under pressure within package
30 (e.g.,
transparent PET). Distance Do represents the difference between the relatively
larger
diameter 44 of insert 34 and the relatively smaller diameter of aperture 38 as
defined by
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inner edge 42. The area between outer diameter 44 of insert 43, and inner edge
42 of
closure 32, is an area of contact between an "outer" or "exterior" (facing
away from an
interior space of a package) surface of insert 34 and an "inner" or "interior"
(facing
toward an interior space of a package) surface of closure 32. As illustrated
at figure 3A,
this area of contact may be sufficiently tight to produce a fluid-tight (e.g.,
air-tight) seal
that will not allow passage of gas or other fluid from a location within an
interior space
of package 30, to an exterior location, by the gas or other fluid passing
between closure
32 and insert 34. In other embodiments of packages described herein, an
engagement
between an outer surface of an insert and an inner surface of a closure may
include a vent
that allows fluid (e.g., gas) to pass from the interior space to an exterior
of a package.
See, e.g., figure 4B and related text.
Figure 3B shows an alternate end of package 30, which is similar to the end of
package 30 at figure 3A, but that has different dimensions, and that also
shows adhesive
patches 50 at peripheral locations of insert 34, at locations to contact an
outer surface of
insert 34 and also an inner surface of closure 32, to maintain contact between
insert 34
and closure 32. The adhesive may be any useful adhesive such as a
thermoplastic
material, a pressure-sensitive adhesive, a pressure-activated adhesive (as
described
herein), or any other food-grade adhesive. In this illustrated embodiment of
package 30,
the engagement between the outer surface of insert 34 and the inner surface of
closure 32
includes a vent that allows fluid (e.g., gas) to pass from the interior space,
to an exterior
of a package. The vent can be formed by the placement of adhesive patches 50
between
closure 32 and insert 34, e.g., a space is created adjacent to each adhesive
patch due to
the thickness dimension of the adhesive patch. In preferred embodiments of
packages
described herein the vent can be closed by expansion of dough inside of the
package,
upon the expanded dough contacting the vent and covering the vent on the
interior of the
package. As illustrated, the pressure-sensitive adhesive is provided in
patches 50 at a
circular location; in alternate embodiments the adhesive may be a continuous
circular (or
other shape) line of adhesive, without gaps between multiple patches.
Figure 4A shows a side perspective view of an embodiment of a package as
described. Referring to figure 4A, package 30 includes a hollow container
having
sidewalls 4 (shown as wound cardboard, but optionally any other material such
as wound
or extruded plastic or other polymeric material). Closure 32 covers an opening
of the
hollow container by an engagement (e.g., a mechanical or adhesive engagement)
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between perimeter 36 of closure 32 and ends of sidewalls 4. The engagement may
be a
mechanical engagement (such as a crimped edge of closure 32, optionally
including a
vent), an adhesive engagement, or any other engagement sufficient to allow
package 30
to contain a dough product under pressure. The engagement may also optionally
include
a vent (e.g., a passage or channel) that allows fluid to escape from an
interior space of
package 30, to an exterior, passing between an end of sidewall 4 and closure
32 upon
expansion of a dough within the interior space (see, e.g., figure 4B). A vent
can
preferably be of a type that can become sealed from within the interior space
upon
contact of the expanded dough composition against the vent from the interior
side of
package 30. A vent could also be located at any other location of the package.
Referring to figure 4B, this shows a side cross-sectional view of package 30,
this
view illustrating dough and two possible venting options, either of which may
be part of
a package according to the present description. In use, a package according to
the
description such as package 30 can be prepared by placing dough 52 in interior
space 54
of hollow container 56, defined in part by sidewalls 4. When placed into
interior space
54, dough 52 has a volume that is less than the volume of interior space 54.
Closure 32
and insert 34 can be placed at ends 58 of sidewalls 4. As illustrated,
perimeter 36 of
closure 32 (e.g., of a metal or plastic) is crimped around ends 58 to secure
closure 32 at
ends of sidewalls 4. Dough 52 expands in size due to leavening or partial
leavening, to
fill interior space 54.
