Patent Grant
8759730
This application claims priority to provisional U.S. Patent Application No. 61/136,644, filed Sep. 22, 2008, the entire content of which is incorporated herein by this reference thereto.
This specification generally concerns a microwaveable food package and methods of using that package to heat a comestible product. More particularly, this specification deals with a microwaveable container that can be configured to provide alternative heating techniques yielding alternate characteristics for the comestible product.
A microwaveable carton according to this disclosure preferably is constructed and arranged so that the carton can be used in at least two configurations to heat and/or cook a food product packaged therein. Preferably, in at least one of the configurations, the carton includes a plurality of microwave susceptor surfaces operable to reflect microwave energy away from a cavity containing the food product, while also generating sufficient radiant heat to affect the heating and/or cooking of at least the top surface of the food product. In addition, at least one other susceptor surface has a diminished reflectivity so that a portion of the incident microwave energy is transmitted and is effective to heat and/or cook other portions of the food product.
Further, a method of heating a food product is disclosed in which one of a plurality of carton configurations is selected depending upon whether a softer textured product or a crispier textured product is desired.
Many objects and advantages of this invention will be apparent to those skilled in the art when this description is read in conjunction with the appended drawings wherein like reference numerals have been applied to like elements and wherein:
As described herein, a microwaveable, food-packaging carton preferably includes a plurality of microwave susceptors. The microwave susceptors may be focused microwave susceptors. That carton is preferably formed or erected from a blank. When used to heat the comestible product in a microwave oven, the carton converts to a microwave heating tray that utilizes (i) microwave energy to directly heat a portion of the comestible product, (ii) radiant heat generated by susceptor materials energized by microwave energy, or (iii) a combination of microwave energy and radiant heat to quickly and uniformly heat a comestible product. Based on the cooking configuration, thermal transfer is accomplished through conduction, radiation, convection, and/or dielectric heating. The carton itself can be arranged in any of several different configurations to provide desired characteristics for the comestible product, which can be either softer or crispier texture in bread products. The carton can be used to provide more uniform heating of food products including breads and toppings. In an alternative embodiment, a carton can have a single cooking configuration.
In the preferred embodiment (see
Preferably, the material used to form the blank 100 has a thickness in the range of about 14 to about 24 points (i.e., about 0.014 inches to about 0.024 inches) and preferably may be a thickness of about 18 points (i.e., 0.018 inch). The material may, for example, comprise solid bleached sulfate (SBS) paperboard. The paperboard can be any color. Nevertheless, the paperboard preferably may be white since white can readily be printed with product marketing indicia prior to formation into the final package. Desirably, the paperboard selected is safe for use with food products and safe for use in microwave ovens. The 18 point paperboard may have 48 gauge (0.00048 inch) metalized oriented polyester (OPET) adhesively laminated to one or more locations on its surface intended to face the interior of the carton. Furthermore, a food safe coating, such as a clay coating, may be provided on the outside surface (or non food contacting surface) to enhance printability. Preferably, any such coatings are microwave safe. At least a portion of the blank 100 may be coated and/or may be printed with designs, indicia, and/or product marketing indicia.
In other embodiments, the blank 100 may be formed from other microwaveable materials, such as heat resistant plastics, and the like when exposed to microwave energy and the resulting heating temperatures. Preferably, these alternative materials are also safe for use with foods.
In a preferred embodiment, the blank 100 includes two major surface portions 200, 202 which may be generally square or rectangular. The first major surface portion 200 eventually becomes the bottom of as assembled carton 300 (see
Integrally attached to two generally parallel side edges of the first major surface portion 200 are a pair of generally rectangular inner side panels 206, 208. Integrally attached to each of the other generally parallel side edges of the first major surface portion 200 are a generally rectangular inner front panel 210 and a generally rectangular back panel 212. Each end of the back panel 212 preferably includes a corresponding laterally extending tab 214, 214′, which may be glued or otherwise affixed to a corresponding one of the adjacent inner side panels 206, 208 during carton assembly.
The second major surface portion 202 of the blank 100 is integrally connected along one side to the back panel 212 so that the two major surface portions 200, 202 are aligned with one another along the longitudinal axis of the blank 100. Integrally attached to two generally parallel sides of the second major surface portion 202 is a generally rectangular corresponding outer side panel 218, 220. Each outer side panel 218, 220 is generally longitudinally aligned with a corresponding one of the inner side panels 206, 208. Integrally attached to the remaining side of the second major surface portion 202 is an outer front panel 230. Each end of the outer front panel 230 includes a locking tab 215, 215′ having a protrusion 217 designed to cooperate with a corresponding one of the inner side panels 206, 208 to form a corner of the carton when assembled. The outer front panel 230 includes 50% cut lines 245 and a pull tab end that form a detachable tear strip 205. A finger-access opening 239 is provided adjacent to the pull tab end of the tear strip 205. Suitable conventional scoring and creasing defines carton edges (shown as broken lines) in the blank 100 so that carton forming machinery can form an open tray and, after the tray is filled with a comestible food product, close and seal the top to make a finished package.
