WO2011082292A1

WO2011082292A1 - Microwave popcorn product including fat blend having double-encapsulated flavor particles

Info

Publication number: WO2011082292A1
Application number: PCT/US2010/062483
Authority: WO
Inventors: Christopher W. Williams; Robert M. Sobel
Original assignee: Weaver Popcorn Company Inc.
Priority date: 2009-12-31
Filing date: 2010-12-30
Publication date: 2011-07-07

Abstract

A fat blend for use in microwave popcorn products that includes double-encapsulated flavor particles. The fat blend may be a solid form, co-crystallized blend of a solid fat and a liquid oil. The double-encapsulated flavoring particles each include multinuclear flavor oil cores encompassed by an inner, water-soluble/oil-insoluble matrix or layer. The inner layer is further encased within a second layer of a water-insoluble/oil-soluble layer having a higher melting point than the fat blend to allow the flavor particlesto be evenly distributed into the fat blend during production, in which the fat blend is melted at an elevated temperature. The double-encapsulated flavor particles may include highly concentrated flavor oils to minimize the usage rate of the flavor particles while also allowing a significant reduction in the quantity of fat per product serving, particularly saturated fat.

Description

MICROWAVE POPCORN PRODUCT INCLUDING FAT BLEND HAVING DOUBLE-ENCAPSULATED FLAVOR PARTICLES

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application

Serial No. 61/291,458, filed December 31, 2009, the disclosure of which is expressly incorporated herein by reference.

BACKGROUND

1. Field of the Invention.

[0002] The present invention relates to microwave popcorn products and, in particular, to a fat blend for microwave popcorn products having double-encapsulated flavor particles.

2. Description of the Related Art. a. Microwave Popcorn.

[0003] Microwave popcorn products are packaged in a microwavable container, such as a paper bag, along with a fat slurry that includes a relatively large amount of a room temperature solid fat, such as palm oil or partially hydrogenated soybean oil, and relatively smaller amounts of other ingredients, such as salt and natural and/or artificial flavors and colors.

[0004] Microwave popcorn products are unique in the food industry in that they are typically packaged in paper bags and yet include a fat slurry that must be in solid form at room temperature to prevent or minimize wicking of the fat slurry through the paper bag and/or leaking of any liquid oil from the interior of the bag. Upon microwave heating, the fat slurry melts and acts as a cooking medium for the popcorn kernels until such time as the kernels pop into popped kernels with the release of moisture as steam.

[0005] In a typical production process for microwave popcorn, an amount of unpopped popcorn kernels are first filled into a paper bag, followed by adding the fat slurry at an elevated temperature at which the fat is melted, with additional ingredients such as salt and natural and/or artificial flavors and colors mixed within the slurry. A metered amount of the fat slurry is added to each microwave popcorn bag through an upper end of the bag directly onto the unpopped popcorn kernels. The bag is then sealed, and the fat slurry, upon cooling, solidifies to prevent or minimize wicking of the fat through the paper bag. The bag is folded, and a clear plastic overwrap may be used to cover each folded bag to minimize the amount of air that may come into contact with the fat. b. Fat Blend with Liquid Flavor Oils.

[0006] In one known microwave popcorn product, the flavor component is in the form of one or more liquid flavor oils, such as a blend of one or more essential oils and/or other aromatic oils that in turn may be blended into an amount of a liquid triglyceride as a carrier. Thus, the flavor oils are liquid at room temperature.

[0007] During production, a relatively large amount of liquid flavor oils are blended into the melted fat slurry, such as melted palm oil, and the melted fat slurry is delivered into microwavable paper bags. Some of the liquid flavor oils may volatize from the melted fat slurry into the surrounding atmosphere, becoming lost from the product. Upon cooling of the fat after packaging and throughout the shelf life of the product, most of the liquid flavor oils are trapped within the solidified fat, though some amount of the liquid flavor oils are disposed at or near the surface of the solidified fat, and therefore exposed to the surrounding environment. In this manner, during the production stage and throughout the shelf life of the product, at least some of the liquid flavor oils will typically be exposed to oxygen in the surrounding environment, which causes the liquid flavor oils to oxidatively degrade and/or evaporate, such that the product may have a limited shelf file due to deterioration of the flavor, and aromas associated with volatizing of the flavor oils are also readily detectable from the packaged product during its shelf life prior to popping. Also, degradation and evaporation of the flavor over the shelf life of the product weakens the quality of the flavors and the intensity of the flavor impact upon microwave heating and consumption of the product. Therefore, manufacturers typically add a relatively large amount of liquid flavor oils to the product to ensure that sufficient flavor remains in the product at the time of consumption after shelf lives of 3,6, 9, or even 12 months.

[0008] When the product is popped in a microwave oven, the fat re-melts and distributes the liquid flavor oil over the popped kernels. Some of the flavor oil volatizes and is available for smelling by the consumer, but only a relatively small portion of the flavor is delivered via the popped kernels to the mouth in a form that can be readily tasted by the consumer. Specifically, because palm oil has a high fat solids content (about 52%), a large portion of the palm oil tends to re-solidify when the product is removed from the microwave oven and allowed to cool before eating. This solid fat again entraps a significant portion of the liquid flavor oils such that during consumption of the popped kernels, the consumer essentially swallows the solid portion of the primary fat with the entrapped liquid flavor oils in a form in which the flavor oils are not available or released to be smelled and/or tasted by the consumer. This "re-solidification" phenomenom is another reason why manufacturers typically add a relatively large amount of liquid flavor oils to the product during manufacture.

[0009] Due to the degradation of the liquid flavor oil over time and the trapping of the liquid flavor oil within the solid portion of the primary fat after popping, producers tend to use very large amounts of both the liquid flavor oil and the fat in each product to compensate for the degradation and/or loss of the flavor oils. The increase in fat content and flavor oil content impacts the nutritional value of the product as well as the cost of the product, and also negatively increases the likelihood that the relatively large quantities of fat and/or flavor oils will eventually wick though the paper bag and/or leak from the interior of the bag, which is unappealing to the consumer. c. Fats and Fat Blends with Single-Encapsulated Flavor Particles.

