WO2004091313A2 - Sweet microwave popcorn and method of preparation - Google Patents

Abstract

Microwave popcorn articles (10) includes a microwave popcorn bag (12, 218), and a food charge disposed therein comprising kernel popcorn, fat, salt and sufficient amounts of a heat tolerant glaze forming carbohydrate ingredient such as isomalt to provide the finished popped popcorn with sweet glaze coating. In preparing such microwave popcorn articles, the isomalt in particulate form is added in a separate step and preferably after the kernel popcorn and fat have been added to the bag (12, 218). In preferred forms to reduce contact with fluid, a square bottom microwave popcorn bag (218) and/or a microwave popcorn bag (12, 218) having a susceptor (230) extending from the bottom wall (240) over folds with the bottom wall and an interconnection of the folds are utilized.

Description

TITLE OF THE INVENTION

SWEET MICROWAVE POPCORN AND METHOD OF PREPARATION

BACKGROUND OF THE INVENTION

The present invention relates to packaged food products and to their methods of preparation. In particular, the present invention relates to microwave popcorn product articles for preparing sweetened popcorn and to methods for filling such articles.

Popcorn is a highly popular snack food item. In the past, the at-home preparation of popcorn by the consumer involved adding kernel popcorn plus a cooking oil to a covered pot and heating until the popcorn kernels popped to make popcorn. As used herein, "kernel popcorn" refers to unpopped popcorn. The noun "popcorn" or synonymously "popped popcorn" refers herein to popped kernel popcorn. The adjective "popcorn" can refer to either. Once prepared, common, relatively coarse, table salt is a frequently added flavoring or condiment. The resultant salted popped popcorn is a familiar snack food.

More recently, microwave popcorn products have become extremely popular. At present, in the U.S., over 70 different brands of microwave popcorn products are available. In general, the more popular microwave popcorn products comprise an expandable paper bag containing a charge of kernel popcorn, and optionally fat and/or salt. The microwave popcorn article is adapted to be heated in a microwave oven for three to five minutes to produce the popped popcorn. More recently, improved microwave popcorn articles have been fabricated employing a metallized susceptor which facilitates the heating of the kernel popcom-fat charge and which, in turn, leads desirably to increases in popcorn volume and decreases in unpopped kernels. Microwave popcorn articles of this type are described in detail in, for example, U.S. Pat. No. 4,450,180 (issued May 22, 1984 to J. D. Watkins and incorporated herein by reference).

The fat component is generally flavored with artificial butter flavor although microwave popcorn with real butter products are known and commercially available (see US 5,919,505 "Shelf-Stable Butter Containing Microwave Popcorn Article and Method of Preparation" issued July 6, 1999 to Monsalve et al.). Sweet popcorn products or "kettle corn" popcorn are well known. Among these, caramel popcorn has long been a popular food item. Such products generally comprise a sweet coating, typically from sucrose and/or small amounts of brown sugar and/or sugar based syrups such as molasses or black strap sugar syrup to provide a caramel flavor and that can also contain butter and/or other fat(s). Bulk amounts of popcorn are prepared (sometimes admixed with nuts) and the sugar-based coating is applied thereto by manufacturers to make the caramel popcorn. Quantities are provided in suitable consumer packaging such as bags whether or not in cartons or other suitable containers, e.g., plastic tubs. Various amounts of salt are added to provide a merely sweet to a sweet-and-salty flavor. With lesser amounts of coating, the coated popcorn can be free flowing. With more coating, agglomerated pieces or even popcorn balls are made.

Microwave products for preparing a sweetened puffed products are known (see for example US 4,409,250 to Van Hulle et al.). However, sweet microwave puffed products comprising sugars can exhibit scorching or even runaway heating due to the high microwave absorption by sugars and salt and the low browning or burning temperatures of sugar. (For a description of such problems, see, for example US 5,443,858 "Composition For Sweetening Microwave Popcorn; Method And Product" issued August 22, 1995 to Jensen, et al.). In extreme cases, the microwave bag can actually ignite due to the burning sugars. Sugar scorching problems are aggravated by salt making provision of "sweet and salty" products (i.e., products having a more pronounced salt flavor due to higher levels of salt) especially difficult. The excessive heat can also scorch the popcorn.

One approach for providing a microwave popcorn product having a sweet or cheese coating that doesn't scorch or burn during microwave popcorn popping is to separately package the coating from the microwave popcorn for post popping addition thereto (see for example, US 4,904,488 "Uniformly-Colored, Flavored, Microwaveable Popcorn" issued February 27, 1990 to LaBaw et al.). •

Another approach is described in US 5,443,858 "Composition for Sweetening Microwave Popcorn; Method and Product (issued August 22, 1995 to Jensen et al.). The '858 teaches a microwave popcorn article including a food charge formulated to include in addition to popcorn ingredients for forming a coating to the popped popcorn. The coating feature ingredients are selected to include a low moisture coarser granulation sugars in combination with selection of a low melting point oil and salt and moisture level control to provide a microwave sweet popcorn product. Another technique for providing a sweet microwave popcorn product is to employ in substitution for low temperature burning temperature sugars a sweetening agent that exhibits greater tolerance to higher temperatures such as acetylsulfame K and/or Sucralose. Sucralose was not approved for use in microwave popcorn products in the United States until August 1999 when sucralose was approved for use for all food categories. Soon thereafter, several microwave popcorn manufacturers began marketing sweet or "kettle com" microwave popcorn products (see for example, published US patent application US 2002/0127306 "Sweet and Salty Microwave Popcorn Compositions; Arrangements and Methods"). Such products generally employ low levels of the intensely sweet sucralose typically dispersed or diluted in small amounts of a heat tolerant powdered carrier or diluent such as a maltodextrin and avoid inclusion of temperature sensitive sugar ingredients. While useful, the sweetened microwave popcorn prepared from such microwave popcorn products lack the quantity of coating or glaze typical of bagged popped caramel popcorn and thus the eating qualities of such heavily coated sweet products. Also, sucralose is a high value, high cost ingredient.

Thus, there is a continuing need for new and useful microwave popcorn products that can be used to provide sweet popped popcorn having a substantial coating level that minimizes undesirable scorching and fire hazards. There is also a need for such products that can be formulated employing less expensive ingredients. There is also a need for consumer food products that are low in or free of "artificial" or high potency sweeteners. There is further a need for a microwave popping bag formed of flexible material and having enhanced ability to prevent fluid leakage at folds, especially when such fluid is at elevated temperatures.

Surprisingly, the above objectives can be realized, and new and improved shelf stable consumer retail products can be provided for the microwave preparation of a sweet popcorn product containing substantial amounts of a sweet coating with reduced scorching problems. The present invention provides microwave popcorn products comprising a popcorn food charge comprising isomalt as a coating ingredient.

Bagged caramel popcorn having a coating comprising isomalt and sucralose has recently been sold as a reduced calorie product. The product does not contain sugar and is marketed especially for the consumer having interest in products for diabetics.

Surprisingly, unlike other caramel coating ingredients, isomalt has now been found suitable for use for inclusion into microwave products for the at-home microwave preparation of popcorn having substantial amounts of a sweet coating. More surprisingly, such products exhibit minimal scorching during preparation using conventional consumer home microwave oven heating. Even more surprisingly, such microwave products can be formulated to include conventional or even elevated levels of salt to provide even "sweet and salty" coated popcorn. The present invention further provides method of fabrication microwave popcorn products containing isomalt. The methods can comprise separate addition of isomalt in particulate form.

BRIEF SUMMARY OF THE INVENTION

In its article aspect, the present invention relates to improved microwave popcorn articles. The present microwave popcorn articles essentially comprise a microwave popcorn bag and food charge dispersed therein comprising isomalt especially in particulate form. The food charge comprises kernel popcorn and optionally further comprises fat and/or salt. The kernel popcorn component essentially comprises about 30 to 90% of the charge. The food charge includes about 10%) to about 60% isomalt. The isomalt has a particle size of less than 1mm. The food charge can include about 1 to 40% of the fat component and about 0.1 to 4% salt.