The surface of the blank 100 as seen in
The second susceptor surface 242 is provided on the second major surface 202 and may be attached to the surface portion 202 adhesively or mechanically, and may be printed thereon, or otherwise affixed thereto. The perimeter of the second susceptor surface 242 is configured and sized so that it can be slightly inside 50% cut lines 244, 246 which define the lines along which a major portion of the second major panel 204 can be separated so as to open the assembled carton. Again, the perimeter of the second susceptor surface may be spaced from those cut lines by a minimum distance lying in the range of about 0.125 to about 0.5 inches from those 50% cut lines 244, 246. In addition, the perimeter of the second susceptor surface may be spaced from the hinge line between the bank panel 212 and the second major portion 204. With such an arrangement, the second susceptor panel 242 provides substantial coextensivity with the removable portion of the second major surface 204. If desired the second susceptor panel 242 may be generally square or generally rectangular. Moreover, the second susceptor panel 242 may include chamfered corner regions so that its perimeter more closely approaches the extent of the removable portion of the surface 204.
The third susceptor surface 241 is preferably located to be on the inner front panel 210. This third susceptor surface 241 may be affixed to the front panel 210 in the manner described above with respect to the first and second susceptors. The third susceptor surface 241 may be generally rectangular with dimensions sufficient to substantially cover the inner front panel 210 such that the perimeter of the inner front panel 210 and the perimeter of the third susceptor surface are spaced from one another in the range of about 0.125 to about 0.375 inches.
The fourth susceptor surface 243 is preferably located on the back panel 212 and may be affixed to the back panel 212 in the manner described above in connection with the other susceptor panels. The fourth susceptor surface 243 may be generally rectangular with dimensions sufficient to substantially cover the back panel 212 while leaving a clearance in the range of about 0.125 to about 0.375 inches between the perimeter of the back panel 212 and the perimeter of the fourth susceptor surface 243.
For the preferred embodiment, four susceptor surfaces are used. However, additional susceptor surfaces may be provided in the carton. The total susceptor surface area should be selected such that the susceptors do not generate so much heat inside the carton when heated in a microwave oven that glue and other adhesives (used to form the carton) melt or otherwise degrade such that the carton loses structural integrity, falls apart, and/or cannot withstand heating. This can be accomplished by selecting high temperature adhesives for the carton or by adjusting the susceptor properties (area, optical density, patterning, and the like) or by a combination of both.
In other embodiments, first susceptor surfaces 242 may have chamfered corners or may be formed in a variety of shapes including, but not limited to, circular, rectangular, oval, and the like. Preferably, the shape of the principal susceptor surfaces 240, 242 is chosen to conform to the principal dimensions of the food product to be heated.
Each susceptor surface 240, 241, 242, 243 can be formed of any suitable microwave-active material including metallic substances, such as aluminum, or non-metallic, ink-based materials. For example, the susceptor surfaces can be formed of a polyester film metalized with aluminum. If used, ink-based susceptor materials can be printed directly onto the paperboard, thus providing a simple, quick, and easy method of forming susceptor surfaces without the need for align, register, an affix laminate susceptor materials. In other embodiments, the susceptor surface described herein can be included in the carton as a loose, separate piece of susceptor card stock that can be placed into position prior to heating.
Preferably, the susceptors used herein have an optical density lying in the range of about 0.20 to about 0.28. For some applications, the optical density may be about 0.215. Optical density can also be used to characterized susceptor materials. The optical density (absorbance) is a measure of the amount of incident electromagnetic energy that transfers through a partially absorbing substance, such as a metalized film, and can be measured in absorbance units (AU), which are logarithmic units in AU used to measure optical density. If T is the percentage of electromagnetic energy transmitted, then the absorbance is calculated from the expression
AU=−log 100 T
An increase in absorbance of 1.0 AU corresponds to a reduction in transmittance by a factor of 10. If the absorbance is 1.0 AU then 10% of the electromagnetic energy is transmitted, while at 2.0 AU, only 1% of electromagnetic energy is transmitted.
The absorbance is a function of the susceptor material as well as its thickness and its pattern. Accordingly, a predetermined absorbance can be attained by suitable combinations of material, thickness, and pattern. Thus, each of the susceptors used in this structure can be made to have the predetermined absorbance characteristic needed for a particular food heating method.
In the preferred embodiment, the susceptors can be supported on a substrate formed of a 48 gauge biaxially oriented polyester metalized with aluminum (MPET), which is then laminated to 18 point solid bleached sulfate paperboard.
Not wishing to be bound by theory, it is believed that increasing the optical density to about 0.26 to about 0.27 will result in optimum bread characteristics because the microwave power ratio changes to approximately 10% transmission, 45% absorption and 45% reflection.
The resistance, absorption and transmittance can be adjusted by altering the optical density, adjusting the patterning of the susceptor material, and/or by layering the susceptor material. For example, as shown in
In the preferred embodiment, the first susceptor surface 240 may be patterned to provide less than full strength heating. Susceptor patterning on all surfaces is dependent on the balance of dough and/or bread based product versus toppings and/or fillings in the food product to be microwave heated, and the intended crisping or browning on the bread. Decreasing the percentage of susceptor on the top and sides of the container will increase the microwave transmission into the various layers of the food product being heated. Not wishing to be bound by theory, it is believed that decreasing the percentage of susceptor on the top and sides of the container may have a negative impact on the quality of bread-based frozen products heated in the microwave.
