Patent Application
20230040559
The present invention concerns a packaging wrapper for food products. More particularly, the invention concerns a packaging wrapper for allergen-free food products, even more particularly for gluten-free food products, such as bread or other baked products, either leavened, savory or sweet, such as pizza, focaccia, crackers, breadsticks, snacks, sweet snacks or suchlike, supplied in large-scale distribution. The packaging wrapper can be used with both baked food products and also raw food products to be cooked after purchase.
In the industrial preparation of foods such as bread, a widespread method provides to prepare the bread, pre-bake the bread, freeze the pre-baked bread and dispatch the frozen bread to the point of sale. Subsequently the bread is baked again to obtain fresh bread, just out of the oven, to be distributed to customers.
The above procedure can also be followed for the preparation of allergen-free food products, in particular gluten-free bread. This type of bread is wrapped in a packaging wrapper, so as not to come into contact with allergens that can be found in the ovens used, or in other food products distributed at the point of sale. For example, to avoid contamination from other food products, allergen-free food products are displayed separately from other food products, even if they are of the same type (for example bread).
The packaging wrapper can be a source of problems, in particular that of retaining the steam that develops inside it during the baking of bread. The steam retained is then reabsorbed by the bread, which therefore does not maintain its crunchy properties, typical of so-called fresh bread, that is, just out of the oven, which make the bread very palatable for the consumer.
To overcome this problem, packaging wrappers have been developed that are at least partly formed by a type of paper impermeable to allergens, but which still allow the passage of air. These types of wrappers allow the product to be kept in a controlled and allergen-free environment, but are not always able to satisfactorily resist the heat differences of this process and the baking temperatures of the bread in the oven.
Document CH 316 308 A describes a package for packing leavened baked products that are still hot, which comprises a filter permeable to air and humidity.
Document U.S. Pat. No. 2,997,224 A describes a sheet of material for making packaging wrappers or containers to contain articles to be sterilized. The sheet is made of a material that prevents the passage of gas and moisture and has a limited width area provided with an adhesive coating sensitive to heat and pressure. The area has spaced apertures and a strip of flexible material having a limited ability to transmit gas and moisture, which is heat-sealed along the edges of this area only, so that the wrapper or container thus made has a limited ability to breathe.
Document DE 34 20 129 A1 describes a multilayer packaging material for food or spices, formed by a first layer of plastic material, which forms the outside of the packaging material, and a second layer of filter paper which forms the inside of the packaging material.
Document EP 1 031 515 A1 describes a composite and transpirant sheet for packaging foodstuffs, such as bread or vegetables. The sheet provides a first layer of plastic material which extends over the entire usable surface of the sheet and a second layer which extends only over one portion, leaving one or more free transparent portions glued to the first layer and made of porous paper-based material. The first layer has a perforation to allow the exchange of moisture.
Document EP 3 028 953 A1 describes a strip of material for producing bags for products such as fruit and vegetables, formed by a continuous plastic sheet on which there is at least one window, and a continuous reticular sheet connected to the plastic sheet by gluing or heat-sealing, present on the side that, during use, is intended for the inside of the bag, in contact with the products.
There is therefore a need to perfect a packaging wrapper for food products that can overcome at least one of the disadvantages of the state of the art.
In particular, one purpose of the present invention is to provide a packaging wrapper for food products which is able to guarantee the safety of the food product, in particular by blocking allergens and gluten.
Within the scope of this aim, another purpose of the invention is to provide a packaging wrapper that also allows to discharge the steam from the inside of the wrapper to the outside, so as to preserve the crunchiness of the bread for a certain time after cooking.
Another purpose of the present invention is to provide a packaging wrapper for food products that can withstand the temperatures of the process, in particular the baking temperatures of the bread in the oven, but also temperature differences between the freezing step, in which the temperature is typically around −18° C., and baking in the oven, in which the temperature is typically higher than 200° C.
The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.
The present invention is set forth and characterized in the independent claims.
The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.
In accordance with the above purposes, the Applicant has produced a packaging wrapper for food products which comprises a multilayer sheet formed by at least one polymeric layer which has at least one aperture, and a filter layer that covers such apertures.
Favorably, the layer of filter material is coupled, by means of adhesive, to the layer of polymeric material.
Advantageously, the filter layer consists of filter paper. Preferably, such filter paper is made of cellulose and/or other natural fibers.
In some embodiments, the filter material has a thickness between 50 and 200 μm.