In its method aspect, the present invention resides in manufacturing methods for filling a microwave popcorn bag with popcorn kernels and isomalt optionally with a fat and salt. The salt can be either ultra fine (mean particle size of about 20 μm) or coarse salt (mean particle size of about 400 μm). The process comprises the steps of:

A. providing a microwave popcorn bag having a sealed bottom end, an open sealable top end defining an upper orifice and a transversely extending seal area in an open configuration and in a vertically aligned orientation;

B. filling the bag through the upper orifice defined by the open top end with a quantity of popcorn kernels; C. filling the bag with a quantity of fat and/or salt;

D. filling the bag through the upper orifice defined by the open top end with a quantity of an isomalt ingredient in particulate form; and,

E. sealing the open top end of the popcorn bag after the bag has been filled with the quantity of popcorn kernels and the quantity of isomalt ingredient to provide a microwave popcorn article. In its container aspects, the present invention relates to extending a susceptor from a bottom wall of a microwave popping bag formed of flexible material and over folds and a corner formed the interconnection of the folds. The susceptor does not fracture as a result of stress from folding, with such fractures being a potential leakage location.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 is a perspective view of an unsealed partially folded microwave popcorn bag ready to for filling. FIGURE 2 is a diagrammatic view of one method of filling a microwave popcorn bag in accordance with the invention.

FIGURE 3 is a perspective view of an expanded microwave popcorn bag after microwave heating, with portions broken away and the food charge removed to expose internal details.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to consumer packaged food items for the microwave preparation of sweet popcorn characterized by high levels of sweet coating that is resistant to heat scorching and to their methods of preparation and use. Each of the product components as well as product use and attributes and methods of their preparation are described in detail below.

Throughout the specification and claims, percentages are by weight and temperatures in degrees Centigrade unless otherwise indicated. Each of the US patents and US patent applications referenced herein are herby incorporated by reference. The present invention relates to improved microwave popcorn articles with an isomalt ingredient to provide the finished popcorn with a sweet coating and to their methods of preparation. The present microwave popcorn articles essentially comprise a microwave popcorn container such as a bag and a food charge disposed within the bag, said food charge comprising a quantity of 1) kernel popcorn, 2) an isomalt ingredient and can further include 3) fat, and/or 4) salt. Each of these article components as well as methods of filling, product use and attributes are described in detail below. In preferred aspects, the microwave popcorn container of the present microwave popcorn article is a square bottom microwave popping bag, and in most preferred aspects, the susceptor located on the bottom wall partially extends unto the end wall and the side walls and thereby the interconnection of the folds therebetween to prevent fluid leakage due to fold stress fracture.

The present invention relates to an improved microwave popcorn bag having a susceptor extending from the bottom wall over folds with the bottom wall and an interconnection of the folds to prevent fluid leakage due to fold stress fracture while the remaining portions of the bag are substantially free of the susceptor. Microwave Container

The present microwave popcorn articles essentially comprise a conventional microwave popcorn popping container. Useful microwave containers herein can include any container for microwave popcorn products presently known in the art or are developed in the future. Cardboard tubs have also been recently developed for microwave popcorn articles and can be used as the microwave container. Particularly useful herein for the microwave popping container are a wide variety of commercially available microwave bags for microwave popcorn. For example, a suitable bag widely used commercially and preferred for use herein is described in U.S. Patent 4,450,180. A generally similar bag is described in US 4,548,826 or in 4,973,810 entitled "Microwave method of popping popcorn and package therefor" issued November 27, 1990 to Arne Brauner. Also useful are structures described in US 4,735, 513 and 4,878,765. Generally, the bag therein described comprises and is fabricated from a flexible sheet material having two collateral tubular sections. The sections are parallel longitudinally extending that communicate with each other at the center of the package.

Referring now briefly initially to Figure 1, there is shown an embodiment of a microwave popcorn article 10 composed of a microwave bag 12 formed from flexible sheet material such as paper and being of collateral tubular configuration, that is to say, being composed of a pair of parallel longitudinally extending tubes 14 and 16 which communicate with one another along a central longitudinal opening 18. The two parallel tubes 14 and 16 are separated by longitudinally extending side indentations 20 and 22. When the package comprises a paper bag, the bag can be composed of first and second face panels 24 and 26 respectively and the indentations 20 and 22 comprises gussets. When in a vertically aligned orientation, the bag has a bottom seal 28 and initially an open top or orifice 30 but a sealable seal area 31 that transversely extends the open sealable top. The sealable area can include a heat activated adhesive or a "cold seal" adhesive, as is convenient. After being filled, the top 30 is also sealed conventionally by means of heat or other suitable adhesive to provide a top seal in the top seal area 31.

While tubes (or chambers, or channels) 14 and 16 can be of equal size, conventionally the susceptor channel 16 is generally slightly smaller. In such a configuration, the gussets include major left gusset face 36, minor left gusset face 37, major right gusset face 38 and minor right gusset face 39. The bag 12 can be provided with a lower transverse fold 40 to define an intermediate portion or pocket 41.

Another bag which is also particularly useful in connection with the present invention is the form of a flexible bag 218 having what would normally be called a square bottom. However, it will facilitate the ensuing description to consider the bag 218 in the horizontal position shown in Figure 3. Therefore, the bag 218 includes a bottom face or wall 240, a top face or wall 260, an end wall 224, first and second side walls 226 and a closed end 280. The cross sectional makeup of the end wall 224 includes a number of folds that are not important to an understanding of our invention so will not be specifically described, although the end wall 224 should be constructed so as to seal adequately the vapor created within the bag 218 during the heating thereof in the microwave oven. In practicing of the present invention, however, it is important that the end wall 224 have a flat rectangular or square configuration. Such bags are commonly referred to as square bottom bags in the trade. Likewise, the construction of the side walls 226 is not critical to a practicing of the present invention. All that need be said is that the side walls 226 include gussets or pleats 226a, 226b, 226c and 226d that enable the side walls 226 to expand during a heating cycle. Still further, the left end 280 is closed by heat sealing the marginal ends of the pleats 226a, 226b, 226c and 226d together. A panel 234 is secured to the end wall 224 such as by an adhesive.

A microwave susceptor 230 providing supplemental heating for heating the food charge to cause popping of the kernel popcorn overlays a portion of the face panel 24 of the bag 12 or the bottom wall 240 of bag 218. Figure 3 is intentionally simplified so as to show the susceptor 230 clearly without resort to the laminations normally made use of in a bag of this type. It might be explained, though, that the bag 12 or 218 is fabricated from tubular bag stock composed of multiple plies including an outer ply 33 which is generally paper and a grease-proof or resistant inner ply 34. As is obvious from the Figures, the laminated construction of the walls constituting the bag 12 or 218 is not shown. Actually, the inner ply 34 has been referred to could extend over the upper surface of the susceptor 230.

In conventional microwave popcorn bags, the microwave susceptor 230 is present only on one major face panel such as face panel 24 of bag 12 or bottom wall 240 of bag 218. However, as illustrated in Figure 3, susceptor patch 230 extends beyond bottom wall 240 and extends partially onto side walls 226 and end wall 224. In particular, susceptor patch 230 continuously extends over the folds defined by the bottom wall 240 and each of the side walls 226, by the bottom wall 240 and the end wall 224, and by the end wall 224 and each of the side walls 226 and over the first and second corners formed by the interconnection of such folds. In the preferred form, the top wall 260 which overlies the bottom wall 240 and the remaining portions of the end wall 224 and of the side walls 226 are substantially free of the susceptor 230.

It might be explained, though, that susceptor 230 is fabricated from a carrier and susceptor material located on the carrier. Typically, the susceptor material is of identical area as the carrier. However, the present invention envisions that the susceptor material could be of a smaller area size than the carrier such that the susceptor material is located only on bottom wall 240 and does not extend unto side walls 226 and/or end wall 224 while the carrier does in the preferred form of the present invention. The carrier is formed of material which does not stress fracture as a result of folding as would occur with paper and in the most preferred form is formed from polyester film.

Although shown and explained with reference to a square flat bottom bag 218, it should be appreciated that the susceptor 230 extending unto other panels than the panel which rests on the floor of the microwave oven during the microwave heating operation can have application to other designs of microwave popcorn bags including but not limited to bags 12.

Although in the present description, a particular description is given to these preferred microwave bags, the present invention is also useful in connection with, for example, bags with or without a bottom fold, with a straight bottom seal or other more complex bottom seal designs. Also, the present methods can be employed using new and improved microwave popcorn bag designs.

Since introduction, microwave popcorn bags have undergone continued development generally directed towards cost reduction especially of the expensive microwave susceptor component. Also, improvements continue to be made (see for example US 6,660,983 entitled "EASILY EXPANDABLE, NONTRAPPING, FLEXIBLE PAPER, MICROWAVE PACKAGE" issued December 9, 2003, by Monforton, et al.) to improve popping performance or to facilitate commercial manufacturing at lower cost or at higher packaging line speeds. While particular attention is given to microwave bags herein as the preferred microwave container, the skilled artisan will appreciate that the present invention is broadly useful when used with a variety of packaging and disposable microwave containers. Popcorn The present article 10 further includes a food charge disposed within the bag.