For example, the susceptors can be 5% to 100% patterned on all surfaces. The second, third and fourth susceptors 241, 242, 243 located on the top and sides of the container are 100% patterned, while the first susceptor 240 is about 40% to about 60% patterned. For example, in a preferred embodiment, the first susceptor surface is 20% patterned to about 100% patterned, more preferably about 25% patterned to about 55% patterned. Also in a preferred embodiment, the second susceptor surface 242 is formed of a substantially continuous susceptor to provide higher heating temperatures. However, in other embodiments, the second susceptor surface 242 may be patterned. The third and fourth susceptor surfaces 241, 243 may be substantially continuous, as in the preferred embodiment, or patterned to reduce the strength thereof. The patterning of the susceptors may be varied depending on the strength needed to quickly and uniformly heat the type of food product contained within the carton. In addition, the patterning of the susceptors can be chosen to adjust the heating strength, which in turn may affect the final texture of the food product. The susceptors 241, 242, 243 may have the same or different patterns.
The susceptors for the second, third and fourth panels 241, 242, 243 are most favorable to the microwave performance of the bread when they have about 100% coverage of the associated surface. This arrangement maximizes reflection and absorption of microwave energy into the non-contact susceptor surfaces. This arrangement will also increase the heating of the product through radiant heat and decrease product exposure to microwaves. The susceptor pattern on the first panel 240 can be varied from 0% to 100% coverage depending on the amount of browning and crisping desired on the bottom surface of the product.
To assemble the package, the inner side panels 206, 208, the inner front panel 210, and the back panel 212 are folded relative to the first major surface 200 so that the first susceptor 240 is located at the bottom of the partially assembled carton. The tabs 214, 214′ are attached to a corresponding interior surface of the corresponding inner side panel 206, 208 so that a self-supporting tray is formed with an integral lid. A food product, that has been enclosed and sealed in an external package, is then deposited in the partially assembled carton. The external package for the food product may, for example, comprise a clear food-grade film material. The dimensions of the food product and the carton blank have been selected such that the food product is received in the partially assembled carton so that dimensions of the food product are substantially coextensive with the first susceptor 240, and are spaced from the back panel 212 and the susceptor surface 243. With the dimensions of the food product and the carton thus being coordinated, the food product has a predetermined weight. The food product may be frozen prior to placement in the partially assembled carton. Alternatively, the food product may be frozen after the formation, filling, and sealing of the carton is completed.
The filled, partially assembled package is subsequently closed and sealed. In particular, the second major surface 202 is folded along the fold line defined between the second major surface 204 and the rear panel 212 so that the second major surface 202 is positioned overlying the tray portion of the package. Thereafter, the outer side panels 218, 220 folded into overlying relationship with the corresponding inner side panels 206, 208 and are sealed and/or attached thereto. Either before or after the side panels for folded and/or sealed, the inner front panel 210 is folded upwardly along the crease line defined between the inner front panel 210 and the first panel portion 200. The outer front panel 230 is folded downwardly along the crease line defined between the outer front panel 230 and the second panel portion 202 so that the outer front panel 230 overlies the inner front panel portion 210. The tabs 215, 215′ are then sealed and/or affixed to corresponding outer side panels 218, 220. If desired, the lower edge portion of the outer front panel 230 may secured to the adjacent bottom portion of the inner front panel 210. Suitable conventional food-safe glues can be used to attach the various surfaces to one another, as set forth above. The completely assembled package is illustrated in
The major dimensions of the blank 100 (see
The particular food product for which the carton described above can be used is not intended to be limited. In this connection the food product may comprise flatbreads (such as pita bread, crepe, tortilla, focaccia, piadina, naan, chapati, lavash, roti, pancake, blintz, lafa, aish mehahra, barbari bread, bazlama, bhakri, bhatura, bing, flammkuchen bread, flatkaka, injera, laobing, laxoox, lefse, luchi, malooga, markook, ngome, papadum, paratha, pide, rieska, sangak, tunnbrod, yufka, galette), panini bread (which could consist of French bread, sourdough bread, ciabatta, or other related forms of leavened or unleavened bread), biscuits, English muffins, muffins, crumpets, scones, shortcake, waffles, pastries, croissants, pizza, ealzones, stromboli, garlic bread, bagels, baguettes, hamburger rolls, hot dog rolls, breadsticks, Brioche, French toast, pocket sandwiches (fillings encased in a bread/dough), quiche and other pastry or pie crusts. Moreover, any of those food products may also be provided with a topping. Thus, the food product may include (a) an open-pored, light, bread-like portion and (b) a denser topping or cover layer containing other edible components. Ordinarily, the width and length of the carton cavity exceed the nominal predetermined dimensions of the food product to accommodate variations in the nominal dimensions that occur during production and so that the food product is fully supported by one of the major surfaces 200, 202. Typically, the food product is about 1 inch to about 1.25 inches thick. Typically, the bread product can include toppings, such that the bread to topping ratio is about 40/60. Preferably, the food product is fully and/or partially cooked so that the food product is only partially cooked and/or heated using the carton 300 described herein. In a preferred embodiment, the food product is fully cooked and is heated using the carton 300.