The filter material is of the porous type. The size of the pores, that is, of the apertures, is preferably less than 150 μm, more preferably equal to 100 μm or less, even more preferably between 1 and 100 μm. Advantageously, the filter material consists of a plurality of overlapping fibrous layers. The hermetic seal against contamination is given by the overlapping of such fibrous layers with a thickness such that the apertures are statistically covered. The calculated thickness value currently in use (and validated for resistance to contamination) is between 50 and 200 μm. A filter with these characteristics is such as to prevent the passage of allergens, including gluten in particular, as well as microbiological contamination.
In some embodiments, the polymeric material, the filter material and the adhesive are resistant to temperatures up to at least 200° C., preferably up to 220° C., for a period of between 5 and 30 minutes, preferably between 10 and 20 minutes.
In some embodiments, the wrapper as above is for baking said gluten-free food products in an oven.
In some embodiments, the polymeric material, the filter material and the adhesive are resistant to differences in temperature from −30° C. to 250° C. for an interval of time from 0 to 2 minutes, in particular from 0 to 30 seconds.
In one embodiment, the filter paper is glued in strips over the polymeric layer, so as to leave some zones of polymeric material uncovered and thus allow an optimal heat sealing during the step of packaging the food product.
Advantageously, the layer of filter material is distanced by two opposite edges of the multilayer sheet so as to leave uncovered two flaps of polymeric material. Even more advantageously, the uncovered flaps of polymeric material are disposed longitudinally with respect to the direction of feed of the multilayer sheet during the production of the packaging wrapper.
Preferably, the multilayer sheet comprises two layers of filter material disposed on a same plane and distanced from each other so as to leave uncovered an intermediate zone of polymeric material.
In another embodiment, the filter paper is disposed between two polymeric layers, so as to obtain a wrapper with greater mechanical strength.
Preferably, the polymeric material is transparent, so as to allow the food product inside the wrapping to be seen.
The present invention also concerns a packaging wrapper of the type described above, containing inside it a food product.
The invention also concerns a method to produce the packaging wrapper containing the food product. The method provides a flow pack type method with the multilayer sheet as above, at the base of the packaging wrapper.
Other embodiments concern a packaging comprising at least one gluten-free food product packaged in a packaging wrapper as described here.
These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of some embodiments, given as a non-restrictive example with reference to the attached drawings wherein:
To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can conveniently be incorporated into other embodiments without further clarifications.
We will now refer in detail to the possible embodiments of the invention, of which one or more examples are shown in the attached drawings. Each example is supplied by way of illustration of the invention and shall not be understood as a limitation thereof. For example, one or more of the characteristics shown or described insomuch as they are part of one embodiment can be varied or adopted on, or in association with, other embodiments to produce further embodiments. It is understood that the present invention shall include all such modifications and variants.
Before describing these embodiments, we must also clarify that the present description is not limited in its application to details of the construction and disposition of the components as described in the following description using the attached drawings. The present description can provide other embodiments and can be obtained or executed in various other ways. We must also clarify that the phraseology and terminology used here is for the purposes of description only, and cannot be considered as limitative.
Embodiments described here concern a packaging wrapper for baking gluten-free food products, generally frozen, in an oven, without gluten contamination and maintaining crunchiness. The embodiments described here generally provide that the wrapper comprises a layer of filter material coupled, by means of adhesive, to a layer of polymeric material, the whole being resistant to a temperature of at least 200° C., possibly even up to 220° C.
With reference to
In
The wrapper 10 is made by means of a multilayer sheet 11 that comprises a layer of polymeric material 12 and at least one layer of filter material 13 coupled to it (see also
The layer of polymeric material 12, which is airtight, has at least one shaped aperture 14, for example two apertures 14 with an elliptical shape. Clearly, the number, shape and sizes of such apertures can vary according to requirements.
The filter material 13, also known as filter paper, is coupled to the polymeric material 12 so as to completely cover the apertures 14. In the example shown, the sheet 11 comprises two layers of filter material 13, each coupled in correspondence with a different zone, so as to each cover two respective apertures 14. It is noted that the two layers of filter material 13 are coupled on a same surface of the layer of polymeric material 12 (
The sheet 11 as shown in
Each layer of filter material 13 is preferably rectangular in shape and advantageously covers the layer of polymeric material 12 from one transverse edge 11A to the other, but not from one longitudinal edge 11B to the other. It is in fact advisable to provide that the layers of filter material 13 have a smaller width than the distance between the two longitudinal edges 11B and that they be disposed so as to leave uncovered at least two longitudinal flaps 12A of polymeric material 12 located along a respective longitudinal edge 11B of the sheet 11.