[0010] The flavor component of other known microwave popcorn products is in the form of single-encapsulated flavor particles in which liquid flavor oils are

encapsulated within a surrounding layer or matrix. Encapsulation of flavor oils is generally known, in particular by a process in which a blend of flavor oils is dispersed into a solution of a water-soluble/oil-insoluble polysaccharide, such as maltodextrin. The dispersion is spray dried by atomizing the dispersion into a stream of heated air into a drying chamber to form particles, each particle being a matrix of maltodextrin carrying the flavor oils.

[0011] During production, the flavor particles are added to a melted primary fat, which may include a single fat, such as partially hydrogenated soybean oil, or a blend of liquid and solid fats. The oil-insoluble coating of the single-encapsulated particles may not facilitate easy dispersion of the particles in the primary fat, and the particles may tend to separate from the fat slurry during mixing. Therefore, the fat slurry may require constant agitation to initially distribute, and to maintain the distribution of, the flavor particles throughout the fat slurry. The constant agitation can potentially lead to the initiation of separation between the polysaccharide and the flavor oil. After mixing, the fat slurry is delivered into microwavable paper bags as described above.

[0012] During the production stage and throughout the shelf life of the product, the water-soluble matrix protects the flavor oils from exposure to the environment, such that the single-encapsulated flavor particles may suffer less degradation than the liquid flavor oils described above. However, single-encapsulated flavor particles may still potentially degrade if exposed to oxygen and moisture.

[0013] When the product is popped in a microwave oven, the fat re-melts and the popcorn pops into popped kernels. Steam from the popped kernels quickly dissolves the water-soluble coatings of the flavor particles to release the flavor oils to distribute over the popped kernels along with the melted fat, and to volatize and release into the surrounding atmosphere to be smelled by the consumer. If the fat includes partially hydrogenated soybean oil, for example, which has a high solids content (about 47%), a portion of the soybean oil re-solidifies when the product is removed from the microwave oven and allowed to cool before eating. This solid portion of the fat entraps the flavor oil to some extent and, during consumption, the consumer may swallow the solid portion of the fat together with a portion of the entrapped flavor oil, such that the flavor oil is not released to be smelled or tasted by the consumer. This "re-solidification" phenomenom necessitates a relatively high usage rate of the flavor particles.

[0014] What is needed is a flavoring system for microwave popcorn products which is an improvement over the foregoing.

SUMMARY

[0015] The present invention provides a fat blend for use in microwave popcorn products that includes double-encapsulated flavor particles. The fat blend may be a solid form, co-crystallized blend of a solid fat and a liquid oil. The double-encapsulated flavoring particles each include multinuclear flavor oil cores encompassed by an inner, water-soluble/oil-insoluble matrix or layer. The inner layer is further encased within a second layer of a water-insoluble/oil-soluble layer having a higher melting point than the fat blend to allow the flavor particles to be evenly distributed into the fat blend during production, in which the fat blend is melted at an elevated temperature.

[0016] During popping of the microwave popcorn product and consumption by the consumer, the flavor oils are released in different modes, including melting of the second layer to allow the water-soluble inner layer to be either dissolved by steam and moisture during popping with volatizing of the flavor oils, or delivered to the consumer's mouth where the inner layer is dissolved for release of the flavor oils. In another mode of flavor release, many of the flavor particles remain substantially intact upon delivery to the consumer's mouth for burst release of the flavor oils by shear action of the consumer's teeth during chewing. The double-encapsulated flavor particles may include highly concentrated flavor oils to minimize the usage rate of the flavor particles while also allowing a significant reduction in the quantity of fat, particularly saturated fat, per product serving.

[0017] The outer, water-insoluble/oil-soluble layer facilitates dispersal of the flavor particles within the melted fat slurry during production to aid in a more uniform distribution of the flavor particles within the melted fat, as well as through the manufacturing process and delivery of the flavor particles within the portions of the fat slurry that are metered into the microwave popcorn bags.

[0018] The outer, water-insoluble/oil-soluble layer, together with the water- soluble/oil-insoluble inner layer or matrix, protects the flavor oils throughout the shelf life of the product, substantially preventing oxidative degradation of the flavor oils to facilitate full delivery of the flavor oils to the consumer primarily at the time of popping the product. The two encapsulation layers also prevent the flavor oils from volatizing during the shelf life of the product, such that smell and aroma are not given off from the product prior to popping the product. This attribute may increase the shelf life of the product.

[0019] Further, the use of double-encapsulated flavor particles allows the flavor oils to be highly concentrated and to have a high degree of flavor loading, thereby allowing a lower usage rate of the double-encapsulated flavor particles in comparison with a much higher usage rate with known flavoring systems that include single- encapsulated flavoring particles. The lower usage rate of the double-encapsulated flavor particles, as well as the ability of the double-encapsulated flavor particles to protect and preserve the flavor oils through manufacturing and shelf life and to deliver the flavor oils at the point of popping and consumption, allows a reduced amount of volatile flavor oils to be used for delivering a flavor impact that is equal to, or better than, existing products.

[0020] The outer, water-insoluble/oil-soluble layer also at least partially protects the inner layer or matrix during the microwave heating process, allowing a substantial number of the particles to retain their inner layers or matrices such that the particles may deliver their flavor oils directly to the consumer for tasting, either by dissolving within the consumer's mouth and/or being burst released upon sheer action during chewing by the consumer. The particles that, in this manner, remain substantially intact add a functional mouthfeel component to the product, which allows a reduction in the amount of fat in the product.

[0021] When used with a co-crystallized fat blend including a relatively small amount of a solid fat and a relatively large amount of a liquid oil, the double- encapsulated flavor particles are able to deliver a high flavor impact to the consumer during consumption of the product, allowing a reduction of both the overall fat content and the overall salt content of the microwave popcorn product.