It should be noted that the completed carton 300 preferably includes 50% cut lines 244′, 246′ extending from the 50% cut lines 245 on the outer front panel 230 at the ends of the pull tab 238. The 50% cut lines 244′, 246′ also extend along (but are spaced from) peripheral side edges of the second major surface 202 between the second major surface 202 and the corresponding side panels 218, 220 (not visible), such that a generally triangular gusset is defined at each corner of the carton 300 on the top surface 202 of the carton 300. Moreover, in the preferred embodiment, the 50% cut lines 244′, 246′ on the inside of the second major surface 202 may be laterally offset from the 50% cut lines 244, 246 (see
A cross-sectional view of the assembled carton 300 containing a food product 400 is shown in
In the preferred embodiment, when assembled, the second major surface 202 and susceptor surface 242, back panel 212 and fourth susceptor surface 243, and inner front panel 210 and third susceptor surface 241 of the carton 300 are spaced from and do not contact the food. Preferably, a “non-contact” space substantially surrounds the sides and top of the food product 400 so as to leave an empty peripheral space 340 between the food product 400 and the panels 202, 212, 210.
As used herein, the terms “non-contact” and “non-contact spacing” refer to the distance between the top and side panels of the carton and the food product contained therein. In the preferred embodiment, the food product is about 1 inch to about 1.25 inches thick. The food product thickness tolerance is about 0.125 inch to about 0.25 inch. The carton has an interior height of about 1.75 inches. Thus, the “non-contact spacing” can lie in the range from about 0.10 inch to about 0.75 inch, or more preferably in the range of about 0.125 inch to about 0.625 inch, and most preferably in the range of 0.125 inch to about 0.375 inch. This “non-contact” spacing is important when the food product is heated within the carton with the top closed. If the non-contact spacing is too small, the food product may be overheated and may burn. If the non-contact spacing is too large, the heating energy may be diminished and the food product will not be uniformly heated.
In the preferred embodiment, the non-contact susceptor surface temperatures range from about 370° F. to about 420° F. after about 40 seconds of heat time, while the temperature range of a susceptor in contact with the product depends upon the product temperature, contact area and mass of the food product.
The second susceptor surface 242 (see
The first step in using a carton of the type described above involves packaging the food product 450 (see
After distribution and purchase, a consumer ultimately decides to prepare the food item for consumption. As a first step in consumption, the consumer opens 456 the package. The opening step is accomplished by grasping the end of the pull tab 238 (see
With the lid 202 opened (see
Once the food product has thus been prepared, the consumer selects 460 (see
The “non-contact” spacing removes the food product from contact with the front and rear susceptor surfaces so that conductive heat transfer is avoided with those susceptor surfaces. In addition, by using a substantially continuous susceptor surface at the front and rear panels of the carton, those susceptor panels function as a shield against microwave radiation through the corresponding surfaces thereby reducing the intensity of microwave energy transmitted to the food product therethrough. Shielding is effected since the susceptors on the non-contact panels act to both reflect microwave energy away from the interior of the package and the food product therein as well as to absorb microwave energy incident on those surfaces. The microwave susceptor on the inside of the top 202 is also preferably substantially continuous and operates in the same manner as the front and rear susceptors to reflect portions of the incident microwave energy and/or absorb portions of that incident microwave energy. Nevertheless, the susceptor surfaces do not transmit significant portions of the incident microwave energy.
Due to the absorption of microwave energy by the top, front and rear susceptors, those susceptors become very hot in the presence of the microwave radiation. Preferably, those susceptors are designed so as to attain a temperature in the range of about 250° F. to less than about 450° F. The upper limit of the temperature range is selected so that the temperature attained is less than the kindling temperature of the paperboard used for the container. In that way, the hot susceptor surfaces will not cause the carton material to burn or become scorched. As a result, of the high temperature attained by the susceptor surfaces, the susceptor surfaces transfer heat by radiation to the food product inside the carton. The non-contact spacing between those susceptors of the food product is selected such that the heat energy transmitted by radiation to the food product is substantial, more particularly the energy transmitted by radiation to the food product exceeds the heat generated by microwave energy, and the heat generated by radiation by the susceptor surfaces may be as high as about 90% of the heat generated by the susceptor surfaces in the presence of microwave energy. Thus, the food product is heated by the radiant heat given off by the non-contact susceptor surfaces. Heating with radiant heat provides an important effect on the surface of the food product, particularly where the food product has a coating—more uniform heating of the topping is effected without hot-spots that are typical of heating only with microwave energy. Moreover, the heat applied from the front, rear, and top susceptors can be applied without substantial microwave interaction.
As discussed above, the bottom susceptor 240 (see
Of course, microwave energy does access the cavity within the carton through the side panels without significant obstruction or degradation. Nevertheless, the different characteristics of the susceptor panels permit microwave heating throughout the body of the food product at the same time that the topping is selectively heated by radiant heating from the top susceptor.
Preferably, the use of radiant heating to heat the food products results in better texture as compared to food products that are heated in a microwave using a single susceptor. In addition, the use of both top and side non-contact susceptors accelerates heating of the top surface of the food product while heating the base of the food product more slowly. This arrangement provides more even and more focused heating of the topping, while increasing the overall heating time necessary to thoroughly heat the bread portion of the food product. In addition, the base exposure to transmitted microwaves is also reduced resulting in a product in which the bread portion is not chewy.