Optionally, and as illustrated at figure 4A, a package as described can
include a
vent to allow gas to escape from interior space 54 as dough 52 expands within
the
package after a closure has been placed to cover an opening. A vent can be any
type of
vent now known or developed in the future and can be located at any location
on the
package such as at a sidewall; at an engagement between a closure and an end
of a
sidewall, such as at a crimp; at an area of contact between a closure and an
insert; or at
any other useful location. Figure 4B shows two different vent embodiments,
either or
both of which may be used separately or together in a package as described
herein. One
vent embodiment is indicated by arrows 60, indicating gas being expelled from
interior
space 54, through a passage between closure 32 and sidewall end 58. A second
vent
embodiment is indicated by arrows 62, indicating gas being expelled from
interior space
54, through a passage between an interior surface of closure 32 and an
exterior surface of
insert 34, traversing a space or distance of overlap (e.g., area of contact)
between these
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surfaces, designated Do. Certain specific examples of packages can include a
vent
indicated by arrows 62 that includes a passage between an interior surface of
closure 32
and an exterior surface of insert 34, and can exclude any other vent,
particularly not
requiring a vent as indicated by arrow 60 that includes a passage between
closure 52 and
sidewall end 58; these specific examples of packages can include any type of
sidewall,
such as a polymeric (e.g., extruded plastic) sidewall.
A package according to this description can be prepared from components as
described, including a hollow container having an opening (e.g., an opening at
one or
two opposing ends of sidewalls), a closure (having an aperture), and an
insert. In
preparation of a packaged dough product, a hollow container can be prepared
from a
material as described, and wound (e.g., from a plastic, paper, or cardboard
material) or
extruded (e.g., from a plastic material). A dough composition can be placed at
an
interior space, and the opening can be closed by placing the closure at the
opening, to
close the opening, and by placing the insert to cover the aperture in the
closure; the insert
may be placed on an interior or an exterior side of the closure.
One or more closures can be prepare from any material, such a by being punched
or otherwise formed from a sheet or a blank of a piece of metal or other
desired closure
material. According to particular methods, a first hollow container can be
provided,
having an interior space. Dough can be provided in the interior space. A first
closure
can be provided from a blank metal disc or a sheet of metal, cardboard,
plastic, or other
suitable closure material, by forming a perimeter to be fitted onto the
opening of the first
hollow container. A first closure aperture can be formed in the first closure,
such as by
punching, cutting, molding, or otherwise forming a closure with an opening in
the
middle. Optionally, forming the aperture can be by punching an opening in the
closure,
whereby a second disc of a smaller (second) perimeter is formed from the
material used
to produce the opening. The first closure, with an insert, can be used to
close an opening
of the first hollow container.
The second disc of a smaller (second) perimeter can be used for any purpose,
such as in producing a separated package, or may be recycled. As an example,
the
second disc can have a perimeter that can be fitted onto an opening of a
second hollow
container having an opening sized to be smaller than the opening of the first
hollow
container. A third disc can be formed (e.g., punched or cut) from a surface of
the second
disc, the third disc having a perimeter that can be fitted onto a third hollow
container
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having an opening sized to be smaller than the opening of the second hollow
container.
By this method, each aperture formed in one closure, for a particularly-sized
opening of a
hollow container, can be used to form a closure sized for a smaller opening of
a smaller
hollow container.
A package as described can be used to contain any type of food or non-food
product, e.g., under pressure (at an interior pressure that is above
atmospheric pressure).
Particular embodiments of packages can be used to contain raw dough. A dough
contained by a package as described may be of any formulation, with preferred
doughs
being capable of expanding within the package to contact a vent to seal the
package from
within. The dough generally will have a rheology, formulation (e.g., water
content), and
texture to allow expansion of the dough inside the package, against the
package interior,
optionally and preferably to contact and close a vent from the package
interior. The
dough may be yeast or chemically leavened, and for use according to the
invention may
desirably include a leavening system that provides predictable leavening and
expansion
after packaging and during refrigerated storage.
Examples of useful dough types include developed and non-developed
chemically leavened doughs such as bread doughs, pizza doughs, sweet rolls,
rolls, etc.