The two layers of filter material 13 are also distanced from each other so as to define an uncovered intermediate zone 12B of the polymer layer. This uncovered intermediate zone 12B is preferably located substantially centrally with respect to the longitudinal edges 11B of the sheet 11, so that when the wrapper is formed said intermediate zone 12B is in a substantially central position on one side of the wrapper 10 (
It should be noted that, obviously, the layers of filter material 13 can have different shapes and sizes, for example they can be such as to cover only one respective aperture 14 and one zone adjacent thereto, without necessarily extending from one transverse edge 11A of the sheet 11 to the other. In this way, it is also possible to delimit two transverse flaps of polymeric material 12, not shown in the drawings.
The layer of polymeric material 12 is preferably transparent, so that the food product 20 can be seen inside the wrapper 10 when it is closed. The polymeric material consists of one or more layers of PET, PA, cast PP or coextruded PP. Preferably, the polymeric material comprises PET with a Mylar coating. Generally, the layer of polymeric material 12 is punched.
The filter material 13 preferably comprises at least 80% by weight of a fibrous material, in particular natural fibers, more particularly cellulose. The basis weight of the filter material 13 is between 30 and 90 g/m2, preferably between 40 and 70 g/m2, even more preferably between 48 and 51 g/m2. The layer of filter material 13 preferably has a thickness between 50 and 200 μm, more preferably between 60 and 100 μm, even more preferably substantially equal to 85 μm. The layer of filter material 13 can have different conformations and mechanical strengths according to the conformation which it is to be given, for example a smooth, rough or crinkled conformation. Amongst these, the rough conformation and the crinkled conformation are preferred, since they provide a greater filtration area and offer high filtration speeds. The crinkled conformation also offers a higher capacity to retain particulates than smooth paper.
The filter material 13 may also comprise other natural fibers, for example alpaca fibers, and/or artificial fibers, such as rayon fibers.
The filter material 13 is of the porous type, and has pores, that is, apertures, the size of which is preferably less than 150 μm; more preferably equal to 100 μm or less, even more preferably between 1 and 100 μm.
The filter material consists of a plurality of overlapping fibrous layers. A filter with this particular configuration is such as to prevent the passage of allergens, including gluten in particular, as well as microbiological contamination.
The filter material has a permeability to air such that water vapor is allowed to pass, which determines the crunchiness of the food product.
The porosity of the filter material 13 is such as to prevent the passage of allergens, including gluten in particular, as well as microbiological contamination.
The layers of filter material 13 are coupled to the layer of polymeric material 12, preferably by means of gluing using one or more layers of adhesive 15 (
The adhesive advantageously consists of a dispersion in a water-based solvent, alcohol, a single-component polyester-based adhesive or a bio-component adhesive with polyester and reagent.
Favorably, the layer of filter material 13 is glued to the external surface of the polymeric material 12 so as to suitably cover the aperture 14, or the apertures 14 if more than one. The external surface of the polymeric material 12 is the surface of the polymeric material 12 opposite the internal surface of the polymeric material 12 normally in contact with the food product, that is, the external surface, in normal use, is not facing toward the food product present in the wrapper 10.
Preferably, the layer of filter material 13 is glued on to the external surface of the polymeric material 12 and only along the perimeter edge of the aperture 14, or the apertures 14 if more than one, so as to overlap with the polymeric material 12 only as much as is necessary to be able cover the respective aperture 14 from the outside.
The polymeric material 12, the filter material 13 and the adhesive 15 are resistant both to sudden changes in temperature from −30° C. to 250° C., and also to high temperatures, that is, the temperatures commonly used to bake bread in an oven, typically for an interval of time from 0 to 2 minutes, in particular from 0 to 30 seconds. Typically, these temperatures are higher than 150° C., more particularly higher than 200° C., for example they can reach 220° C., for a period of time between 5 and 30 minutes, preferably between 10 and 20 minutes. This resistance to heat can be obtained by means of a chemical treatment of a type known in the field. It is advisable to carry out a treatment to cross-link the polymeric structure of the cellulose.
The wrapper 10 is preferably made starting from a sheet 11 as shown in
Thanks to the polymeric material 12 and the filter material 13, the wrapper 10 effectively prevents the passage of allergens, in particular gluten, from the outside to its inside. It therefore becomes possible to freeze and cook the food product in industrial equipment (freezers, ovens) without the risk of contamination. It can also be provided to display the gluten-free food product at the point of sale next to other food products of the same type.