For example, when heating a microwave pizza, the heating of the toppings can be accelerated while the bread portion of the pizza is heated more slowly. The increased water activity in the toppings of the pizza acts to absorb microwave energy thereby providing additional protection of the bread from transmitted microwaves. By adding a susceptor to the top of the container, the water contained in toppings of the food product are more quickly transitioned from solid to liquid state. Because the bread is heated by microwave energy—albeit at a substantially reduced energy level, the bread is heated throughout at a level that allow the bread portion to be heated in the same amount of heating time required for the radiant heating to heat the topping portion. As a result, there is substantially no change in the physical, internal structure of the bread and the bread maintains a soft texture.
Not wishing to be bound by theory, it is believed that in use the heat transfer by radiation drops off about 0.1% to about 10% through the non-contact distances set forth above. In addition, because the carton 300 is closed when heating in the first configuration, the food product is heated in a moisture-rich environment with the benefits of convective heat currents reducing total water loss and further shortening product heat time.
Besides the heating aspects noted above, the first susceptor surface 240 contacts the bottom of the food product during heating. In the preferred embodiment, the first susceptor surface 240 is less than full strength and functions to moderately crisp and/or bake the bottom of the food product without degrading its texture.
After the food product has been heated in the microwave oven 468 (see
When the consumer selects the crispy product heating configuration for the package, (see
Once the food product has been exposed, the consumer can remove the food product 400 from the carton 300 (see
Preferably, after being subjected to microwave heating, the second heating configuration for the carton yields a heated food product having a crispy texture with a tender inner crumb. More particularly, during heating, the bottom of the food product receives heat by conduction from the underlying susceptor 242 originally position on the inside of the top of the carton. Moreover, the susceptor 242 rests in a back-to-back arrangement resulting with the susceptor 240 originally located in the bottom of the carton. Because the top 202 is a planar surface, heat is normally lost to both sides. But, by placing the bottom 200 and the first susceptor surface 240 in a back-to-back relationship with the top 202 and second susceptor surface 242, the susceptor 240 both reduces heat loss from the susceptor 242 away from the food product and improves the thermal energy available to the food product by conduction during the heating operation. Given that the second susceptor 242 has a continuous configuration, while the first susceptor 240 has a patterned configuration, the second susceptor 242 provides a hotter surface for crisping the bottom of the food product. As a result, a food product cooked or heated with this second carton configuration has a crispier texture than a food product cooked or heated by the first carton configuration.
When using the crispy heat method, first and second susceptors 240, 242 are back to back and can reach a combined temperature of about 425° F. A container having a single susceptor typically reaches a temperature of about 355° F., while a container without any susceptors typically reaches a temperature of only about 200° F. Not wishing to be bound by theory, it is believed that the higher temperatures reached by the containers described herein provide more desirable heating for bread products and gives a crispy texture to the outside of such products. The container as designed minimizes overheating of toppings due to the reflection of microwave energy from the second susceptor, while simulating pizza-oven-like heating of the crust. When the same food products are heated in microwave containers lacking second, third and fourth susceptors, the toppings tend to be overheated while the underlying bread product is properly heated. When heated in microwave containers lacking any susceptors, the toppings are also overheated, while the lower bottom surface is heated resulting in a tough crust.
Furthermore, when a food product is heated in the microwave oven 466 with this second carton configuration, the top, sides, and full thickness of the food product are exposed to microwave energy in the oven, and are not shielded from that energy, except through the bottom surface. Interaction of that microwave energy with the bread portion of the food product increases the chewiness of the food product being heated in comparison to a food product heated with a carton in the first configuration discussed above. After heating, the food product can be folded 468 as described above (see
When using the soft heat method, the final temperature of the crust has been measured at about 178° F. after heating on high in a 1200 W microwave for about 2 minutes and 30 seconds. The food product being heated is a flatbread product including about 33.51% plain flatbread, 14.76% sauce, 20.58% vegetable blend, 21.16% protein and about 9.99% cheese. The ratio of bread to toppings preferably is about 1:2, for example about 34:66. The flatbread may be a leavened, pressed, par-baked, pocketless pita style bread that is about 0.24 to about 0.30 inch thick. When the same flatbread product is heated using the crisp heat method, the final temperature of the crust was measured at about 187° F. The increase in topping temperature was about 15° F.
For both the soft and crispy heat methods, the specified susceptor optical density is about 0.215 (measured at a wavelength of 626 mm). For such susceptor material, 20% of the microwave energy is reflected, 45% is absorbed, and 35% is transmitted to the product. Therefore, the susceptor, as designed, for the non-contact surfaces of the package reduces transmission of microwave energy by about 65%. The effective area of the package having this reduction in transmission is about 51.625 inches or about 64% of the package internal surface area not including the bottom crisping portion. Despite this reduction of microwave transmission, the topping and crust final temperatures with and without the top and side susceptors are substantially the same.
Ideally, the container is designed so that the toppings and bread reach about 165° F. simultaneously. However, for optimum bread performance, the bread can be brought to about 165° after the toppings.