The food charge essentially includes a quantity of kernel popcorn, the isomalt ingredient and can include fat(s), salt, and supplemental ingredients such as flavors, colors, vitamins and minerals, and/or supplemental sweeteners. The food charge can comprise from about 30 to 15 Og in a microwave bag for example. For single serve products, the food charge can be smaller and can comprise about 30 to lOOg. For regular sized products, the food charge can comprise about 50 to 150 g, preferably about 100 to 13 Og.

Conventionally, microwave popcorn food charge formulations are now expressed based upon the weight of the entire kernel popcorn and food charge. This convention is followed in the present description of the invention. Broadly, the popcorn can range from about 30 to 90% of the popcorn charge. Typically, about 15 to lOOg of kernel popcorn is added to the bag, preferably about 40 to 85 g and more preferablyabout 50 to 70g/bag for regular sized products and about 25 to 40g/bag for "single portion" sized products. Jn general practice, the amount of kernel popcorn is set and the other ingredients are varied to provide variations such as full fat, reduced or low fat, and/or salted or low salt embodiments.

Generally, microwave popcorn is dried to moisture contents ranging from about 10% to 18%, preferably about 12% to 16% and for best results about 14% to insure sufficient moisture for popping of a high fraction of kernels while minimizing moisture that might cause or promote bacterial growth during the long term distribution and storage characteristic of shelf stable packaged products.

Conventional kernel popcorn varieties can be used and are preferred for use herein. Also useful herein are relatively larger kernel popcorn varieties for providing "Jumbo Pop" products as well as "mushroom" sized popcorn which is commonly used for ready-to-eat popcorn snack products. Useful are those larger varieties having a kernel count up to 60 kernels per lOg, preferably less than 55, which are commercially available.

In certain less preferred variations, the popcorn can be infused with materials, e.g., flavor or colors, intended to provide popcorn products of enhanced visual or flavor appeal. In other variations, the popcorn can be bred to provide natural color and/or flavor variations.

Additionally, all or a portion of the microwave popcorn can be substituted with expandable or microwave puffable pellets such as are described in the '250 patent to Van Hulle. Also useful herein are those products described in US 5,102,679 "Half products for microwave puffing of expanded food product" issued April 7, 1992 to Whelan. See also US 6,083,552 "Microwaveable Popcorn Product And Method" issued July 4, 2000 to Kershman et al. In certain variations comprising a blend of kernal popcorn and puffable pellets, weight ratio of the kernal popcorn to puffable pellets can range from about 10:1 to about 1:10, preferably aboutl:4 to about 4:1 and for best results about 1:3 to about 3:1. Glaze Forming Carbohydrate

The microwave food charge additionally comprises a moderate sweetness carbohydrate glaze forming ingredient. Useful here as the glaze forming ingredients are those browning resistant moderate sweetness carbohydrates of thermally stability such that they that melt or at least soften to form a parisol flowable under gravity (i.e., are at least thermoplastic) at temperatures below 170°C but also have smoke point values higher than about 125°C and thus exhibit heat stability during brief exposure to the high microwave popcorn popping which generally occurs at a temperature of about 170-180°C. By moderate sweetness is meant having a sweetening power of about 0.1 to 2 relative to sucrose.

Useful glaze forming carbohydrates can be selected from the group consisting of isomalt, maltitol and lactitol and mixtures thereof. Preferred for use herein due to sweetness and eating characteristics properties is isomalt.

The isomalt ingredient upon microwave heating provides a sweet coating to the puffed popcorn. Isomalts are well known and the skilled artisan will have no difficulty in selecting useful commercially available isomalt ingredients from commercial suppliers. Discovered in the 1960s, isomalt has been used in Europe since the early 1980s and is currently used in a wide variety of products in more than 50 countries worldwide. Isomalt is made from sucrose and can be supplied in the form of bead particulates. It is white, crystalline and odorless. Isomalt is a mixture of two disaccharide alcohols — gluco-mannitol and gluco-sorbitol. Sucrose, by comparison, is a disaccharide sugar, gluco-fructose. Chemically, isomalt belongs to the class of disaccharide polyols like maltitol and lactitol. It is derived exclusively from sucrose. It consists of two components in a 1:1 ratio, 1,6-glucopyranosyl-D- sorbitol (GPS) and 1,1-glucopyranosyl-D-mannitol (GPM). Compared to the group of polyols currently used as sweeteners, isomalt like maltitol and lactitol has a high molecular weight of 344. Isomalt is a bulk sweetener exhibiting a very clean sucrose-like taste profile with no significant off-tastes or aftertastes. Isomalt liquid grade contains a blend of pure crystalline isomalt and maltitol syrup sometimes fortified with minor amounts of hydrogenated oligosaccharides. Isomalt has a sweetness potency about 50% that of sucrose. Consequently, when using pure crystalline isomalt, a combination with an intense sweetener may be required.

Isomalt is made from sucrose; is used in a variety of foods and pharmaceuticals; provides the taste and texture of sugar; is synergistic with other sweeteners; is low calorie (provides at most 2 calories per gram); does not promote dental caries; and does not increase blood glucose or insulin levels. While liquid isomalt can be used, preferred for use herein is isomalt in particulate form. In particulate form, especially when used in combination with a hydrogenated fat component, the isomalt ingredient is adhered to and intermixed with the popcorn and is thus less likely to migrate within the microwave popcorn bag during distribution and storage prior to use. While particulate isomalt is available in the form of larger sized particles, it has been found useful herein to employ isomalt in particulate form having an average particle size of less than 1mm. Larger particles can exhibit only partial or incomplete melting upon microwave cooking to provide popped popcorn with an incomplete coating or a coating having a mottled appearance. Isomalt can be simply and conveniently milled or ground into a powder prior to addition to the microwave container. While the isomalt can be ground to a fine powder, e.g. having an average particle size ranging up to 500 microns, in preferred form, the isomalt or other glaze forming carbohydrate is ground to a coarse powder having an average particle size ranging from about 600-800 microns. In one preferred embodiment, the isomalt has a mean particle size of less than 750 microns. Within this preferred range, finished coated popcorn having a mottled appearance is minimized while dust control in production is also likewise minimized.

Maltitol is a member of a family of bulk sweeteners known as polyols or sugar alcohols. It has a pleasant sweet taste-remarkably similar to sucrose. Maltitol is about 90% as sweet as sugar, non-cariogenic, and significantly reduced in calories. It is available worldwide from. For example, Cerestar, Roquette, SPI Polyols, Inc. and Towa Chemical Industry Co., LTD.

Maltitol is made by the hydrogenation of maltose which is obtained from starch. Malitol does not brown or caramelize as do sugars. Maltitol 's high sweetness allows it to be used without other sweeteners. It exliibits a negligible cooling effect in the mouth compared to most other polyols.

Lactitol is made by reducing the glucose part of the disaccharide lactose. Unlike the metabolism of lactose, lactitol is not hydrolyzed by lactase. It is neither hydrolyzed nor absorbed in the small intestine. Lactitol is metabolized by bacteria in the large intestine, where it is converted into biomass, organic acids, carbon dioxide and a small amount of hydrogen. The organic acids are further metabolized resulting in a caloric contribution of 2 calories per gram (carbohydrates generally have about 4 calories per gram).

In one preferred form, the food charge can comprise about 20% to about 50% of the glaze forming carbohydrate ingredient(s). Preferably the isomalt is present in the food charge in the microwave popping article at ranges from about 35 to 45% and for best results about 38 to 42%. In another preferred form, the food charge includes about l-80g of the scorch resistant glaze forming ingredient. The present thermally resistant glaze forming ingredient(s) is to be distinguished from those carbohydrates or sugars that either scorch during microwave heating or that do not melt or soften under microwave heating. Fat The food charge of the present articles can additionally comprise a quantity of an edible fat. Generally, the present methods are useful in connection with full fat, reduced-fat and with low-fat embodiments or even no-fat embodiments. The present invention finds particular suitability for use in connection with snack products that are perceived as being more healthy, such as low fat microwave products. Less preferred but nonetheless useful herein are reduced fat or full fat products. Low fat products have an even lower fat content than reduced fat embodiments. Reduced fat products have a fat content of about 8 to 15% fat. All fat percentages are descriptive of added fat and are not meant to include fat which may be included in the finished product from other ingredients, e.g., the fat from the kernel popcorn. Thus, broadly, the fat can range from about 0 to 40% and about 1 to 25%, (most preferably 11 to 17%) for reduced fat embodiments. Preferred full fat products can comprise about 20 to 35% fat. In the low fat embodiments the charge essentially comprises about 2 to 10% fat, preferably 5 to 8% fat and for best results about 6.5%.