Specific formulations of dough compositions that may be useful as doughs
within the
present description, include chemically leavenable dough formulations, yeast-
leavened
dough formulations, combinations of yeast and chemically leavened dough
formulations.
The dough may be a developed dough formulation or a non-developed dough, such
as
one of those described in any of the following patent applications: U.S.
Serial No.
09/945,204, filed August 31, 2001, titled "CHEMICAL LEAVENED DOUGHS AND
RELATED METHODS," (now U.S. Patent Publication No. 2003/0049358); U.S. Serial
No. 10/446,481, filed May 28, 2003, titled "PACKAGED DOUGH PRODUCT IN
FLEXIBLE PACKAGE, AND RELATED METHODS," (now U.S. Patent Publication
No. 2004/0241292); U.S. Serial No. 10/273,668, filed October 16, 2002, titled
"DOUGH
COMPOSITION PACKAGED IN FLEXIBLE PACKAGING WITH CARBON
DIOXIDE SCAVENGER," (now U.S. Patent No. 7,235,274); U.S. Serial No.
11/132,831, filed May 19, 2005, titled "PACKAGED, NON-DEVELOPED DOUGH
PRODUCT IN LOW PRESSURE PACKAGE, AND RELATED COMPOSITIONS
AND METHODS," (now U.S. Patent Publication No. 2005/0271773); U.S. Serial No.
11/132,826, filed May 19, 2005, titled "PACKAGED, DEVELOPED DOUGH
21
81616495
PRODUCTION IN LOW PRESSURE PACKAGE, AND RELATED METHODS,"
(now U.S. Patent Publication No, 2005/0281922); U.S. Serial No. 12/306,745,
Sled July
11,2007, titled "DOUGH PRODUCT AND VENTED PACKAGE," (now U.S. Patent
Publication No. 2010/0021591); and U.S. Serial No. 11/334,301, filed January
18,2006,
titled "REFRIGERA113D DOUGH AND PRODUCT IN LOW PRESSURE
CONTAINER," (now U.S. Patent Publication No, 2006/0177558),
As stated, the packaged dough product can include any type or formulation of
yeast or chemically-lettvenable dough composition that expands, such as by
production
of carbon dioxide, after packaging and optionally during refrigerated storage.
Many if
not all formulations of (pre-proofed or unproofed) yeast and chemically-
leavenable
dough compositions evolve an amount of carbon dioxide prior to or during
refrigerated
storage, causing expansion of the dough as presented in this description,
within a
package baying vents.
Preferred dough compositions can be formulated, in combination with selection
of a size of an internal volume of it package and an amount (e.g., volume) of
dough to be
contained within the package, such that upon expansion of the dough within the
package
a desired internal pressure is achieved. An exemplary pressure can be a
positive pressure
(gauge) such as greater than one atmosphere (0 psig), such as a pressure in
the range
from Ito 30 pounds per square inch, gauge (psig), such as within the range
from 5 to 25
psig. The dough can be placed in the package at a specific volume that is
below the
specific volume to which the dough will expand in the package, e.g., a
specific volume
of less than 2.0 cubic centimeters per gram (cc/g), such as below 1.5 cc./g,
or a specific
volume In the range from 0.9 to 1,1 or 1.2 orig. After being placed in the
package, and
after the package is closed (e.g., a closure is placed on an opening) the
dough can expand
to partially proof or proof within the package to a desired mw specific
volume. An
example of a partially-proofed or pre-proofed dough may be a dough having an
expanded raw speelfic volume in the range from 1,5 to 2.0 cubic centimeters
per gram
(as measured after removal from the package).
Yeast and chemically-leavened dough compositions can be prepared from
ingredients generally known in the dough and bread-making arts, typically
including
flour, a liquid component such as oil or water, a leavening agent such as
yeast or
chemical leavening agents, and optionally additional ingredients such as
shortening, salt,
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sweeteners, dairy products, egg products, processing aids, emulsifiers,
particulates,
dough conditioners, yeast as a flavorant, flavorings, and the like.