Other configurations of the carton 300 can be used in additional heating and heating methods. For example, the top can be completely removed prior to heating. In such a configuration, the food product would be heated principally by microwave energy, with a reduced heating of the bottom surface because the bottom susceptor 240 is patterned and has a reduced heating capacity and the shielding provided by the top susceptor 242 is not available. In another configuration, the top of the carton can be removed, rotated by an angle of about 45° and placed at an angle over the top edge of the side, back and front panels of the carton. In this configuration, moisture released during heating of the food product is released from the carton cavity and allowed to vent into the microwave oven.
Generally, the texture of a food product heated in one of the heating configurations disclosed herein is improved as compared to the texture of foods heated using a single microwave susceptor surface, and other microwave carton configurations. The texture of food products heated with the carton disclosed herein may be measured and evaluated for comparison using a standard food texture analyzer, such as the TA.XTPlus or the TA.XT2i Texture Analyzer, available from Texture Technologies Corp of Westchester County, New York. Such texture analyzers can utilize different functions and/or attachments, such as a variety of probes, to quantify the crunchiness, crispness, brittleness, hardness, swelling, firmness, adhesiveness, tack, tackiness, resilience, springiness, cohesiveness, fracturability, shelf life, and many other characteristics of food products.
For example, to study microwave heated flatbread, the flatbread can be heated in either the first heating configuration (non-contact method) or the second heating configuration (contact method). Susceptor material is placed inside the package in both contact and non-contact methods to convert microwave energy to radiant and conductive heat to ensure the flatbread texture is preserved and any toppings it may contain are heated evenly and thoroughly.
For testing purposes, cartons made of the same material are first constructed. Some of the cartons should be constructed as described herein, while other cartons should include a single, standard susceptor on the bottom surface as in conventional microwave heating trays. Identical flatbreads with no toppings may then placed in each carton and heated for 1 minute. The flatbreads are then allowed to cool for 1 minute after heating. The cartons and the flatbread can then be removed from the microwave, sliced into four equal sections having a width of about 1.5 inches at the widest point. The slices can then be evaluated for texture using one of the texture analyzers described in detail above. The results should indicate that the texture of the flatbread is preserved after heating when heated in the carton described herein, as contrasted to flatbread heated in standard cartons having no susceptors or cartons having a single susceptor. After heating, the flatbreads heated in the different heating methods can have the same or different temperatures. However, the flatbread heated in the cartons described herein should prove to be crispier when heated in the second configuration or softer when heated in the first configuration, when compared to flatbreads heated in standard, single susceptor cartons or cartons having no susceptors.
The food products heated using the first container configuration and radiant heating have a soft texture when compared to foods heated using a single microwave susceptor and tested using a texture analyzer. Food products heated using the second container configuration have a crispier texture with a tender inner crumb as measured by the texture analyzer than food products heated using a single microwave susceptor or no susceptors.
In a first test, the difference in toughness of a flatbread product heated in the containers described herein (test) and using the crispy heat method as compared to flatbread products heated in conventional microwave heating trays having no susceptors (control) is determined. The flatbread product used for all tests conducted herein include about 33.51% plain flatbread, 14.76% sauce, 20.58% vegetable blend, 21.16% protein and about 9.99% cheese. The ratio of bread to toppings is about 1:2. The flatbread is a leavened, pressed, par baked, pocketless pita style bread that is about 0.24 to about 0.30 inch thick.
First, a control flatbread is prepared using a standard microwave box and a test flatbread is prepared in a test container as described herein and having a patterned aluminum susceptor. Each sample is placed pre-grilled side face down in the package. Each sample is microwave heated for about 45 seconds at 100% power in a 1200 W microwave oven and allowed to stand for about 2 minutes after heating. Each sample is then removed from the container and quickly cut into strips of about 1⅛ inch to about 1¼ inch in width by about 3 inches to about 3⅛ inches in length using a knife and cutting board. The sample strips are carefully yet quickly mounted onto the lower and upper tines of a pizza rig, with care being taken not to tear or bend the sample.
The pizza rig used herein is a Pizza Tensile Rig (A/PT) using a 5 kg load cell that is mounted on a TA-XT2 Plus (TA) Texture Technologies Incorporated. Once the samples are loaded, the TA-XT2 Plus is activated. A second strip from the same Flatbread is run immediately afterward. Preferably, the TA-XT2 Plus has the following settings during testing: Mode: Measure Force in Tension; Option: Return to start; Pre-Test speed: N/A; Test speed: 5.0 mm/s; Post-Test speed: 10.0 mm/s; Distance: 45 mm; Time: 60 sec; Trigger Type: Button; and Data Acquisition Rate: 400 pps. A macro is written to determine the Maximum force (g), the force area (g.sec) and the gradient (g/sec) of the resulting plots from the TA-XT2 Plus run.
10 tests were done for each of the test group and the control group. For a few of the Flatbreads heated, a third strip was cut to ascertain whether the sample was becoming significantly tougher after more elapsed time following heating. The max force and force area values were used to evaluate sample “toughness” and compare the samples heated in the test box and those heated in the control box.