The fat, preferably semi-solid or solid fat, can be from any conventional, suitable fat(s) or oil(s) or mixtures thereof from vegetable or animal sources including from soybean, cottonseed, safflower, com, peanut oil(s), butter and mixtures thereof. Liquid oils (medium chain trigycerides or interesterified oils) can be used in full or in part as a possible variation to reduce trans fatty acid oils. Liquid oils can be thickened to increase their viscosity (e.g., with silicon dioxide or by being fortified with small amounts of fat hardstock). In other variations, the oils can be partially hydrogenated. Preferred for use herein are fats that are partially hydrogenated soybean and/or corn oil. Also useful herein are tropical oils such as coconut oil and palm kernel oil, although present consumer health trends disfavor utilization of such oils. Also useful herein are non-absorbable fat mimics such as polyglycerol esters. In preferred variations, the fat ingredient is selected to provide microwave popcorn products having a low level of trans fatty acids. (See for example, US 6,013,289 "Microwave Popcorn with Liquid Fat and method of Preparation issued January 11, 2000 to Glass et al.), i.e., having no more than 30% of the fat comprising trans fatty acids, more preferably less than 5% of the fat and for best results less than 2%. In a preferred variation, at least a portion of the fat ingrdeint is supplied by a butter ingredient, especially a low moisture butter ingredient. Suitable low moisture butter ingredients and methods of preparing microwave popcorn products therewith are described in commonly assigned US 5,919,505 and/or US 6,093,429 entitled "Shelf-Stable Butter Containing Microwave Popcorn" issued July 25, 2000 or US 6,333,059. In general, however, the butter ingredients therein described are low moisture (i.e., less than 3%) butters that are commercially available. The fat/butter blends comprise about 750 ppm antioxidants. To assure shelf stability, the butter content is preferably limited to 10% of the added fat. Salt

The present microwave popcorn articles can additionally include a salt component. While microwave popcorn products without added salt are contemplated herein, in preferred embodiments, the food charge additionally includes about 0.1% to about 5% added salt, preferably about 0.5% to about 4% salt and for best results about 0.5% to about 2.5% salt. Typically, the salt component is a microsized salt, also known as ultrafme salt or pulverized salt or "flour" salt, typically having a mean particle size of about 22 microns. This flour salt is simply physically admixed in with the melted fat component to form a fat and salt slurry.

In the preferred embodiments, at least a portion of the total salt can be added in the form of a flour sized particulate to the fat slurry. In those embodiments, it is more preferred that the portion of the total salt added as a salt flour to the slurry be at least 60% of the total salt, even preferably more than 75% of the total salt.

In certain variations, a coarse salt ingredient can be employed such as described in co-pending commonly assigned US 5,897,894 entitled "Microwave Popcorn With Coarse Salt Crystals and Method of Preparation" issued April 27, 1999. Generally, the coarse salt therein described has a larger particle size of about 250 to 750 μm. Such coarse salt is added to impart an organoleptic attribute in the finished product microwave popcorn to be more reminiscent of the stove-top at-home popped and seasoned popcorn. While in some preferred embodiments herein the salt is in flour form, in other embodiments all or a part of the salt can be in the form of coarse salt added in the third or even a fourth station or in the separate particulates addition step herein. While common sodium chloride is the preferred salt, also useful in full or partial substitution is potassium chloride. While employments of potassium chloride in full or partial substitution finds appeal to those consumer interested in limiting their sodium chloride intake, some consumers find potassium chloride bitter in taste. 50:50 weight% blends of potassium and sodium chloride salts are common. While not common, any of the salts can be iodized to provide essential iodine fortification. In one preferred embodiment, the food charge can include about 1-15g salt. Calcium Ingredient

The present microwave popcorn products can optionally further comprise a calcium ingredient of defined particle size in an amount effective to provide the desired calcium enrichment. (See, for example, US 5,997,916 entitled "Microwave Popcorn Fortified with Calcium and method of Preparation" issued December 7, 1999 to Dickerson et al.). Good results are obtained when the present microwave popcorn products contain about 360 to 3600 mg of calcium per 100 grams of the food charge. Better results are obtained when the calcium is present at levels of about 360 to 1800 mg per 100 grams. For best results, the total calcium present ranges from about 930 to 1400 mg per 100 grams of the food charge. Excessive calcium fortification is to be avoided in part because the finished product can undesirably exhibit a dry texture, gritty mouth feel, and lower taste perception of flavor and salt. The calcium mineral is essentially characterized by a particle size wherein at least 50% of the calcium component has a particle size of about 1 to 20 microns ("μm").

At a calcium concentration of 360 to 930 mg per 100 grams of the food charge, the finished popped product provides about 10% of the currently recommended daily intake for calcium and thus can be described as "a good source of calcium." The levels in the microwave article suitable for microwave popping account for an estimated 40% loss factor for calcium as the popcorn goes from its unpopped state to the popped state. In addition, these levels also reflect the amount consumed based on the current serving size of 30 grams for popped product as defined by the Food and Drug Administration (FDA) of the United States of America. Useful herein are calcium ingredients that supply at least 20% calcium. For example, a good calcium ingredient herein is calcium carbonate in that calcium carbonate comprises about 40% calcium. Preferred for use herein are calcium ingredients selected from the group consisting of food grade calcium carbonate, ground limestone, calcium phosphate salts and mixtures thereof. Optional Minor Ingredients The present food charges can comprise a variety of ingredients to improve the taste, appearance and/or nutritional properties of the finished sweet coated popped popcorn herein. Supplemental Sweeteners

In particular, the food charges can comprise an effective amount of a heat tolerant high potency sweetener such as potassium acesulfame, sucralose or mixtures thereof. Sucralose is preferred for use herein since acesulfame K or potassium acesulfame (colloquially, "Ace K") can impart a bitter taste to some consumers sensitive to potassium. Alitame, neotame, saccharin and cyclamates can also be employed although , current food regulations do not permit usage of these sweeteners in microwave popcorn products. Talin and thaumatin can also be used and provides the advantage of flavor masking off flavors. Also useful herein are trehelose, taglatose and mixtures thereof. In less preferred variations, the products can employ supplemental high potency "natural" or plant sweeteners such as stevioside such as from ground stevia leaf, stevia extract (an herb, Stevia rebaudian, native to Peru and Paraguay) or essence or tincture of Rubus suavissimus. Such products are used at amounts effective to provide desired sweetness levels. Such materials are often blended with or formed into powder form by mixing with a solid substrate or carrier such as a starch or maltodextrin. While not temperature stable per se, the sweeteners can be added at levels that compensate for losses during microwave heating. Generally, such products are used at levels ranging from about 0.05% to about 1% depending upon sweetening power of the active ingredient and concentration of the active ingredient in the sweetener ingredient. Preferred for use are sucralose, acesulfame, and mixtures thereof since such sweeteners are more resistant to scorching than the plant derived sweeteners. While in the preferred embodiment the particulate addition in the third or separate particulate addition step after the slurry has been added is a calcium ingredient, the skilled artisan will appreciate that other particulates can be conveniently added in the third filling station or in this step. Such additional particulates can include a wide variety of materials intended to provide various flavor or nutritional advantages. Such materials include sugars, dried dairy ingredients such as dried cheese solids, other minerals, flavored bits, colorants, and mixtures thereof. However, in more preferred embodiments, the present microwave products are additionally characterized as being sugar free (i.e., by total mono- or disaccharide content of less than 0.5%). Such products exhibit greater shelf stability as well as minimization of sugar related scorching and burning. However, the products can include minor amounts of flavor ingredients that are intended to provide an enhanced caramel flavor or color such as caramel flavors or colors. In other more preferred embodiments, the present microwave products are additionally characterized as being free of a cheese constituent (i.e., having a cheese ingredient content of less than 0.5% dry weight basis). Cheese ingredients can also undesirably contribute to scorching and burning problems in microwave popcorn products. It is believed that these problems are due to the protein and their carbohydrate (e.g., lactose) constituents thereof. Thus, dried cheeses being generally low in fat and thus high in other constituents are particularly undesirable. Generally, the food charges should minimize the presence of those ingredients that cause undesirable browning or burning at the high temperatures 160-170°C characteristic of microwave popcorn popping. In many cases, flavors free of (i.e., less than 0.5% by weight) protein and carbohydrates fractions can be used to provide these flavors to form glazes without scorching (e.g., cheese flavors, cream flavors, etc.) in microwave products.