As an example, unproofect doughs generally have a raw specific volume within
the approximate range of 0.9 to 1.1 cubits centimeters per gram (cc/g). An
amount of
dough having predictable refrigerated leavening properties can be expected to
expand to
a desired raw specific volume during refrigerated storage, when allowed to
expand
within a fixed-volume container. A relevant parameter is the amount of
unleavened raw
dough volume compared to internal package volume (meaning a fixed or a maximum
or
"expanded" package volume). According to embodiments of the invention, a
volume of
unproofed dough per package volume (e.g., having a raw specific volume in the
range
from 0.9 to 1.1) can be about 50 to 90 percent dough volume per package
volume, such
as from 80 to 85 percent dough volume to package volume. With certain doughs
of the
invention. having predictable refrigerated leavening properties, this ratio of
non-
expanded dough to maximum package volume has been identified as useful to
produce a
packaged dough product having an internal pressure of I to 30 psig, e.g., 5 to
25 psig, or
8 to 15 psig, after allowing the dough to expand inside of the package to a
raw specific
volume in the range from 1.5 to 2.0 wig, e.g, 1.6 to 1.9 cc/g (measured after
removal
from the package).
Dough compositions that exhibit predictable refrigerated leavening properties
can
include various types of dough, including doughs formulated with yeast for
leavening,
chemical leavening systems, or a combination of yeast and chemical leavening
systems
used for leavening. Doughs may be developed or non-developed types of doughs
and
dough products. Yeast-leavened dough,s can exhibit predictable refrigerated
leavening
properties based on selection of a yeast that has predictable behavior such as
a substrate-
limited yeast (in combination with selected substrates), a cold-temperature
sensitive
yeast, combinations of these types of yeasts, and combinations of these types
of yeasts
with other ingredients such as a cold-temperature sensitive yeast used in
combination
with ethanol. Examples of these types of predictable yeasts are described in
US patent
Nos. 5,939,109, 5,798,256, 5,759,596, 5,650,183.
Other examples dough formulations having predictable refrigerated leavening
properties can he certain types of chemical leavened doughs, such as those
formulated
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with acidic or basic chemical leavening agents that are specifically chosen to
produce a
desired effect on the timing or amount of leavening during refrigerated
storage.
Chemically-leavenable (also referred to as "chemically-leavened") dough
compositions are dough compositions that leaven to a substantial extent by the
action of
chemical ingredients that react to produce a leavening gas. Typically the
ingredients
include a basic chemical leavening agent and an acidic chemical leavening
agent that
react to produce carbon dioxide, which, when retained by the dough matrix,
causes the
dough to expand.
Acidic chemical leavening agents are generally known in the dough and bread-
making arts, with examples including sodium aluminum phosphate (SALP), sodium
acid
pyrophosphate (SAPP), monosodium phosphate, monocalcium phosphate monohydrate
(MCP), anhydrous monocalcium phosphate (AMCP), dicalcium phosphate dihydrate
(DCPD), glucono-delta-lactone (GDL), as well as a variety of others.
Commercially
available acidic chemical leavening agents include those sold under the trade
names:
Levn-Lite (SALP), Pan-O-Lite (SALP+MCP), STABIL-9 (SALP+AMCP), PY-
RAN (AMCP), and HT MCP (MCP). Optionally, an acidic chemical leavening agent
can be encapsulated. Optionally, a combination of acidic agents can be useful
to produce
desired leavening properties; e.g., a dough formulation may include a soluble
acidic
agent to produce a desired (predictable) amount of leavening and expansion of
a dough
during refrigerated storage, and an amount of low solubility acidic agent can
be included
to produce additional expansion during baking.
Soluble acidic chemical leavening agent is considered to be soluble in a
liquid
(e.g., aqueous) component of the dough composition, at a temperature used
during
processing (e.g., from 40 to about 72 degrees Fahrenheit) or refrigerated
storage (e.g.
from about 32 to about 55 degrees Fahrenheit). A soluble acidic chemical
leavening
agent is an acidic agent that is sufficiently soluble to dissolve in a dough
composition at
a temperature within processing and refrigerated storage ranges to react with
a basic
chemical agent if available, e.g., is freely soluble or will substantially
entirely dissolve.