The outliers were identified using Grubb's test for statistical outliers, and is based on the assumption of normality. The Grubb's test calculates a P value only for the value furthest from the rest. Table 1 shows the critical values for Grubb's test. If Z is greater than the tabulated value, then P is less than 0.05.
After discarding outliers (only one was identified), the following number of data points, shown in Table 2, remain to be tested.
The maximum force test results for the control and test groups are shown in Table 3.
The normality testing showed that the test group's maximum force test results did not follow a normal distribution as shown in
Since susceptor maximum force results did not follow a normal distribution, the Levene test was used to determine whether there was equal variance for the two maximum force results. The Levene test is an inferential statistic used to assess the equality of variance in different samples. The p-value of 0.000 assures that the variances are unequal. Results of Levene's test are also shown in
As shown in Table 4, the means for maximum force of the samples heated in the control box are different from the maximum force in grams (g) of samples heated in the test box at 95% confidence. Table 4 includes the results of a 2 sample t-test with unequal variances.
The force-area results are shown in Table 5.
As shown in Table 5 and
The force test was used to determine whether there was equal variance for the two force-area results in grams per second (g/sec) and the results are shown in Table 6 below. The p-value of 0.000 assures that the variances are unequal.
As shown in the data, for the samples tested, two separate parameters from the texture analysis representing toughness of the sample are shown to be statistically different when comparing measurements of samples heated in the control box versus the test box. Thus, the containers described herein function to provide different textures to food products heated using the containers described herein as compared to conventional microwave containers.
In a second test for analyzing the texture of flatbreads heated using the containers described herein, identical flatbreads were heated in both the soft heat method and the crispy heat method. The property of “crispness” is then examined by statistical analysis of gradients (average slope of force plot in g/sec) obtained from the TA runs and potential differences between the heat preps will be determined.
A first sample is heated for about 2 minutes and thirty seconds using the soft heat method, while a second sample is heated for about 2 minutes and forty-five seconds using the crispy heat method. The samples were both heated in a 1200 W microwave oven. Following microwaving, the samples are allowed to sit in the microwave for an additional 1 minute. The toppings are then scraped off and the samples are placed top-down on a cutting board. Two replicate measurements are made on opposing sides of the sample.
During testing, the texture analyzer the following settings: Mode: Measure Force in Compression, Pre-Test speed: 1.0 mm/s, Test speed: 1.0 mm/s, Post-Test speed: 10.0 mm, Distance: 5.0 mm, Trigger Type: Auto-5 grams, and Data Acquisition Rate: 400 pps.
The Grubb's test for outliers, as described above, was applied to the data sets for both the soft and crispy heat methods. One data point was excluded from the “soft” set as it was determined to be a statistical outlier. Table 7 shows the data points obtained for 29 soft samples and 30 crisp samples. The data shown is measured in grams per second (g/sec).
Normality tests were then applied to both the soft data sets and the crispy data sets. Normality tests are used to determine whether data follows a normal distribution. Normality tests can further compute how likely an underlying random variable is to be normally distributed.
Both data sets were found to have a normal distribution (p>0.5). The data sets were then tested for equal variance, and the results are shown in Table 8. As shown, the data exhibits 95% Bonferroni confidence intervals for standard deviations, the F-test showed normal distribution, the test statistic was 0.39, and the P-value was 0.016.
Next, a two sample T-test assuming unequal variances was run and the results are shown in Table 9.
As shown in
As shown, the gradients obtained from the texture analyzer runs, which are analogous to the crispness of the samples, are visually and statistically different at 95% confidence. The samples heated in the microwave in the platform susceptor carton configuration for 2 minutes and 45 seconds are crispier than those heated in the microwave enclosed in the susceptor carton for 2 minutes and 30 seconds.
In alternative embodiments, the carton can be a top load carton formed of a blank 600 as substantially shown in
The second major surface portion 502 of the blank 600 is integrally connected along one side to the back panel 512 so that the two major surface portions 500, 502 are aligned with one another along the longitudinal axis of the blank 600. Integrally attached to two generally parallel sides of the second major surface portion 502 is a generally rectangular corresponding outer side panel 518, 520. Each outer side panel 518, 520 is generally longitudinally aligned with a corresponding one of the inner side panels 506, 508. Integrally attached to the remaining side of the second major surface portion 502 is an outer front panel 530. The outer front panel 530 includes cut lines 545 and a pull tab end 538 that form a tear zone 505 that can be pulled to lift and separate the top second major surface portion 502 from the remainder of the carton after assembly.
Preferably, the blank 600 includes five microwave susceptor surfaces disposed on portions of the blank that form inner portion of the assembled carton. The first susceptor surface 540 is provided on the first major surface portion 500 of the blank 600. This susceptor surface 540 may be attached to the surface portion 500 adhesively or mechanically, and may be printed thereon or otherwise affixed thereto. Preferably the first susceptor surface conforms to the shape of perimeter of the first surface portion 500. As illustrated, the first susceptor may be generally square, having dimensions sufficient to substantially cover the first major surface portion 502 while leaving a small clearance between the perimeter of the first susceptor surface 540 and the perimeter of the first major surface portion 500. Preferably the clearance may be on the order of about 0.125 to about 0.5 inches. To properly heat the food product, the first susceptor surface 540 should preferably be sized to correspond to the predetermined width dimensions of the food product to be packaged and to be substantially coextensive with the first major surface portion 500. While a 0.125 inch clearance distance between the respective perimeters meets the condition of substantial coextensivity, distances greater than 0.125 inch can also be accommodated as long as the product to be heated will have substantial surface contact with the susceptor material.