[0022] According to an embodiment of the present invention, a microwave popcorn product is provided, including a container, including: a quantity of unpopped popcorn kernels; an amount of a fat blend, said fat blend being a solid form, co- crystallized blend of at least one solid fat component and at least one liquid fat component; and encapsulated flavor particles present in an amount of less than 0.1 gram per 30 grams of a combined weight of the unpopped popcorn kernels and the fat blend.

[0023] According to another embodiment of the present invention, a microwave popcorn product is provided, including a container, including: a quantity of unpopped popcorn kernels; an amount of at least one fat; and double-encapsulated flavor particles, each particle including at least one core including at least one flavor component; an inner, water-soluble layer encompassing said at least one core; and an outer, water-insoluble layer surrounding said inner layer.

[0024] According to yet another embodiment of the present invention, a method is provided for producing a microwave popcorn product. The method includes the steps of: producing a fat blend that includes at least one solid fat component, at least one liquid fat component, and double-encapsulated flavor particles, each double-encapsulated flavor particle having an outer, oil-soluble layer; and introducing the fat blend into a container, the container further including a quantity of unpopped popcorn kernels. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0026] Fig. 1 is a cross-sectional view of a microwave popcorn product including a microwavable bag containing unpopped popcorn kernels and a fat blend;

[0027] Fig. 2A is a schematic, cross-sectional view of a pair of first and second types of exemplary double-encapsulated flavor particles, the flavor particles shown as substantially regular or circular shapes;

[0028] Fig. 2B is another schematic, cross-sectional view similar to FIG. 2A, the flavor particles shown as irregular or uneven shapes; and

[0029] Fig. 3 is a schematic representation of a process for producing and the microwave popcorn product of Fig. 1.

[0030] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

[0031] Fig. 1 depicts an exemplary microwave popcorn product 10 of the present invention. Microwave popcorn product 10 includes a quantity of unpopped popcorn kernels 12 and a fat composition 14 distributed over kernels 12, which may be either a single fat or a fat blend as described in detail below. Microwave popcorn product 10 is packaged in a container, such as a microwavable paper bag 16, though in other embodiments, microwave popcorn product 10 may be packaged in any type of microwavable container, such as a plastic container, for example. 1. Description of the Fat Blend.

[0032] In one embodiment, the fat 14 may be a single type of room temperature solid fat, such as palm oil or partially hydrogenated soybean oil, including the present double-encapsulated flavoring particles together with other components such as salt and other natural artificial flavors and/or colors. However, as discussed below, many additional advantages are obtained if the fat 14 is a blend of two or more fats, such as a co-crystallized fat blend that is in solid form at room temperature.

[0033] An exemplary fat blend, such as fat blend 14 of Fig. 1, includes (1) at least one liquid fat, (2) at least one solid fat, (3) optionally salt, and (4) any desired additives, such as flavors and colors, including the double-encapsulated flavor particles described in detail below. As used herein, the weight percent ("wt.%") of the components of the fat blend are based on the total weight of the fat blend (i.e., the total of all of the foregoing components (1) through (4)).

[0034] The liquid fat portion of the fat blend includes at least one fat that appears liquid at room temperature (i.e., is a liquid oil at room temperature), that therefore will typically include relatively high amounts of mono- and poly-unsaturated fatty acids. Examples of suitable liquid fats include vegetable-based oils, such as canola oil, sunflower oil, and corn oil, that appear as clear or substantially clear liquids at room temperature. Other suitable liquid fats include soybean oil, palm oil, rapeseed oil, sunflower seed oil, peanut oil, cottonseed oil, olive oil, and fatty acid trait-modified versions of the foregoing oils, such as low-linolenic canola oil, high-oleic canola oil, low- linolenic soybean oil, and high-oleic soybean oil, for example. These oils lack trans fats. However, as discussed below, the use of oils having a reduced or minimized amount of saturated fat is also beneficial.

[0035] The liquid fat portion may comprise less than 80 wt.% of the total weight of the fat blend, and alternatively, may comprise 78.5 wt.%> or less, 75 wt.%> or less, 72.5 wt.%) or less, 70 wt.%> or less, 67.5 wt.%> or less, or 65 wt.%> or less, for example, of the total weight of the fat blend. Alternatively stated, the liquid fat portion may comprise as little as 65 wt.%, 67.5 wt.%, or 70 wt.%, or as great as 72.5 wt.%, 75 wt.%, 78.5 wt.% or 80 wt.% of the total weight of the fat blend, or may comprises any value within any range delimited by the foregoing values.

[0036] The solid fat portion of the fat blend is a fat that appears solid at room temperature, sometimes referred to as a "hardstock" or "hard fat", such as cottonseed stearines, and will typically include a relatively higher content of saturated fatty acids. Other suitable room temperature solid or hard fats include stearines or saturated fats of the above-listed oils. Still other suitable hard fats include fractionated fats, mono- or do- glycerides or inter-esterified fats of the above-listed oils, such as fractionated palm oil or interesterified soybean oil, for example.

[0037] The solid fat portion may comprise less than 15 wt.% of the total weight of the fat blend, and alternatively, may comprise 14 wt.% or less, 12 wt.% or less, 10.5 wt.%) or less, 10 wt.% or less, 8 wt.% or less, or 6 wt.% or less, for example, of the fat blend. Alternatively stated, the solid fat portion may comprise as little as 6 wt.% or 8 wt.%, or as great as 10 wt.%, 10.5 wt.%, 12 wt.% or 14 wt.% of the total weight of the fat blend, or may comprises any value within any range delimited by the foregoing values.