Particularly useful soluble acidic chemical leavening agents include glucono-
delta-
lactone and sodium acid pyrophosphate (SAPP) of a moderate to high solubility
e.g.,
SAPP 60, SAPP 80, as well as other acidic chemical leavening agents that
exhibit similar
solubility behavior.
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Soluble acidic chemical leavening agent can be present in an amount that
provides refrigerated stability, desired refrigerated raw specific volume, and
desired
baked leavening properties following refrigerated storage. Exemplary amounts
of
soluble acidic agent can be included to provide a raw specific volume in the
range from
1.5 to 2.0 grams per cubic centimeter upon expansion during refrigerated
storage, as well
as a desired baked specific volume upon baking, such as a baked specific
volume in the
range from 3.0 to 4.5.
Insoluble acidic chemical leavening agent refers to acidic chemical leavening
agents that are not substantially soluble at a processing or refrigeration
temperature, but
are insoluble or only slightly soluble at processing and refrigerated storage
temperatures,
and that are substantially soluble at temperatures that a dough reaches during
baking
(e.g., early baking). Insoluble acidic chemical leavening agents include
sodium
aluminum phosphate (SALP) and other acidic chemical leavening agents that have
solubility properties that are similar to SALP.
A combination of soluble and insoluble acidic agents may be useful to produce
a
combination of desired raw and baked specific volumes. A desired raw specific
volume
can result from the soluble acidic agent reacting to produce a desired amount
of
leavening gas during processing or refrigerated storage. A desired baked
specific
volume can result from the insoluble acidic agent reacting to produce an
amount of
leavening gas during baking.
The total amount of acidic chemical leavening agent included in a dough
composition can be an amount that is useful to prepare a dough composition
having
desired raw and baked specific volumes, and desirable expansion properties for
use
within a package of this description. An amount of acidic agent that is
stoichiometric to
the amount of basic agent can be useful, as well as amounts that are above and
below a
stoichiomettic amount. Amounts of acid or base leavening agents are sometimes
used in
amounts based on neutralization value, which is the amount of base (by weight)
neutralized by 100 parts by weight leavening acid. Amounts of soluble and
insoluble
acidic agents can be in the range from 40:60 to 60:40, based on neutralization
values.
Specific exemplary ranges of useful amounts of total acidic chemical leavening
agent
(e.g., soluble acidic agent, insoluble acidic agent, or a combination of
these), can be in
the range from about 0.5 to about 2.75 weight percent based on the total
weight of a
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dough composition, including the range from about 0.75 to about 2.25 weight
percent,
based on total weight of a dough composition.
The dough composition also includes basic chemical leavening agent, such as an
encapsulated basic chemical leavening agent. Useful basic chemical leavening
agents
are generally known in the dough and baking arts, and include soda, i.e.,
sodium
bicarbonate (NaHCO3), potassium bicarbonate (KHCO3), ammonium bicarbonate
(NRIHCO3), etc. These and similar types of basic chemical leavening agents are
generally freely soluble in an aqueous component of a dough composition at
processing
and refrigerated storage temperatures.
The amount of basic chemical leavening agent used in a dough composition may
be sufficient to react with the included acidic chemical leavening agent to
release a
desired amount of gas for leavening, thereby causing a desired degree of
expansion of
the dough product. Exemplary amounts of basic chemical leavening agent such as
sodium bicarbonate may be in the range from about 0.2 or 0.25 to about 1.5
weight
percent based on the total weight of a dough composition, including the range
from about
0.75 to about 1.25 weight percent based on total weight of a dough
composition. (As
used throughout this description and claims, unless otherwise noted, amounts
of basic
chemical leavening agents and encapsulated basic chemical leavening agents are
given in
terms of the amount of active basic agent, not including the weight of any
encapsulant or
barrier material.)
Encapsulated basic chemical leavening agents are generally known, and can be
prepared by methods known in the baking and encapsulation arts. An example of
a
method for producing enrobed particles is the use of a fluidized bed.
