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Sweet microwave popcorn product and method for production thereofRelated Patent Categories: Food Or Edible Material: Processes, Compositions, And Products, Packaged Or Wrapped Product, Having Specific Electrical Or Wave Energy FeatureSweet microwave popcorn product and method for production thereof description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060204622, Sweet microwave popcorn product and method for production thereof. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The present invention relates to a sweet microwave popcorn product that can be prepared by the consumer in a single-step and a method for its production. BACKGROUND OF THE INVENTION [0002] Microwaveable popcorn is one of the most popular snack foods on the market today. Currently, there are several commercially available microwaveable popcorn products containing a sugar-based glaze or coating. In these products, the sugar-based glaze or coating is added separately to the popcorn after it has been popped. Manufacturers have experienced difficulties producing a product where the sugar-based coating is formed on the popcorn during popping (i.e., in a single step) due to technical difficulties in popping popcorn and heating a sugar-based composition simultaneously in a microwave oven. Specifically, at elevated temperatures and in the presence of moisture, simple sugars darken and polymerize in a process known as carmelization. Carmelization occurs at virtually the same temperature at which popcorn pops. Carmelization is enhanced by the presence of oil in the product. As a result, when a sugar-based glaze is heated in a microwave along with the popcorn, a food product is obtained that is not only visually undesirable, but also effectively inedible due to its burnt odor and flavor. Accordingly, a need exists for a single-step sweet microwave popcorn product that avoids these drawbacks. SUMMARY OF THE INVENTION [0003] The present invention concerns a sweet microwave popcorn product that can be prepared by the consumer in a single step, as well as a method for its production. In one embodiment, the invention is directed to a sweet microwave popcorn product comprising a microwaveable container; a plurality of unpopped corn kernels in the container; and a plurality of sugar pellets in the container. Each sugar pellet comprises sugar in an amount of at least about 15% by weight, based on the total weight of the sugar pellet. The sugar pellets are substantially free of an emulsifying agent. [0004] In another embodiment, the invention is directed to a method for producing a microwave popcorn product. The method comprises providing a microwaveable container having a top, a bottom, and an opening at the top of the container. The method further comprises introducing into the container sugar pellets and unpopped corn kernels, wherein the sugar pellets and unpopped corn kernels are not homogeneously mixed; and introducing into the container an oil component, wherein more of the oil component is maintained in the container with the unpopped corn kernels than is maintained with the sugar pellets. [0005] In another embodiment, the invention is directed to a method for producing a microwave popcorn product. The method comprises providing a microwaveable container having a top, a bottom, and an opening at the top of the container. Sugar pellets and unpopped corn kernels are introduced into the container so that the sugar pellets and unpopped corn kernels are not homogeneously mixed. Each sugar pellet comprises sugar in an amount of at least about 15% by weight, based on the total weight of the sugar pellet, and is substantially free of an emulsifying agent. DESCRIPTION OF THE DRAWINGS [0006] These and other features of the advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein: [0007] FIG. 1 is a top cut-away view of a microwave popcorn product according to the invention with the susceptor shown in phantom. [0008] FIG. 2 is a top cut-away view of an alternative microwave popcorn product according to the invention with the susceptor shown in phantom. DETAILED DESCRIPTION [0009] The invention concerns a sweet microwaveable popcorn composition comprising unpopped corn kernels, sugar pellets, and optionally an oil component. In accordance with the invention, the unpopped corn kernels can be any hulled or dehulled popcorn kernel capable of use as a microwave popcorn. The kernels may be large, medium, small, white, yellow, flavored or any other suitable type of kernel. A particularly preferred type of popcorn is "mushroom" or "butterfly" popcorn. [0010] The sugar pellets comprise sugar and preferably corn syrup. Each sugar pellet preferably comprises at least about 15%, more preferably from about 30% to about 75%, by weight sugar, based on the total weight of the sugar pellet. As used herein, the term "sugar" includes mono-, di-, tri-, and polysaccharides, including polydextrose, as well as sugar substitutes, such as sugar alcohols, including sorbitol, xylitol, and mannitol. The preferred sugar for use in the sugar pellets of the invention is sucrose. The sugar pellets are substantially free of an emulsifying agent, and preferably contain less than 0.1 wt % of an emulsifying agent, and more preferably contain no emulsifying agent. [0011] The corn syrup component of the sugar pellet comprises a partial hydrolysate of starch or a hydrogenated starch hydrolysate. The term "corn syrup" is further intended to embrace not only those syrups that are generally called in the trade glucose syrups, but also all other partial hydrolysates of starch including high fructose corn syrups. The term is also intended to include solid corn syrup. The sugar to corn syrup ratio in the sugar pellets preferably ranges from about 1:1 to about 5:1. [0012] The term "pellet" as used herein is not limited to pellet-shaped or -sized pieces, but is intended to encompass all three dimensional shapes. Suitable pellet shapes include regular and irregular shapes, such as spheres, ellipses, cubes, rods, chips, flakes and the like. Suitable sugar pellets for use in connection with the invention are commercially available from Primrose Candy Company (Chicago, Ill.) and Ferrera Pan Candy Company (Forest Park, Ill.). [0013] Regardless of the sugar used, the sugar pellets should possess a sweet taste. Therefore, if in preparing the sugar pellets, a sugar is used that does not possess a sweet taste, such as certain polysaccharides, then an additional sugar should be used