[0038] By using a liquid fat that is low in saturated fat, and/or by minimizing the amount of solid fat used, the final product may contain less than 0.5 grams of saturated fat per serving, making the final product "Saturated Fat Free" under current U.S. Food and Drug Administration (FDA) guidelines, including 21 CFR § 101.62(c). Particular amounts of saturated fat content in exemplary products are discussed in detail below. Also, by using liquid and solid fats that each lack trans fats, the final product may contain less than 0.05 grams of trans fats per serving, making the final product also "Trans Fat Free" under current U.S. Food and Drug Administration (FDA) guidelines. When it is referred to herein that the fats do not include trans fats, or lack trans fats, it is meant that such fats include only any trace amounts of trans-isomers of unsaturated fatty acids that may be naturally occurring in such fats. [0039] Advantageously, the liquid and solid fats, such as canola oil and cottonseed stearines, respectively, for example, may be any commercially available, commodity fats from any commercial source and, as discussed below, these commodity fats may be purchased in bulk form and blended and melted together at the start of the present process.

[0040] The fat blend may also optionally include salt in an amount of as little at 5 wt.%, 7 wt.%, 9 wt.%, 11 wt.%, or 13 wt.%, or as much as 15 wt.%, 17 wt.%, 19 wt.%, 21 wt.%), 23 wt.%), or 25 wt.%, for example, of the total weight of the fat blend.

Advantageously, salt has been found to be readily blendable into the present fat blends without exhibiting any observed detrimental effects on the crystal structure of the fat blend that is produced. The salt may be in the form of a flour salt, for example, though the type and form of the salt may vary as desired. One exemplary salt is available from Morton International, Inc., having a specified mean crystal (particle) size of 30 microns.

[0041] The fat blend also includes additives, such as flavors and colors. An exemplary flavor ingredient is provided in the form of double-encapsulated flavor particles, as described in detail further below. These double-encapsulated flavor particles may comprise less than 2 wt.% of the total weight of the fat blend, and alternatively, may comprise less than 1.5 wt.%, 1.0 wt.%, 0.5 wt.%, or even 0.25 wt.% for example, of the fat blend.

[0042] When the fat blend is co-crystallized, as described in detail below, the fat blend is in solid form, is very stable at room temperature and at elevated temperatures above room temperature, and does not fully melt until a exposed to temperatures above about 120 °F.

[0043] Two exemplary formulations of fat blends made in accordance with the above description are set forth in Table 1 and Table 2 below: Table 1

Exemplary Fat Blend Formulation No. 1 with

Double-Encapsulated Flavor Particles

[0044] In both Exemplary Fat Blend Formulation Nos. 1 and 2, canola oil is used as the liquid fat, which appears as a clear liquid at room temperature, and cottonseed stearines are used as the solid fat, which is a "hard fat" that appears as a solid at room temperature. Exemplary Fat Blend Formulation No. 2 (Table 2) contains less total fat (liquid fat plus solid fat) and more salt than Exemplary Fat Blend Formulation No. 1 (Table 1). As will be apparent from these formulations, the fat blends include a relatively large amount of the at least one liquid fat and a relative small amount of the at least one solid fat such that the fat blends are highly unsaturated. 2. Description of the Double-Encapsulated Flavor Particles.

[0045] Referring to Figs. 2A and 2B, a pair of exemplary double-encapsulated flavor particles 20A and 20B are schematically illustrated in sectional view. Each double-encapsulated flavor particle 20A and 20B includes one or more cores 22, a first, inner layer, shell, or matrix 24 that surrounds one or more of the cores 22, and a second, outer layer or shell 26 that surrounds one or more of the first, inner shells 24.

[0046] Flavor particles 20A and 20B may be provided in a wide range of sizes and in either regular shapes, as shown in Fig. 2A, or irregular shapes, as shown in Fig. 2B. Exemplary flavor particles 20 A and 20B include a first type of flavor particle 20 A that includes only a single inner layer, or sub-particle 24, encapsulated or encased within a second layer 26, and a second type of flavor particle 20B that includes a plurality of inner layers, or sub-particles 24, encapsulated or encased within a common second layer 26. Exemplary double-encapsulated flavor particles are available from FONA

International, Inc., of Geneva, Illinois.

[0047] Each core 22 of flavor particle 20 will typically be in the form of a

"pocket" having a major dimension on the order of about 1 micron, with each core 22 including at least one flavor component, which may be one or more natural and/or artificial flavor components such as flavor oils. According to an exemplary embodiment, core 22 of flavor particle 20 includes a blend of flavor oils that impart a butter or buttery flavor to the microwave popcorn product. It is also within the scope of the present invention that core 22 of flavor particle 20 may include a blend of flavor oils that impart a caramel flavor, a chocolate flavor, a cheese flavor, a cinnamon flavor, a spiced flavor, a candied flavor, a nutty flavor, or another suitable flavor to the microwave popcorn product.

[0048] The flavor components in core 22 may also include "umami" components to impart a savory flavor. Umani components may represent the taste imparted by amino acids, such as glutamate, and ribonucleotides, such as inosinate and guanylate. [0049] Each inner layer 24 of the flavor particles 20 is formed of a water- soluble/oil- or fat-insoluble material. Suitable materials for inner shell 24 include one or more of gelatin, water-soluble gums, such as gum acacia/gum arabic, and

polysaccharides, such as starches, dextrin, and maltodextrin. In an exemplary

embodiment, inner layer 24 is formed of gum acacia. The material used to form inner layer 24 of flavor particle 20 may have a melting point of approximately 180 °F, 200 °F, 220 °F, 240 °F, or more. The particles, after formation of inner layer 24, may have an average particle size (i.e., major dimension, as measured in a suitable manner such as by laser light diffraction by ISO 13320, for example) of approximately 5 microns, 10 microns, 15 microns, or more. As shown in Figs. 2A and 2B, inner layer 24 will typically contain a plurality of individual cores 22, such that the cores 22 within inner layer 24 are multinuclear.

[0050] Outer layer 26 of flavor particle 20 is formed of a lipid-based material.