In preferred variations, the food charge is substantially free (i.e., less than 0.5%) of any mono- or disaccharides or sugars such as sucrose, lactose, fructose, com syrup, dextrose, corn syrup solids, dried honey, fruit juice solids, fruit paste or proteins that would brown or burn during microwave popping. In highly preferred embodiments, the present articles are both sugar(s) free and cheese ingredient free. Method of Preparation

Broadly, the present methods of preparation include the steps of adding the food charge to an at least partially open microwave popping container to form a filled container and sealing the filled container to provide a finished sweet coating microwave popcorn article product.

In one variation, the food charge can be formed in a single composite mass such as a toroid or ring and the composite mass charged to an open microwave popcorn bag or other container prior to final sealing. (See for example US 4,450,180, issued May 22, 1984).

In another variation, one or more ingredients are added separately to the open microwave bag. For example, microwave bags having an unsealed open end and a folded lower portion are advanced to a first kernel popcorn filling station. While being maintained in an open position, the loose kernel popcorn is charged to the desired channel in desired amounts to form partially filled bags containing kernel popcorn. The kernel popcorn is added first to facilitate more even distribution of the balance of ingredients over the popcorn to thereby provide a finished popcorn having a more even distribution of the coating ingredients. In those variations that include puffable pellets other than or in admixture with kernel popcorn, the puffable pellets or popcorn-and-pellet mixtures are likewise first added to the microwave popcorn bag. Thereafter, the partially filled bags can be advanced to a second filling station at which a fat/salt slurry is added to the bag. Typically, the slurry is added in the form of a vertically dispensed pencil jet (i.e., a confined stream) of the slurry. (See, for example, US 4,604,854 entitled "Machine For Forming, Filling and Sealing Bags," issued August 12, 1986 to D. W. Andreas). The slurry contains the fat ingredient(s), is typically heated to melt a solid fat to liquid or fluid form, and optionally includes flavors, colors, etc. For those embodiments comprising salt in flour form, the slurry can include all or a portion of the flour salt. At the same station, a separate quantity of the isomalt or other glaze forming carbohydrate is added to the open partially filled microwave popcorn bag (See, for example, Fig 2, line 70). The slurry addition and isomalt addition can be practiced sequentially (in either order) or simultaneously. Simultaneous addition or parallel addition is preferred since this technique allows for high packaging line processing speeds, thereby increasing efficiency compared to sequential addition in a two station filling method. In preferred form, the isomalt is added in the form of a powder. Other particulate or dry ingredients, e.g., salt in coarse form and/or calcium, flavors, colors, can conveniently be admixed with the isomalt. Single station filling methods are also known that involve applying the fat/salt slurry as a spray onto the kernel popcorn as the kernel popcorn falls into the bag. (See, for example WO 95/01105 entitled "Reduced Fat Microwave Popcorn and Method of Preparation" published January 12, 1995, or, equivalently, US 5,690,979 issued November 25, 1997; or US 5,171,950 entitled "Flexible Pouch and Paper Bag Combination For Use In The Microwave Popping of Popcorn" issued December 5, 1992 to Brauner et al., which is incorporated herein by reference). Such single station filling techniques are especially useful for the preparation of low fat microwave popcorn products. In this variation, the isomalt in powder form can be added to the popcorn filling funnel along with the kernel popcorn, e.g., after the kernel popcorn has been charged to the bag.

The bags now containing both kernel popcorn and slurry and other ingredients are then advanced to a sealing station where the bags are provided with a top seal to complete the closure of the bag. The sealed popcorn bags are advanced to subsequent finish packaging operations that complete the folding of the bags, providing the bags with an overwrap, and inserting appropriate numbers of the bags into cartons, etc.

While single station and two station filling methods can be used to prepare the present sweet coating microwave popcorn products herein, it has been surprisingly discovered and the present invention further includes particular three station filling embodiments that are particularly convenient and useful for fabricating the present sweet coating microwave popcorn article products (See for example US 5,997,916 entitled "Microwave Popcorn Fortified With Calcium And Method of Preparation" issued December 17, 1999) or addition of coarse salt (See for example US 5,897,894 entitled "Microwave Popcorn With Coarse Salt Crystals and Method of Preparation" issued April 27, 1999 to Brian Glass or US 6,210,721 entitled "Microwave Popcorn Incorporating Coarse Salt and Method of Preparation" issued April 3, 2001 to Dickerson et al.).

Adding the isomalt along with the salt to the slurry can result in a first problem of increased slurry viscosity. The slurry viscosity rises rapidly as more particulates are added. If an additional particulate is desired to be added to the slurry such as for the sweetener coating, then addition of requisite amounts of salt to the slurry results in a slurry having a paste consistency and a viscosity too high to pump. This is especially true in the more concentrated slurry typically used for ultra low fat popcorn—usually about 94% fat free. Additionally, high levels of particulate contents in the slurry can result in some settling in turn leading to loss of homogeneity in the slurry added to the bag.

A second problem is plugging of the orifice of the pencil jet nozzle used to charge the slurry to the bag that can occur when the slurry viscosity is too high. While plugging is a problem when salt alone is added to the slurry, such plugging problems are compounded when the slurry contains supplemental particulates such as the isomalt ingredient.

Now referring to Figure 2, there is seen a schematic of the preferred method of preparation preferred for use herein generally designated by reference numeral 50. The drawing shows a conventional microwave packaging line and depicts three stations thereof designated generally by reference numbers 51, 52 and 53. In upstream stations, (not shown) the tubular bag material is cut into desired lengths and is provided with the bottom seal 28 or purchased pie cut and bottom sealed. Additionally, in upstream stations (not depicted), the bags 12 are folded to have their bottom third folded up as depicted in first station 51 of Figure 2 to provide the first lower transverse fold 40 to provide a sealed portion so that the kernel popcorn, fat charge, and isomalt can be positioned within the bag in the desired middle portion 41 thereof. The bags 12 are advanced from station to station (left to right) by suitable drive means such as the endless drive chain 54 depicted having bag engagement clips 55. Packaging line speeds range from about 40 to over 100 bags per minute. Also, the bottom third of the bags are maintained in the closed position by appropriately spaced parallel guide bars 56 and 58. As can be seen, the bag has an open sealable top portion defining an orifice and has a seal area extending across the orifice. The bag at station 51 is provided in an open configuration and in a vertically aligned orientation.

In the present preferred method of filling microwave popcorn bags, the first station 51 is a popcorn filling station. As indicated above, the fat is heated to form a liquid fat. The fat addition is charged to the bag at a second separate station 52. Optionally, admixed with the fat are any butter ingredients and/or fat soluble flavors, e.g., butter and any portion of the salt that is in flour salt sized form to form the fat slurry.

Thereafter, the bags still being maintained in the upright, folded orientation depicted in Figure 2 are advanced in the preferred embodiment to the third particulate filling station 53. At station 53, it can be seen that the present methods additionally comprise the step 66 of filling the bag with a quantity of a particulate after the bag is filled with popcorn and fat. At the particulate filling station, a quantity of a isomalt in particulate form is then charged to the bag 12 in a separate step as indicated by addition line 72 to form an open ended microwave popcorn bag filled with the food charge. Generally, however, the particulate filling station 53 includes a means for dispensing a measured quantity of particulates such as the isomalt, salt, calcium ingredient(s), other particulates and mixtures thereof.

Once filled with the popcorn, fat slurry and particulate, the bags are then advanced to the sealing station (not shown) wherein the open top end is sealed such as by retractable heat or pressure sealing jaws which impart a seal in the seal area to form finished sealed microwave popcorn articles for the microwave preparation of a sweet microwave popcorn.