Moreover, thanks to the particular configuration of the filter material 13, the steam that develops inside the wrapper while the food product is cooked flows out of the wrapper 10. The organoleptic properties of the food product 20, in particular its crunchiness, in the case of freshly baked gluten-free bread, are preserved for a predetermined period of time starting from the cooking of the product.
The adhesive 15 is applied in the contact zones between polymeric material 12 and filter material 13, in particular around the apertures 14, preferably also in the contact zones between the two layers of polymeric material 12, for example in correspondence with the longitudinal flaps 12A and with the intermediate zone 12B between the two layers of filter material 13.
We have analyzed the crunchiness of a gluten-free bread baked in a wrapper 10 specimen as described above.
The analysis was performed by means of a TA-AT2i texture analyzer with a P75 flat type probe, in order to have a greater contact surface on the bread crust.
The analysis graph contains the time in seconds on the x-axis and the force expressed in grams on the y-axis. During the analysis, the probe compresses the bread, and this increases the force. If the bread is crunchy, the compression causes cracks on the external surface. The slight change in force during these breakages creates typical spikes on the graph's force line. The linear distance is the function that calculates the length of an imaginary line that joins all the points on the graph comprised between the point in which the force curve begins (that is, when the probe touches and begins to compress the sample) and the point in which the experiment ends (generally after about 5 seconds). The more peaks are present, the greater the crunchiness and the greater the numerical value of the linear distance.
The parameters measured and taken into account in the evaluation of crunchiness are therefore:
The analysis was performed 30 minutes after 8 loaves were removed from the oven, each baked in a respective wrapper according to the invention. More precisely, the procedure provides to place the 8 frozen gluten-free bread samples, each wrapped in a respective wrapper as described here, in the oven at 200° C. for 10 minutes, to remove them and let them cool down at room temperature for 30 minutes. Then the wrapper is removed and the whole loaf of bread is positioned under the probe of the texture analyzer. The operation was repeated for all 8 bread samples made. The samples have an average force of 4900 g and an average linear distance of 57.
These values, however, are in line with the analysis by texture analyzer of a fresh loaf of wheat bread analyzed a few hours after purchase, having an average force of 4500 g and an average linear distance of 49. These values differ greatly from those obtained from the analysis by texture analyzer of a loaf of bread packaged in modified atmosphere which has an average force of 1800 g and a linear distance of 19. The following Table 1 reports the results obtained for gluten-free frozen bread packaged with a wrapper described here, bread packaged in modified atmosphere and fresh wheat bread.
The optimal crunchiness values or parameters correspond to a force between 2500 and 6000 g, a linear distance between 25 and 90. The values obtained during the tests are all within these limits.
A subsequent analysis was performed 30 minutes, 1 hour, 2 hours, 3 hours and 4 hours after 16 loaves were removed from the oven, each baked in a respective wrapper according to the present description and following the procedure identified here, and the results were compared with 16 loaves each baked in their currently existing wrapper.
Table 2 below reports the results obtained for force (g) for samples packaged with an existing wrapper and samples packaged with a wrapper described here, while Table 3 reports the results obtained for linear distance for samples packaged with an existing wrapper and samples packaged with a wrapper described here.
The data show that the bread packaged with the wrapper described here has a greater force and linear distance than the existing wrapper, if analyzed after 30 minutes, but also after 1, 2 and 3 hours. Only after 4 hours does the bread packaged with the wrapper described here reach an average force and a linear distance similar to that of the bread packaged with the currently existing wrapper and analyzed after 30 minutes, that is, an average force of 1600 g and an average linear distance of 19.
Further embodiments concern a packaging comprising at least one gluten-free food product packaged in a packaging wrapper 10 as described here. Favorably, the gluten-free food product has the following crunchiness parameters: force between 2500 and 6000 g, linear distance between 25 and 90. The gluten-free food product as above can be packaged in wrapper 10 in frozen form. Typically, the frozen product, packaged in the wrapper 10, can then be subjected to cooking in an oven. Therefore, it can also be provided, according to this description, that the packaging comprises the wrapper 10 in which the gluten-free food product cooked in the oven is present.
It is clear that modifications and/or additions of parts may be made to the packaging wrapper for food products as described heretofore, without departing from the field and scope of the present invention, as defined by the claims.
It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art shall certainly be able to achieve many other equivalent forms of packaging wrapper for food products, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.
In the following claims, the sole purpose of the references in brackets is to facilitate reading: they must not be considered as restrictive factors with regard to the field of protection claimed in the specific claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102019000022737 | Dec 2019 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IT2020/050297 | 12/1/2020 | WO |