Outer layer 26 may have a thickness that is greater than that of inner layer 24. For example, after formation of outer layer 26, the particles may have an average particle size of approximately 25 microns, 30 microns, 35 microns, 40 microns, 45 microns, or more. According to an exemplary embodiment, the material used to form outer layer 26 of flavor particle 20 has a melting point above that of the solid fat of the fat blend. For example, for the reasons discussed below, if the solid fat of the fat blend is cottonseed stearines having a melting point of about 140 °F or less, the material used to form outer layer 26 of flavor particle 20 may have a greater melting point, such as approximately 145 °F or greater, 150 °F or greater, 160 °F or greater, or 170 °F or greater, for example. Suitable materials for outer shell 26 may include, for example, partially or fully hydrogenated vegetable oils (having a melting point of about 130-160 °F) including partially or fully hydrogenated soybean oil (having a melting point above 152 °F), glyceryl monostearate (having a melting point of about 158 °F), beeswax (having a melting point of about 143-150 °F), Carnauba wax (having a melting point of about 180- 186 °F), and other edible waxes, for example. [0051] Flavor particles 20 A and 20B may be produced using any suitable encapsulation method to encapsulate the flavor oil cores 22 within inner layer 24, and to in turn encapsulate inner layer 24 within outer layer 26 in the manner described above. The particular techniques and processing conditions associated with the method(s) of encapsulation that may be used by one of ordinary skill in the art to arrive at the type of double-encapsulated flavor particles described herein may vary.

[0052] Suitable encapsulation methods are discussed in Dziezak, J.D.,

"Microencapsulation and Encapsulated Ingredients" , Food Technology, April 1988, pp. 136-151 and in Cho, Y.H. et al. "Characteristics of Double-Encapsulated Flavor Powder Prepared by Secondary Fat Coating Process" , Journal of Food Science, vol. 67, No. 3 (2002), pp. 968-972, the disclosures of each are expressly incorporated herein by reference. These processes include, for example, spray drying, air suspension, extrusion, centrifugal extrusion, spray chilling, rotational suspension separation, coacervation, inclusion complexation, and combinations thereof. In one embodiment, cores 22 are encapsulated within first or inner layer 24 by a spray drying process, and the resulting sub-particles are then encapsulated within second or outer layer 26 by a spray chilling process or by a fluidized bed coating process. An exemplary process for producing flavor particles 20 A and 20B is set forth in Example No. 4 below.

[0053] Advantageously, the present double-encapsulated flavor particles, when constructed as described above, may achieve higher flavor loading than single- encapsulated flavor particles. As used herein, for a given amount of flavor particles, "flavor loading" refers to the total weight of the flavor components themselves (i.e., cores 22) as a percentage of the overall weight of the particles. For example, double- encapsulated flavor particles 20 may achieve flavor loading of approximately 20%, 25%, 30%), 35%), 40%), or more, while a single-encapsulated flavor particles typically achieve flavor loading of only about 2% to about 12%. Therefore, a substantially smaller quantity of double-encapsulated flavor particles may be used to achieve the same flavor content or impact as would be realized with a substantially larger quantity of single- encapsulated flavor particles. [0054] Table 3 below, for example, provides an exemplary fat blend formulation using known single-encapsulated flavor particles.

Table 3

Sample Fat Blend Formulation with

Single-Encapsulated Flavor Particles

[0055] As shown by comparing the fat blend formulations of Tables 1-3, using double-encapsulated flavor particles as opposed to single-encapsulated flavor particles may significantly reduce the required quantity of flavor ingredients, referred to herein as the "usage rate" of the flavor ingredients. For example, Exemplary Fat Blend

Formulation Nos. 1 and 2 having double-encapsulated flavor particles (Tables 1 and 2) represent about an 80% reduction in the quantity of flavor ingredients as compared to the Sample Fat Blend Formulation having single-encapsulated flavor particles (Table 3). This reduction in the usage rate of flavor ingredients may substantially reduce material and production costs.

3. Formulation of Microwave Popcorn Products.

[0056] Referring back to Fig. 1, microwave popcorn product 10 includes a container, such as a microwave popcorn bag 16, having a desired amount of popcorn kernels 12 mixed with a desired amount of fat blend 14.

[0057] The total amount of unpopped popcorn product in bag 16 may vary depending on the desired number of servings per bag 16. As used herein, "unpopped popcorn product" refers to the combination of unpopped popcorn kernels 12 and fat blend 14. For example, each bag 16 will typically be sized to include between approximately 1 and 4 servings, such as 2 servings, 2.5 servings, or 3 servings. Each serving generally includes about 28 grams (g) to 34 g of unpopped popcorn product, such as about 30 g of unpopped popcorn product, which is equivalent to about 2 tablespoons of unpopped popcorn product. After the popcorn product is popped in a microwave oven, the serving size is equivalent to about 5 cups of popped popcorn product. Therefore, if 2 servings are desired per bag 16, and if each serving includes about 30 g of unpopped popcorn product, for example, bag 16 would include about 60 g of unpopped popcorn product.

[0058] Also, the relative amounts of the two components of the unpopped popcorn product (i.e., unpopped popcorn kernels 12 and fat blend 14) may vary depending on the desired fat content and flavor profile. For example, fat blend 14 may make up as little as approximately 5 wt.%, 10 wt.%, or 15 wt.%, or as much as 20 wt.%, 25 wt.%, 30 wt.%, or more, of the total weight of unpopped popcorn product, with unpopped popcorn kernels 12 making up the balance. Returning to the previous example, if bag 16 includes about 60 g of unpopped popcorn product, bag 16 may include between about 3 g and 18 g of fat blend 14, with unpopped popcorn kernels 12 making up the balance.