The second susceptor surface 542 is provided on the second major surface 502 and may be attached to the surface portion 502 adhesively or mechanically, and may be printed thereon, or otherwise affixed thereto. The perimeter of the second susceptor surface 542 is configured and sized so that it can be slightly inside 50% cut lines 544, 546 which define the lines along which a major portion of the second major panel 504 can be separated so as to open the assembled carton. Again, the perimeter of the second susceptor surface may be spaced from those cut lines by a minimum distance lying in the range of about 0.125 to about 0.5 inches from those 50% cut lines 544, 546. In addition, the perimeter of the second susceptor surface may be spaced from the hinge line between the bank panel 512 and the second major portion 504. With such an arrangement, the second susceptor panel 542 provides substantial coextensivity with the removable portion of the second major surface 504. If desired the second susceptor panel 542 may be generally square or generally rectangular. Moreover, the second susceptor panel 542 may include chamfered corner regions so that its perimeter more closely approaches the extent of the removable portion of the surface 504.
The third and fourth susceptor surfaces 541, 541′ are preferably located to be on the inner front panel 510. The third and fourth susceptor surfaces 541, 541′ may be affixed to the front panel 510 in the manner described above with respect to the first and second susceptors. The third and fourth susceptor surfaces 541, 541′ may be generally rectangular with dimensions sufficient to substantially cover the inner front panel 510 such that the perimeter of the inner front panel 510 and the perimeter of the third and fourth susceptor surfaces 541, 541′ are spaced from one another in the range of about 0.125 to about 0.375 inches.
The fifth susceptor surface 543 is preferably located on the back panel 512 and may be affixed to the back panel 512 in the manner described above in connection with the other susceptor panels. The fifth susceptor surface 543 may be generally rectangular with dimensions sufficient to substantially cover the back panel 512 while leaving a clearance in the range of about 0.125 to about 0.375 inches between the perimeter of the back panel 512 and the perimeter of the fifth susceptor surface 543.
Each of the susceptor surfaces can be formed of any suitable microwave-active material as discussed in detail above.
To assemble the package, the inner side panels 506, 508, the inner front panel 510, and the back panel 512 are folded relative to the first major surface 500 so that the first susceptor 540 is located at the bottom of the partially assembled carton. The tabs 214, 214′, 215, 215′ are then attached to the corresponding interior surface of the corresponding inner side panel 506, 508 so that a self-supporting tray is formed with an integral lid. A food product, that has been enclosed and sealed in an external package, is then deposited in the partially assembled carton. The external package for the food product may, for example, comprise a clear food-grade film material. The dimensions of the food product and the carton blank have been selected such that the food product is received in the partially assembled carton so that dimensions of the food product are substantially coextensive with the first susceptor 540, and are spaced from the back panel 512 and the susceptor surface 543.
The filled, partially assembled package is subsequently closed and sealed. In particular, the second major surface 502 is folded along the fold line defined between the second major surface 504 and the rear panel 512 so that the second major surface 502 is positioned overlying the tray portion of the package. Thereafter, the outer side panels 518, 520 folded into overlying relationship with the corresponding inner side panels 506, 508 and are sealed and/or attached thereto. Either before or after the side panels for folded and/or sealed, the inner front panel 510 is folded upwardly along the crease line defined between the inner front panel 510 and the first panel portion 500. The outer front panel 530 is folded downwardly along the crease line defined so that the outer front panel 530 overlies the inner front panel portion 510.
In certain broad aspects, this invention concerns the use of a contact susceptor in combination with a plurality of non-contact susceptors to substantially surround a food product to be heated, where the non-contact susceptors function to reflect incident microwave radiation away from the food product and to convert microwave radiation to thermal radiation directed toward one or more surface portions of the food product. Accordingly, it will be appreciated that, while the description herein has been directed to a carton having generally rectangular prism form, the carton could also have other shapes and still fall within the spirit and scope of this disclosure. By way of example, packages which are polygonal, arcuate, curved or circular when viewed from above are within the spirit and scope of this disclosure. To similar effect, cross-sectional shape of the package may also have configurations other than the generally rectangular shape shown and described above.
In this specification, the word “about” is often used in connection with a numerical value to indicate that mathematical precision of such value is not intended. Accordingly, it is intended that where “about” is used with a numerical value, a tolerance of 10% is contemplated for that numerical value.
Moreover, when the words “generally” and “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. When used with geometric terms, the words “generally” and “substantially” are intended to encompass not only features which meet the strict definitions but also features which fairly approximate the strict definitions
While the foregoing describes in detail a microwaveable carton having multiple focused susceptors, methods of making the carton, and methods of use, it will be apparent to one skilled in the art that various changes and modifications may be made to the disclosed carton and methods and further that equivalents may be employed, which do not materially depart from the spirit and scope of the invention. Accordingly, all such changes, modifications, and equivalents that fall within the spirit and scope of the invention as defined by the appended claims are intended to be encompassed thereby.
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