The filled and sealed microwave popcorn bags can then be advanced to subsequent downstream packaging operations (not shown). Such subsequent downstream packaging operations can and preferably include folding the bags again to provide a three-folded bag, i.e., to provide a second upper transverse fold; overwrapping the folded bags with an overwrap or moisture barrier layer; and inserting desired numbers (e.g, 1 or 3-6 to, preferably 5-6, of the packaged article into cartons or even 10 to 40 especially for variety packs). Now that the present methods have been described in general terms, in particular, at the filling station 51, the process involves the step 62 of filling the bag through the upper orifice with a quantity of popcorn kernels. Generally, however, the process step can conveniently be practiced at filling station 51 by employing a means for dispensing a measured quantity of kernel popcorn such as a dispensing wheel. The dispensing wheel discharges at timed intervals a measured quantity (e.g., 50 to

70g) of the kernel popcorn into a vertically oriented filling horn or funnel. The funnel causes the kernel popcorn to fall by gravity into the bag 12.

At the second or fat slurry filling station 52, the present methods additionally include the step 64 of filling the bag 12 through the upper orifice with a quantity of fat (with or without butter).

The term slurry is used herein as is common in the microwave popcorn art to refer to any coating applied to the kernel popcorn. The term "slurry" as used generally herein thus includes fat alone; fat and a lesser portion of salt in flour form; fat, flour salt, flavors and/or color or sweetener(s); fat, a portion of the flour salt and a portion of the calcium ingredient; and fat and substantially all of the calcium ingredient as well as any other variation or combination of ingredients used as an addition to the kernel popcorn herein.

The slurry can additionally optionally comprise minor amounts of other materials employed to make the microwave popcorn more aesthetically or nutritionally or organoleptically appealing. Such adjuvant ingredients can include, for example, limited amounts of sugar(s), micro fortification levels of minerals, vitamins, colorants, preservatives and flavors. If present, each of these constituents can comprise from about 0.01 to about 2% by weight of the fat slurry. Especially popular for use herein is a butter flavor. The flavors can be either in liquid, fat soluble forms and/or in dry powder forms such as a liquid oil absorbed onto a particulate carrier, e.g., gum arabic, starch, silicon dioxide, or dehydrated cheese solids or in the form of an oil suspension.

The fat slurry is prepared simply by admixing the fat (in a fluid or melted state) together with any optional ingredients with salt and blending the mixture to form a stable dispersion or slurry. The fat or slurry, while still fluid (21° to 55°C), is then sprayed into the microwave popcorn bag as described in detail below.

The slurry application step can be practiced by employing an applicator for spraying the fat slurry (e.g., commercially available from Hibar Systems Limited, Ontario, Canada) that is supplied by a slurry supply means (not shown). The slurry supply means can conveniently include a conventional positive displacement reciprocating metering pump having a piston and a pressurized slurry inlet. The pump precisely pumps metered amounts of the fat slurry to the applicator at closely controllable time intervals. If the slurry viscosity is too high, the slurry becomes unpumpable. The concentrations of salt and calcium ingredients are selected such that the slurry has a viscosity of less than 10,000 cps, preferably less than about 1,000 cps, and, for best results, less than 300 cps.

The slurry can be added at temperatures ranging from about 15.5° to 65.5°C, preferably about 38° to 54.4°C.

While a pencil jet spray is preferred for use herein, equivalents thereof in terms of dispensing the slurry can also be used. For example, a multiplicity of very fine jet streams, (e.g., 3-12), or a sparge can be used to achieve the desired dispersion hereunder. Also, other spray types, (e.g., a cone spray, a mist spray, or a fan spray) are useful herein. However, great care must be taken in selecting such useful alternatives so as to avoid getting slurry in the bag seal area. In other embodiments, the spray can be gas assisted, e.g., air, steam, or inert gas. In preferred embodiments, the bag 12 has a microwave chamber (i.e., wherein one major face panel has an intermediate microwave susceptor layer between the inner and outer bag layers) and, for cost considerations, a microwave susceptor-free chamber. In the preferred practice, the kernel popcorn, fat slurry and particulate(s) are charged to the microwave channel. Conventionally, the microwave channel is the lesser channel (i.e., being formed by the smaller major face 24) and the greater channel is the microwave free channel. Such a configuration minimizes the amount of relatively expensive microwave susceptor material required while nonetheless providing the needed expansion volume upon microwave popping. In the preferred form, the popcorn charging and slurry addition are practiced at separate stations and as separate steps. However, in other embodiments, the kernel popcorn and slurry addition can be practiced in a single station concurrently. Apparatus and techniques for such concurrent filling of the popcorn and slurry are described in commonly assigned US 5,690,979 entitled "Method Of Preparing Reduced Fat Microwave Popcorn" issued November 25, 1997.

If high levels of salt and calcium ingredients are desired in the finished products, addition of the total quantity of each of these materials to the slurry will cause the slurry viscosity to be excessively high. That is, while the slurry may be able to carry all of the salt or all of the calcium ingredient, or half of each, the slurry cannot carry all of both. Thus, either all of the salt or all of the calcium ingredient or a portion of each (e.g., 50:50 or 70:30) must be added as dry particulates in the third filling station or in the present essential particulates addition step. Useful herein for practicing this step are particulate metered feeding equipment that are commercially available such as are used for filling salt or sugar packets. Product Use

The microwave popcorn products prepared as described can be used in a conventional manner for the at-home preparation of a sweet coated popcorn by microwave heating. Conveniently, the microwave preparation does not require constant or even intermittent stirring during preparation. However, if desired, after the completion of the microwave heating step, the inflated microwave popcorn bag including the popped popcorn (and/or expanded pellets) can be shaken while the glaze is still warm to more evenly distribute the glaze coating on the popped product. Upon microwave heating of the sealed microwave popcorn article in a conventional home microwave oven, the resultant popped popcorn in the form of free flowing of individual substantially unagglomerated popped popcorn kernels exhibits excellent organoleptic attributes notwithstanding the sweet coating and with minimal scorching or browning.

Industrial Applicability The present invention finds suitability for use in the commercial production of a mass market, shelf stable consumer packaged food item adapted to prepare an oiled, sweetened glazed popcorn upon microwave heating in a consumer microwave oven. Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative and not limitative of the remainder of the disclosure. It will be appreciated that other modifications of the present invention, within the skill of the microwave popcorn art, can be undertaken without departing from the spirit and scope of the invention. Example 1

An improved microwave popcorn article of the present invention comprising a microwave popcom bag is prepared having the popcorn/fat charge of the composition indicated below. The microwave popcorn bag is fabricated substantially in accordance with the teachings of U.S Pat. No. 4,450,180. Microwave popcorn articles comprising microwave popcorn bags of this type are available under the brand name Betty Crocker™/Pop Secret™. The popcorn fat charge has the following composition:

Ingredients Weight %

Popcorn 35.3

Fat¹ 28.4

Salt 0.75

Isomalt² 35.3

Artificial butter flavor 0.25

100.0

1. A hydrogenated soybean oil available from Cargill Foods under the trade name 600S.

Isomalt available from Cargill Foods Inc. and milled to have a mean particle size of 600 μm. A supply of the fat, salt and butter is prepared to form a warm slurry (about 50°C). The slurry has a viscosity of 50 - 150 cps. The fat slurry comprises:

Ingredient Weight %

Fat 96.6%

Salt 2.55%

Butter 0.85%

The salt added to the slurry was a flour salt having a mean particle size of about 22 μm.

A quantity of microwave popcorn bags are filled as follows: At a first filling station, a open ended microwave popcom bar is advanced to a first filling station where 50g of kernel popcorn is dispensed by the dispensing wheel into the funnel that directs the kernel popcorn to fall into the open bag. The popcorn filled bag was then advanced to a second filling station. A fat slurry applicator is timed to dispense about 42g of the slurry in the form of a downwardly projecting vertically aligned pencil jet spray. The duration of the spray is about 0.5 seconds. The slurry charged the fat slurry within the microwave popcorn bag below the seal area. The popcorn and fat filled bags are then advanced to a third filling station.

About 55g of the isomalt is dropped by gravity into the open end of the bag. The isomalt is in flour form having a mean particle size of about 600 μm.

The food charge filled bags are advanced to sealing station then heat sealed to form finished sweet coating microwave popcorn articles of the present invention. The articles are provided with a moisture resistant overwrap (e.g., fabricated from polypropylene material). The microwave popcorn articles so prepared can be conventionally microwave heated to provide popped popcorn having a sweet coating.

Reduced fat and full fat microwave products of the present invention can be prepared wherein in the Example the fat and butter content are adjusted in amount.