[0059] Several exemplary unpopped popcorn product formulations made in accordance with the present process are set forth in Tables 4-6 below:

Table 4

Exemplary Popcorn Product Formulation A

Table 5

Exemplary Popcorn Product Formulation B

[0060] The fat blends of Exemplary Popcorn Product Formulations A-C include, in various relative amounts, Exemplary Fat Blend Formulation Nos. 1 and 2 (from Tables 1 and 2). With reference to Tables 4 and 5, in particular, both Exemplary Popcorn Product Formulations A and B contain the same Exemplary Fat Blend Formulation No. 1 (from Table 1). However, Exemplary Popcorn Product Formulation B (Table 5) achieves a reduced fat content compared to Exemplary Popcorn Product Formulation A (Table 4) because Exemplary Popcorn Product Formulation B contains less total fat per serving and more popcorn kernels per serving than Exemplary Popcorn Product Formulation A. With reference to Table 6, Exemplary Popcorn Product Formulation C achieves an even further reduced fat content because Exemplary Fat Blend Formulation No. 2 (from Table 2) contains less fat than Exemplary Fat Blend Formulation No. 1 (from Table 1), and because Exemplary Popcorn Product Formulation C contains less total fat per serving and more popcorn kernels per serving than both Exemplary Popcorn Product Formulations A and B. [0061] In Tables 7A-9B below, ingredient and nutritional information regarding

Exemplary Popcorn Products A through C is presented, in which some of the values result from rounding to the nearest integer value:

Table 7A

Ingredients per Serving (30 g unpopped / about 5 cups popped)

of Exemplary Popcorn Product Formulation A

Table 7B

Nutritional Information per Serving (30 g unpopped / about 5 cups popped) of Exemplary Popcorn Product Formulation A

Table 8A

Ingredients per Serving (30 g unpopped / about 5 cups popped)

of Exemplary Popcorn Product Formulation B

Table 8B

Nutritional Information per Serving (30 g unpopped / about 5 cups popped) of Exemplary Popcorn Product Formulation B

Table 9A

Ingredients per Serving (30 g unpopped / about 5 cups popped) of Exemplary Popcorn Product Formulation C

Table 9B

Nutritional Information per Serving (30 g unpopped / about 5 cups popped) of Exemplary Popcorn Product Formulation C

[0062] Thus, as shown in the above tables, for each 30 g serving of unpopped popcorn product, the present microwave popcorn products may include less than 0.3 g of the double-encapsulated flavor particles or, in other embodiments, 0.1 g or less, 0.075 g or less, 0.050 g or less, or 0.025 g or less. [0063] The high flavor loading and the ability of the double-encapsulated flavor particles to deliver the flavor oils at the time of popping and consumption provides a demonstrable taste impact that allows for both a low salt usage rate, as well as reduced amounts of fat (particularly saturated fat) as compared with known microwave popcorn products.

[0064] For each 30 g serving of unpopped popcorn product, the present microwave popcorn products may include less than 2 g of salt or, in other embodiments, 1.5 g or less, 1 g or less, or 0.75 g or less.

[0065] Further, for each 30 g serving of unpopped popcorn product, the total fat content may be less than 10 g and, in other embodiments, 8 g or less, 7 g or less, 5 g or less, 4 g or less, or 3.5 g or less.

[0066] Notably, for each 30 g serving of unpopped popcorn product, each of the exemplary products includes 0 g trans fat, as defined above, and also includes less than 2 g of saturated fat and, in other embodiments, 1.5 g or less, 1 g or less, or 0.5 g or less.

4. Description of the Manufacturing Process.

[0067] An exemplary method or process by which microwave popcorn product 10 may be manufactured is discussed below with reference to Fig. 3.

[0068] In the first step of the present process, the liquid fat(s) 100, solid fat(s)

102, as well as salt 104 and any desired additives 106, which may include double- encapsulated flavor particles 20 (Figs. 2A and 2B), are added to a use tank 200. In use tank 200, the ingredients are blended and heated to a temperature sufficient to completely or substantially completely melt liquid fat 100 and solid fat 102, such that liquid fat 100 and solid fat 102 no longer have a crystalline form. This temperature will typically be higher than 120 °F, 130 °F, 140 °F, 150 °F, 160 °F, or more, for example, which may be selected primarily based on the melt point of solid fat 102. In one embodiment, a set temperature of 140 °F has been found to be sufficient to substantially completely melt solid fat 102 in the form of cottonseed stearines. The liquid fat 100 and solid fat 102 may be simply added to use tank 200 in their room temperature liquid and solid forms, respectively, and then melted and combined together. The remaining ingredients, including salt 104 and additives 106 may then be added to the melted fat blend while stirring, for example.

[0069] According to an exemplary embodiment of the present invention, the material used to form outer layer 26 of flavor particles 20 (Figs. 2 A and 2B) has a melting point above the set temperature of use tank 200. For example, if the set temperature of use tank 200 is about 140 °F, the material used to form outer layer 26 of flavor particle 20 may have a melting point of approximately 150 °F, 160 °F, 170 °F, or more. Thus, flavor particles 20 are able to remain substantially intact in the melted fat blend.

[0070] Also, the oil-soluble material (i.e., the lipid-based material) used to form outer layer 26 of flavor particles 20 (Figs. 2A and 2B) improves the miscibility between flavor particles 20 and the melted fat blend in use tank 200 compared to single- encapsulated flavor particles having water-soluble/oil-insoluble outer layers or matrices. Therefore, flavor particles 20 may disperse substantially evenly throughout the melted fat blend, such as under only mild agitation.

[0071] Next, the melted liquid fat blend exits use tank 200 via one or more suitable conduits 202 and is pumped through the system via a suitable pump 204. Pump 204 provides both a back pressure in the overall system and also affects the speed or rate at which the liquid fat blend travels through the system.

[0072] Then, the melted liquid fat blend is thoroughly mixed, agitated, and chilled to initiate co-crystallization of liquid fat 100 and solid fat 102. This step may be performed by pumping the liquid fat blend via pump 204 through a scraped surface heat exchanger 206, such as a Votator® heat exchanger, available from Waukesha Cherry- Burrell, Inc. of Cedar Rapids, I A, a unit of SPX Process Equipment Corp. (Votator® is a registered trademark owned by SPX Equipment Corporation). The use and operation of such scraped surface heat exchangers is well known in the art of shortenings, for example. In the scraped surface heat exchanger 206, the fat blend may be cooled from an inlet temperature of about 140 °F to an outlet temperature between about 70 °F and 95 °F, for example.