A dough for use according to this description, whether chemically or yeast-
leavened, developed, or non-developed, can contain other ingredients generally
known in
the dough and bread-making arts, typically including flour, a liquid component
such as
oil or water, sugar (e.g., glucose), chemical leavening agents as described,
and optionally
additional ingredients such as shortening, salt, dairy products, egg products,
processing
aids, emulsifiers, particulates, dough conditioners, yeast as a flavorant,
other flavorings,
etc. Many dough formulations are known to those skilled in the dough and
baking arts
and are readily available to the public in commercial cookbooks.
A flour component can be any suitable flour or combination of flours,
including
glutenous and nonglutenous flours, and combinations thereof. The flour or
flours can be
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whole grain flour, flour with the bran and/or germ removed, or combinations
thereof.
Typically, a dough composition can include between about 30 and about 50
weight
percent flour, e.g., from about 35 to about 45 weight percent flour, based on
the total
weight of a dough composition.
Examples of liquid components include water, milk, eggs, and oil, or any
combination of these, as will be understood to be useful in chemically-
leavened, non-
developed dough compositions. Water from these components and similar
ingredients is
available to hydrate flour or protein, and is understood to be "available
water." For
example, liquid components may provide available water (added as an ingredient
and as
part of other ingredients), e.g., in an amount in the range from about 15 to
40 weight
percent, e.g., from 25 to 35 weight percent, although amounts outside of this
range may
also be useful. Water may be added during processing in the form of ice, to
control the
dough temperature in-process; the amount of any such water used is included in
the
amount of liquid components. The amount of liquid components included in any
particular dough composition can depend on a variety of factors including the
desired
moisture content of the dough composition.
A dough composition can optionally include fat ingredients such as oils and
shortenings. Examples of suitable oils include soybean oil, corn oil, canola
oil,
sunflower oil, and other vegetable oils. Examples of suitable shortenings
include animal
fats and hydrogenated vegetable oils. Fat may be used in an amount less than
about 20
percent by weight, often in a range from 5 or 10 weight percent to 20 weight
percent fat,
based on total weight of a dough composition.
Dough compositions described herein can be prepared according to methods and
steps that are known in the dough and dough product arts. These can include
steps of
mixing or blending ingredients, folding, lapping with and without fat or oil,
forming,
shaping, cutting, rolling, filling, etc., which are steps well known in the
dough and
baking arts.
Example of canned dough formula and packaging configuration.
Refrigerated biscuit dough was mixed, sheeted and formed using the following
formula.
The batch sizes were 22.5 kg.
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Dough Ingredients Percent
FLOUR, HARD WINTER 48
WATER, FOOD CONTACT 28
SHORTENING FLAKES 14
GRANULATED SUGAR 4
BUTTERMILK SOLIDS EXTRA GRADE 3
SALT 1
SODIUM ACID PYROPHOSPHATE
(SAPP) 1
SODIUM BICARBONATE 1
SODIUM ALUMINUM PHOSPHATE
(SALP) 0.2
Biscuits were placed into standard refrigerated dough cans with a diameter of
2.875
inches. Inserts were placed on top of the dough, and the can was sealed with
lids
(closures) with holes (apertures) of 2.0 and 2.5 inches in diameter.
The cans were then held at 40F and the package integrity and product evaluated
over 12
weeks.
The types of insert material tested were PET (polyester), LDPE (low density
polyethylene), HIPS (high impact polystyrene), and can wall material
(cardboard). The
thickness of the inserts ranged from 10-30 mils. The diameter of the insert
was held
constant at 2.75 inch.
Insert material Thicknesses tested (inches) Can integrity
PET 0.018 inch, 0.030 +++,+++
HDPE 0.018, 0.025 +++
LDPE 0.020 +++
HIPS 0.030
Can Wall material
(composite)
Satisfactory can integrity was achieved with all the insert materials except
HIPS, which
cracked upon pressurizing. Thinner materials deflected more than thicker
materials. Can
wall material held pressure, but developed a large bend or fold.
Product performance was typical, i.e. no changes in baked specific volume,
color or
texture were evident when compared to product packaged with control can ends.
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