I Substantially equivalent microwave popcorn articles of the present invention are prepared when the isomalt ingredient of the above example is substituted with maltitol and lactitol and mixtures thereof of similar particle size (with adjustments to other sweeteners to allow for the different level of sweetness of each glazing ingredient). It should be appreciated that microwave heating of the sealed microwave popcorn article in a conventional home microwave oven is intended to result in large amounts of a hot viscous slurry during the popping of the popcorn, with the amount of slurry being significantly greater than the amount of liquid or fluid material in a buttered or unbuttered popcorn package. Additionally, the time for such slurry to cool down to transform from a flowable state to a non-flowable state can be longer than hurried consumers expect (based upon prior experience with fat flavored microwave popcorn). Further, the slurry is intended to coat the popped popcorn and thus has a greater tendency to cling to skin or other surfaces rather than ran therefrom such as in the case of oil, fat, butter or the like. Thus, there is increased importance to minimize contact of liquid or fluid material exiting a bag containing sweet microwave popcom as the bag is being removed from a microwave oven or being transported thereafter. One approach is to contain the liquid or fluid material in the bag independent the orientation of the bag during removal or transport from the microwave oven. A preferred form of such an approach is shown and described U.S. Appln. No.

10/676,826 filed on September 30, 2003, which is hereby incorporated herein by reference. See also U.S. Patent No. 6,660,983 and U.S. Appln. No. 10/786,219 filed February 25, 2004.

An alternate approach is to utilize a bag design which predisposes the consumer to remove and transport the bag in a preferred orientation. In this regard, the square bottom bag 218 has proven to arrive at unexpected advantages. In particular, although utilized previously for buttered or unbuttered popcom, square bottom bags have fallen from favor and are not being presently utilized by at least the major producers due to a variety of factors, including but not limited to cost, difficultly of fabrication, and the like. However going against conventional wisdom, it has been discovered that the square bottom bag 218 has particular advantages when utilized with sweet microwave popcorn according to the teachings of the present invention. In particular, consumers will tend to grasp the end 280 (which vents during microwave cooking) such that the bag 218 will be held in a vertical orientation with the end 280 at the top. Even if the bag 218 should be orientated in the microwave oven at the end of the popping cycle with the end wall 224 being closest to the microwave door opening, consumers tend not to attempt to grasp the end wall 224 but rather tend to rotate the bag 218 in the microwave oven until access to the end 280 is available. A vertical orientation with the end 280 at the top will minimize leakage of liquid or fluid material from the interior of the bag during removal and transport from a microwave oven. Additionally, the square bottom bag 218 holds the bag 218 in a vertical orientation when the end wall 224 is rested upon a horizontal support surface such as a table, countertop or the like. During the formation of the square bottom bag 218 and in particular the end wall 224 thereof, it is necessary to create hard folds between the end wall 224 and walls 226, 240 and 260, and the folds are folded and unfolded during the formation of bag 218. The formation and folding and unfolding may result in fracturing of the fibers forming the grease proof or resistant inner ply 34. Fiber fracture is most severe at the corners where three folds interconnect, i.e., at the interconnections of the folds between the side walls 226 and top wall 260, between the top wall 260 and end wall 224, and between the side walls 226 and end wall 224 and the interconnection of the folds between the side walls 226 and bottom wall 240, between the top wall 240 and end wall 224, and between the side walls 226. Fiber fracture of the inner ply 34 can result in the allowance of leakage from the interior of the bag through the inner ply 34. During transport and storage, leakage can result in discoloration of the outer ply 33 and/or collection of grease within the plastic overwrap, which is more of an aesthetic concern. However, during and immediately after microwave cooking, liquid grease and fluid can leak through the paper fractures of the bag 218 at the corners between walls 224, 226 and 240 abutting with the microwave oven floor.

It should be appreciated that the extension of susceptor 230 and in particular the polyester film carrier thereof from the bottom wall 240 unto walls 224 and 226 results in the corners having the polyester film carrier. Thus, as polyester is not prone to fracture from stress due to folding even though the paper fibers may fracture, leakage from the corners between walls 224, 226 and 240 is prevented. Additionally, as extension of the susceptor 230 results in only a minor increase in the size (and cost) of the susceptor 230 such that the total fabricated cost of the bag 218 is not detrimentally increased as would occur if the bag 218 included a polyester ply equal to the entire or substantially entire interior surface of bag 218. Further, susceptor 230 of the preferred form is rectangular in form for manufacturing reasons by the same equipment utilized to apply prior susceptors. Surprisingly, the multiple layers of the susceptor 230 at the corners and resulting during the creation of the end wall 224 did not create spots which detrimentally reacted to microwave energy. However, susceptor 230 and/or the polyester film thereof could be patterned such as to eliminate multiple layers, could be an annular strip extending around the entire periphery of the end wall 224 and each of the walls 226, 240 and 260 such that all four corners and the end wall 224 would include a polyester film extension or could be formed free of susceptor material if not desired. However, it can be appreciated that the corners between the end wall 224 and the walls 226 and 260 do not encounter the same concerns as the corners between the end wall 224 and walls 226 and 240 due to its elevated position during microwave cooking.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A microwave popcorn article for preparing sweet popcorn, comprising: a continuously sealed microwave popcorn container; and a food charge disposed therein comprising:

A. unpopped popcorn kernels, and

B. a high temperature thermoplastic carbohydrate glaze forming ingredient of moderate sweetness.

2. The article of claim 1 wherein at least a portion of the glaze forming ingredient is in particulate form.

3. The article of claim 1 or 2 wherein at least 50% of the glaze forming ingredient has a mean particle size of less than 1000 microns.

4. The article of any one of the preceding claims wherein at least a portion of the glaze forming ingredient is isomalt.

5. The article of any one of the preceding claims, wherein the food charge additionally comprises salt.

6. The article of claim 5 wherein at least a portion of the salt is coarse sized salt said coarse sized salt portion having a mean particle size ranging from about 250-750 microns.

7. The article of any one of the preceding claims wherein the food charge additionally comprises a high potency sweetener.

8. The article of any one of the preceding claims wherein the food charge additionally comprises an edible fat.

9. The article of claim 8 wherein the edible fat includes at least one member selected from the group consisting of low melting point fats, partially hydrogenated oils, fluid fats, butter, and mixtures thereof.

10. The article of claim 8 or 9 wherein at least a portion of the edible fat is butter and is supplied by a high butterfat low moisture butter.

11. The article of any one of the preceding claims wherein the food charge includes about 40 to 85g unpopped popcorn kernels.

12. The article of any one of the preceding claims wherein the popcorn kernels additionally includes a puffable pellet.

13. The article of any one of the preceding claims wherein the food charge includes about 1 to 80 g of the glaze ingredient.

14. The article of any one of the preceding claims wherein the food charge includes about 1 to 15g salt and a supplemental high potency sweetener selected from the group consisting of sucralose, potassium acesulfame and mixtures thereof.

15. The article of any one of the preceding claims wherein the food charge includes about 1 to 45g edible fat and wherein the microwave container is a microwave popping bag.

16. The article of any one of the proceeding claims with the continuously sealed microwave popcorn container comprising a square bottom microwave popping bag.

17. The article of claim 16 with the square bottom microwave popping bag including an end wall interconnected to a bottom wall, a top wall, and first and second side walls, with the square bottom microwave popping bag further including a susceptor located on the bottom wall and partially extending unto the end wall and the first and second side walls, with the top wall and a portion of the end wall and a portion of the first and second side walls being free of the susceptor.

18. The article of claim 17 with the susceptor including a carrier which does not stress fracture as a result of folding and including susceptor material located on the carrier.

19. The article of claim 18 with the carrier being polyester film and the susceptor material being of an area size equal to the polyester film.

20. The article of any one of claims 1-15 with the continuously sealed microwave popcorn container comprising a microwave popping bag formed of flexible material defining a hollow interior for receipt of the food charge, with the microwave popping bag including a bottom wall having a susceptor disposed thereon, with the microwave popping bag including at least a first corner formed by an interconnection of at least first and second folds with the bottom wall, with the susceptor extending from the bottom wall over the first and second folds and the first corner, with the microwave popping bag further including a top wall overlying the bottom wall, with the top wall being substantially free of the susceptor.

21. In a microwave popcorn article comprising a sealed microwave popcorn container and a food charge disposed within the container comprising popcorn, fat and salt, the improvement comprising: fortifying the food charge with a isomalt ingredient in amounts sufficient to provide 60 to 150g of isomalt per 100 grams of unpopped popcorn, and wherein the isomalt ingredient has a mean particle size of less than lOOOμm.