[0073] Following discharge from the outlet of the scraped surface heat exchanger

206, the partially crystallized fat blend is pumped under pressure through suitable conduits 208 to a metering apparatus which, in one embodiment, may be one or more metering pumps 210, through which metered amounts or portions of the partially or substantially co-crystallized fat blend 14 are discharged into bags 16 of the final microwave popcorn products 10. Between the scraped surface heat exchanger 206 and metering pumps 210, the crystal structure of the partially crystallized fat blend may continue to develop to a form approaching a substantially fully co-crystallized, solid form upon discharge into the bags 16.

[0074] At metering pumps 210, metered amounts, or portions, of the fat blend 14 are discharged into bags 16 that are moved into and out of position via a suitable conveyance system 212 and then packaged in a known manner. According to an exemplary embodiment of the present invention, bags 16 are pre-filled with unpopped popcorn kernels 12 (Fig. 1) before receiving fat blend 14. Suitable metering pumps are available from Hibar Systems Limited of Richmond Hill, Ontario, CA, and are adjustable to vary the amount of fat blend 14 which is metered into each bag. The partially crystallized fat blend is partially crystallized, yet pumpable, downstream of the scraped surfaced heat exchanger 206. However, upon discharge into the microwave bags 16, the development of the crystal structure of the fat blend 14 has progressed such that the fat blend 14 may achieve a substantially solid form immediately after discharge and contact with a substrate, such as bag 16.

[0075] Any partially crystallized fat blend which is not pumped via metering pumps 210 into the bags 16 is fully re-melted and recycled to the use tank 200 via return line 214. The partially crystallized fat blend may be directed to a second, or re-melt, scraped surface heat exchanger 216 that is similar to scraped surface heat exchanger 206. In the scraped surface heat exchanger 216, the fat blend is thoroughly mixed, agitated, and re -heated to promote even melting of liquid fat 100 and solid fat 102. The fat blend may be heated in the scraped surface heat exchanger 216 from the discharge temperature at which the fat blend 14 is discharged from metering pumps 210 to the melt temperature of use tank 200, which melt temperature may be higher than 120 °F, 130 °F, 140 °F, 150 °F, 160 °F, or more, for example.

[0076] Following discharge from the scraped surface heat exchanger 216, the re- melted fat blend is pumped through a suitable return line 218 to use tank 200, where it is combined with newly added, make-up ingredients including liquid fat(s) 100, solid fat(s) 102, salt 104, and any desired additives 106, which may include flavor particles 20 (Figs. 2A and 2B). The re-melted fat blend and the newly added ingredients then continue through the above-described continuous loop process.

[0077] During the above-described process, and while flavor particles 20 are dispersed throughout the fat blend or slurry, outer layer 26 and inner layer 24 of each flavor particle 20 (Figs. 2 A and 2B) remain substantially intact to surround and protect cores 22. Therefore, outer layer 26 and inner layer 24 prevent oxidative degradation of core 22 and/or premature flavor release from core 22.

[0078] Referring still to Fig. 3, microwave popcorn products 10 that receive fat blend 14 from metering pumps 210 are packaged, stored, shipped, and delivered to a consumer though suitable commercial channels, indicated at 300, which represents the "shelf life" of the products. Microwave popcorn products 10 may remain in such commercial channels for several days, weeks, or months. During this time, outer layer 26 and inner layer 24 of each flavor particle 20 (Figs. 2 A and 2B) remain substantially intact to surround and protect the flavor oil cores 22 of the particle. In particular, as discussed above, the water-insoluble/oil-soluble outer layer 26 of each flavor particle 20 has a melting point that will typically exceed 140 °F, and therefore remains substantially intact even if microwave popcorn product 10 is exposed to significant heat. Further, the water- insoluble/oil-soluble outer layer 26 of each flavor particle 20 is resistant to moisture during the shelf life of the product. 5. Popping and Consumption.

[0079] After distribution through commercial channels 300, microwave popcorn products 10 are purchased by a consumer and popped in a microwave oven, indicated at 302 in Fig. 3. In microwave oven 302, microwave popcorn product 10 is initially exposed to microwave radiation and, after the kernels begin to pop, microwave popcorn product 10 is exposed to both microwave radiation and steam heat from the popping kernels. The microwave heating generates temperatures up to 400 °F to 450 °F and, upon commencement of heating, the fat blend 14 is quickly melted and surrounds the unpopped kernels 12. The liquid oil becomes superheated, and aids in more evenly transferring heat to the unpopped kernels 12, which will begin to pop and release steam.

[0080] Also, the microwave heating will cause the outer layers 26 of some of the flavor particles 20 (Figs. 2A and 2B) to absorb energy and transition from a solid phase to a liquid phase, depending on the physical location and exposure of the particles to the microwave heating. To complete this transition, outer shell 26 of each flavor particle 20 must acquire sufficient energy to pass from the solid phase, through intermediate glass transition and fusion phases, and then to a liquid phase. Inner layer 24 of each flavor particle 20 also undergoes a similar transition. The time that passes during these energy absorption steps delays the release of flavor components from the cores 22 of the flavor particles 20. According to an exemplary embodiment of the present invention, flavor components from core 22 of flavor particle 20 may be released at temperatures above 165 °F, with minor release occurring at or around 150 °F.

[0081] In one mode of flavor release, both outer and inner layers 26 and 24 of some of the particles 20 melt or otherwise disintegrate to allow the flavor oils of their cores 22 to volatize and release into the surrounding environment where they may be smelled by the consumer, or absorb onto the popped popcorn kernels.

[0082] In another mode of flavor release, once the outer layers 26 of others of the particles 20 have melted, the inner layers 24 are dissolved by steam from the popped popcorn kernels, which also allows the flavor oils of their cores 22 either to volatize and release into the surrounding environment where they may be smelled by the consumer, or absorb onto the popped popcorn kernels.