that, either alone or in combination with the non-sweet sugar, possesses a sweet taste. Artificial sweeteners such as sucralose, acesulfame potassium, and aspartame can also be used to provide a sweet taste if the sugar used in preparing the pellets does not itself do so. [0014] The sugar pellets can further comprise a polishing material, such as paraffin wax, microcrystalline wax, beeswax, candelilla wax, carnauba wax, polyethylene wax, animal fat, vegetable oil, hydrogenated vegetable oil, partially hydrogenated vegetable oil, cocoa butter, corn zein, whey protein, hydroxymethylcellulose, methylcellulose, or ethylcellulose. [0015] To minimize burning of the sugar during microwaving, the sugar pellets have a relatively low moisture content. Preferably the moisture content of the sugar pellets ranges from about 0.5% to about 6%, more preferably from about 1% to about 5%, still more preferably from about 1.5% to about 3.5%. [0016] A particularly preferred method for preparing the sugar pellets in accordance with the invention comprises admixing sugar and corn syrup. The admixture is heated to a temperature ranging from about 110.degree. C. to about 170.degree. C., more preferably from about 130.degree. C. to about 150.degree. C., to remove moisture. The heated admixture is then formed into pellets. Preferably following heating and prior to forming pellets, the admixture is subjected to a vacuum, which helps reduce the moisture content of the pellets. The sugar pellets prepared according to this process can be, following the forming step, substantially the same size and density as the unpopped kernels. [0017] If the sugar pellets are to comprise a polishing material, preferably following the forming step the pellets are coated with a coating material and then polished with the polishing material. Preferably the coating material (e.g., sugar syrup) is poured over the sugar pellets using traditional panning procedures as such as that described by Minifi, B. in Chocolate Manufacture, Chocolate, Cocoa and Confectionary, AVI Publishing Co., Inc., Westport, Conn. (1982), although other coating procedures known in the art may be used as well. For hot panning, the coating material is preferably a crystallizing syrup containing sucrose. Successive layers of syrup are applied to the sugar pellets with excess sugar moisture removed through the application of heat to the pan. For cold panning, the coating material is preferably a non-crystallizing syrup containing sucrose or other sugars, and one or more corn syrups. Successive layers of syrup are applied to the sugar pellets with excess syrup moisture absorbed by dry sugar or starch, which is applied directly to the syrup-coated sugar pellets. Regardless of whether a crystallizing or non-crystallizing syrup is used, the syrup can also contain minor amounts of gums, flavoring agents, and/or coloring agents. A suitable coating machine is the Thomas Engineering Accela Cota Tablet Coating System from Thomas Engineering, Inc. Other coating devices include the Driacoater, Hi-Coater, and Volvo or tulip pans. Thereafter, the pellets are coated with wax, which is then polished using a panning process, as is known in the art. Suitable waxes for use in connection with the invention include paraffin wax, microcrystalline wax, beeswax, candelilla wax, carnauba wax, and polyethylene wax. [0018] The oil component is preferably present in the form of a slurry at elevated temperatures, e.g., around 120.degree. C., and in generally solid form at room temperature. Oils suitable for use in the present invention include partially hydrogenated oils, such vegetable oil, sunflower oil, safflower oil, rapeseed oil, cottonseed oil, maize oil, linseed oil, high oleic acid residue containing varieties thereof, groundnut oil, and mixtures thereof. The oil enhances the flavor of the microwaved product. If desired, the oil component can include an artificial sweetener, such as those listed above. A particularly preferred composition for the oil component comprises partially hydrogenated soybean oil, salt, color, butter flavor and sucralose. [0019] The oil component can further include a flavoring agent and/or coloring agent. Suitable flavoring agents include natural and artificial flavors, such as synthetic flavor oils and flavoring aromatics and/or oils, oleoresins and extracts derived from plants, leaves, flowers, fruits, and so forth, and combinations thereof. Particularly useful flavorings include artificial, natural and synthetic fruit flavors such as vanilla, and citrus oils including lemon, orange, lime, grapefruit, and fruit essences including apple, pear, peach, grape, strawberry, raspberry, cherry, plum, pineapple, and apricot. The flavoring agents may be in liquid or solid form. Commonly used flavors include mints such as peppermint, menthol, artificial vanilla, cinnamon derivatives, and various fruit favors. Other flavorings that can be used include aldehyde flavorings, such as acetaldehyde (apple), benzaldehyde (cherry, almond), anisic aldehyde (licorice, anise), cinnamic aldehyde (cinnamon), citral, i.e., alpha-citral (lemon, lime), neral, i.e., beta-citral (lemon, lime), decanal (orange, lemon), ethyl vanillin (vanilla, cream), heliotrope, i.e., piperonal (vanilla, cream), vanillin (vanilla, cream), alpha-amyl cinnamaldehyde (spicy fruity flavors), butyraldehyde (butter, cheese), valeraldehyde (butter, cheese), citronellal (modifies, many types), decanal (citrus fruits), aldehyde C-8 (citrus fruits), aldehyde C-9 (citrus fruits), aldehyde C-12 (citrus fruits), 2-ethylbutyeraldehyde (berry fruits), hexenel, i.e., trans-2 (berry fruits), tolyl aldehyde (cherry, almond), veratraldehyde (vanilla), 2,6-dimethyl-5-heptanal, i.e., melonal (melon), 2,6-dimethyloctanal (green fruit), and 2-dodecenal (citrus, mandarin), cherry, grape, strawberry shortcake, and the like. Preferred flavoring agents include butter, brown sugar, caramel, cooked milk, maple, vanilla, cream, pastry, marshmallow, cheese, cinnamon, and honey. Other examples of suitable flavoring agents are described in S. Arctander, Perfume and Flavor Chemicals (1969) and Allure Publishing Corporation's Flavor and Fragrance Materials (1993), the disclosures of which are incorporated herein by reference. In general, the amount of flavoring agent used should be in an amount effective to provide the desired or acceptable taste to the consumer. Continue reading about Sweet microwave popcorn product and method for production thereof... 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