22. The microwave popcorn article of claim 21 wherein the isomalt ingredient has a mean particle size of less than 750 μm.

23. The microwave popcorn article of claim 21 or 22 wherein the food charge additionally comprises a high potency sweetener.

24. The microwave popcom article of claim 23 wherein at least a portion of the high potency sweetener is provided by sucralose.

25. The microwave popcorn article of any one of claims 21 -24 additionally comprising a moisture barrier overlap.

26. The microwave popcorn article of any one of claims 21 -25 with the continuously sealed microwave popcorn container comprising a square bottom microwave popping bag.

27. The microwave popcorn article of claim 26 with the square bottom microwave popping bag including an end wall interconnected to a bottom wall, a top wall, and first and second side walls, with the square bottom microwave popping bag further including a susceptor located on the bottom wall and partially extending unto the end wall and the first and second side walls, with the top wall and a portion of the end wall and a portion of the first and second side walls being free of the susceptor.

28. The microwave popcorn article of claim 27 with the susceptor including a carrier which does not stress fracture as a result of folding and including susceptor material located on the carrier.

29. The microwave popcorn article of claim 28 with the carrier being polyester film and the susceptor material being of an area size equal to the polyester film.

30. The microwave popcorn article any one of claims 21 -25 with continuously sealed microwave popcorn container comprising a microwave popping bag formed of flexible material defining a hollow interior for receipt of the food charge, with the microwave popping bag including a bottom wall having a susceptor disposed thereon, with the microwave popping bag including at least a first corner formed by an interconnection of at least first and second folds with the bottom wall, with the susceptor extending from the bottom wall over the first and second folds and the first corner, with the microwave popping bag further including a top wall overlying the bottom wall, with the top wall being substantially free of the susceptor.

31. A method for filling a microwave heating container with a food charge of microwave expandable pellets, and a sweet coating forming ingredient, comprising the steps of:

A. providing a microwave heating container having a sealed portion, an open sealable top portion defining an orifice in an open configuration and in a vertically aligned orientation;

B. filling the container through the orifice with a food charge comprising a quantity of microwave heating expandable popcom kernels or pellets and a moderate sweetness glaze forming carbohydrate coating ingredient to form a container filled with a food charge; and,

C. sealing the filled microwave container to provide a microwave packaged food product.

32. The method of claim 31 wherein the filling of popcorn kernels or pellets is performed prior to filling with the carbohydrate coating ingredient.

33. The method of claim 31 or 32 wherein the container is a microwave popcorn bag and wherein the food charge additionally comprises salt.

34. The method of claim 33 wherein the particulate carbohydrate coating ingredient includes at least a portion of the salt in coarse form having a particle size of about 250 to 600 microns.

35. The method of claim 33 or 34 wherein the food charge additionally comprises a fat ingredient and wherein at least a majority portion of the salt is provided by sodium chloride.

36. The method of claim 35 wherein the fat ingredient is added in the form of a slurry of liquid fat and at least a portion of the salt.

37. The method of claim 36 wherein the fat slurry is added before the addition of the carbohydrate coating ingredient.

38. The method of claim 36 or 37 wherein the slurry is filled in the form of a pencil jet with a spray temperature of between about 21° to 54.5°C and the fat is a material selected from the group consisting of low melting point fats, partially hydrogenated oils, fluid fats, butter and mixtures thereof.

39. The method of any one of claims 35-39 wherein at least a portion of the fat ingredient is supplied by butter.

40. The method of any one of claims 35-39 wherein the fat ingredient includes about 750 ppm of antioxidant.

41. The method of any one of claims 31 -40 wherein the carbohydrate coating ingredient is selected from the group consisting of isomalt, maltitol and lactitol and mixtures thereof.

42. The method of claim 41 wherein the carbohydrate coating ingredient includes isomalt.

43. The method of claim 42 wherein the popcorn quantity ranges from about 35 to 70% and the isomalt quantity ranges from about 20 to 40%.

44. The method of any one of claims 31-43 wherein the food charge is free of a cheese ingredient.

45. The method of any one of claims 31-44 wherein the food charge is free of added sugar(s).

46. The method of any one of claims 31 -45 wherein the food charge additionally includes a caramel flavor or color.

47. The method of any one of claims 31-46 wherein the food charge additionally comprises a calcium ingredient selected from the group consisting of pure calcium carbonate, ground limestone, calcium phosphate salts, and mixtures thereof in sufficient amounts of the calcium ingredient to provide about 360 to 1800 mg per 100 grams of unpopped popcom.

47. The method of claim 37 wherein at least a portion of the calcium ingredient is ground limestone.

48. The method of any one of claims 31 -47 wherein the food charge filling is practiced in a single station.

49. The method of any one of claims 31-47 wherein the microwave popcorn or expandable pellet filling is practiced at a first station and the remainder of the food charge filling is practiced at a second station.

50. The method of any one of claims 31-49 wherein the food charge additionally comprises a supplemental high potency sweetener.

51. The method of claim 50 wherein at least a portion of the supplemental high potency sweetener is sucralose.

52. The method of any one of claims 31-51 wherein the microwave container is a tub.

53. The method of any one of claims 31-51 with providing the microwave heating container comprising providing a square bottom microwave popping bag.

54. The method of claim 53 with providing the square bottom microwave popping bag comprising providing the square bottom microwave popping bag including an end wall interconnected to a bottom wall, a top wall, and first and second side walls, with the square bottom microwave popping bag further including a susceptor located on the bottom wall and partially extending unto the end wall and the first and second side walls, with the top wall and a portion of the end wall and a portion of the first and second side walls being free of the susceptor.

55. The method of claim 54 with the square bottom microwave popping bag including an end wall interconnected to a bottom wall, a top wall, and first and second side walls, with the square bottom microwave popping bag further including a susceptor located on the bottom wall and partially extending unto the end wall and the first and second side walls, with the top wall and a portion of the end wall and a portion of the first and second side walls being free of the susceptor.

56. The method of claim 55 with the susceptor including a carrier which does not stress fracture as a result of folding and including susceptor material located on the carrier.

57. The method of any one of claims 31-51 with providing the microwave heating container comprising providing a microwave popping bag formed of flexible material defining a hollow interior for receipt of the food charge, with the microwave popping bag including a bottom wall having a susceptor disposed thereon, with the microwave popping bag including at least a first corner formed by an interconnection of at least first and second folds with the bottom wall, with the susceptor extending from the bottom wall over the first and second folds and the first comer, with the microwave popping bag further including a top wall overlying the bottom wall, with the top wall being substantially free of the susceptor.

58. The method of any one of claims 31-57 wherein at least a portion of the carbohydrate coating ingredient is in particulate form having a mean particle size of less than 1000 microns.

59. A continuously sealed microwave popcorn container comprising a microwave popping bag formed of flexible material defining a hollow interior for receipt of a food charge, with the microwave popping bag including a bottom wall having a susceptor disposed thereon, with the microwave popping bag including at least a first corner formed by an interconnection of at least first and second folds with the bottom wall, with the susceptor extending from the bottom wall over the first and second folds and the first corner, with the microwave popping bag further including a top wall overlying the bottom wall, with the top wall being substantially free of the susceptor.

60. The continuously sealed microwave popcorn container of claim 59 with the microwave popping bag further including a first side wall between the top wall and the bottom wall, with a third fold being formed between the bottom wall and the first side wall, with the first, second and third folds interconnecting at the first corner, with the susceptor extending from the bottom wall over the third fold and the first corner.

61. The continuously sealed microwave popcom container of claim 60 with the microwave popping bag further including an end wall, with the first fold being between the bottom wall and the end wall, with the second fold being between the bottom wall and the first side wall.

62. The continuously sealed microwave popcom container of claim 61 with the microwave popping bag further including a second side wall between the top wall and the bottom wall, with a fourth fold being formed between the bottom wall and the second side wall, with a second corner being formed by an interconnection of the first fold and the fourth fold.

63. The continuously sealed microwave popcorn container of any one of claims 59-62 with the susceptor including a carrier which does not stress fracture as a result of folding and susceptor material located on the carrier.

64. The continuously sealed microwave popcorn container of any one of claims 59-63 further including a food charge located in the interior.

65. The continuously sealed microwave popcorn container of claim 64 with the food charge including unpopped popcorn kernels.

66. The continuously sealed microwave popcorn container of claim 64 or 65 with the food charge including a high temperature thermoplastic carbohydrate glaze forming ingredient of moderate sweetness.