[0083] In still another mode of flavor release, some flavor particles 20 may not be exposed to sufficient heat to fully degrade and/or dissolve. For example, outer layer 26 and/or inner layer 24 of some flavor particles 20 may remain substantially or fully intact after popping. These flavor particles 20 provide a delayed and extended flavor release. In one form of this delayed or extended flavor release, any inner layers 24 that remain intact are also delivered to the consumer's mouth upon delivery via the popped kernels, where such layers may be dissolved within the saliva of the consumer's mouth to release the flavor oils in their cores 22. In another form of this delayed or extended release, any outer layers 26 and/or inner layers 24 that remain intact are broken down under the shear force of the consumer's teeth on chewing the popped kernels.

[0084] Notably, because fat blend 14 includes a much greater amount of liquid fat than solid fat as described above, fat blend 14 is highly unsaturated. Therefore, after fat blend 14 melts upon microwave heating, only a very small portion of the fat blend 14, corresponding primarily to the solid fat portion, is able to re-solidify when the product is removed from the microwave oven and allowed to cool before eating, and only a very small portion of the flavor particles 20 are trapped within this re-solidified fat. However, the vast majority of the fat blend 14, corresponding primarily to the liquid fat portion, does not re-solidify when the product is removed from the microwave oven and allowed to cool before eating, but rather remains as liquid oil and does not entrap the flavor particles 20 such that, during consumption, this liquid oil will tend to spread within the consumer's mouth while releasing the flavor components as described above.

EXAMPLES

[0085] The following non-limiting Examples illustrate various features and characteristics of the present invention, which is not to be construed as limited thereto.

1. Impact of Holding Time on Fat Blend Integrity.

[0086] In this Example, an experiment was conducted to evaluate the stability of a fat slurry or blend containing the double-encapsulated flavor particles when subjected to holding over a period of time at an elevated temperature typical of manufacturing conditions.

[0087] The fat blend of Exemplary Fat Blend Formulation No. 1 (Table 1) was prepared. The fat blend was held under agitation in a holding tank for 72 hours at 145 °F.

[0088] Various sample microwave popcorn products were produced by metering portions of the fat blend into microwave popcorn bags with unpopped popcorn kernels at the following times following initial blending: 0 hours (control sample), 4 hours, 8 hours, 12 hours, 24 hours, and 72 hours. Also, a 500 mL portion of the 12-hour sample was placed in an incubator and held for 12 days at 120 °F to produce a 12-day accelerated aged sample.

[0089] The sample microwave popcorn products were prepared in a microwave oven and served to 9 highly-trained Descriptive Analysis panelists. The panelists were asked to compare the 4-hour, 8-hour, 24-hour, 72-hour, and 12-day samples to the control sample using the "Difference from Control Method." Samples were evaluated primarily for butter flavor degradation and loss of character based on initial flavor, aftertaste, and mouthcoat. The results are presented in Table 10 below. Table 10

Impact of Holding Time on Fat Blend Integrity

[0090] The 5-point scale used by the panelists to compare the 4-hour, 8-hour, 24- hour, 72-hour, and 12-day samples to the control sample is described in Table 11 below.

Table 11

Scores

[0091] The descriptive phrases used by the panelists to describe the samples are defined in Table 12 below. Table 12

Descriptions

[0092] A qualitative measure taken during preparation did not indicate the presence of any objectionable odors during popping of the bags and following initial removal from the microwave oven. The aroma was typical of what would be expected from such a product.

[0093] As indicated in Table 10 above, the apparent quality of butter flavor remained either unchanged, or only slightly changed, over all of the test periods. For most attributes, "No Differences" were observed relative to the control sample, even for the 72-hour sample and the 12-day sample. In fact, for all of the test samples, "No Differences" were observed for aftertaste relative to the control sample. Only "Slight Differences" were observed for initial flavor between the 24-hour sample and the 48-hour sample relative to the control sample, and for mouthcoat between the 4-hour sample and the 48-hour sample relative to the control sample. Such slight differences most likely are not noticeable across the product spectrum.

[0094] As discussed above, the 12-day sample was held at an elevated

temperature of 120 °F for 12 days. Because no differences were observed between the control sample and the 12-day sample, it may be reasonable to assume that, at ambient temperatures, the fat blend could remain stable for up to 6 months, 12 months, or more.

2. Impact of Manufacturing on Fat Blend Integrity.

[0095] In this Example, an experiment was conducted to evaluate the stability of a fat slurry or blend containing the double-encapsulated flavor particles when subjected to the manufacturing conditions described in Section 4 above.

[0096] The fat blend of Exemplary Fat Blend Formulation No. 1 (Table 1) was prepared and circulated through the manufacturing process described in Section 4 above. Samples were taken at 3 hours and 6 hours.

[0097] The samples were served to 9 highly-trained Descriptive Analysis panelists. The panelists were asked to compare the 3-hour and 6-hour samples to a control sample using the "Difference from Control Method." Samples were evaluated primarily for butter flavor degradation and loss of character based on initial flavor, aftertaste, and mouthcoat.

[0098] With respect to initial flavor, the panelists found only slight differences between the 3 -hour sample and the 6-hour sample relative to the control sample. With respect to aftertaste and mouthcoat, the panelists found the 3 -hour sample and the 6-hour sample to be unchanged relative to the control sample. These results indicate that, after 3 hours or 6 hours, the manufacturing process described in Section 4 above has little impact on the character or the intensity of the butter flavor in the fat blend.

[0099] Next, the control sample, 3-hour sample, and 6-hour sample were added to microwave popcorn bags with unpopped popcorn kernels, prepared in a microwave oven, and served to the Descriptive Analysis panelists. The panelists analyzed the samples using the same 5 -point scale (Table 11) and descriptive phrases (Table 12) from Example No. 1. The results are presented in Table 13 below.

Table 13

Impact of Manufacturing on Fat Blend Integrity

[00100] The control sample was perceived as having an initial flavor composed of salt, butter, oil and corn. Slight changes in initial flavor were noticed in the 3-hour and 6- hour samples relative to the control sample, because cardboard and oxidized dairy notes became slightly more pronounced. With respect to aftertaste, no differences were observed relative to the control sample, the flavors notes being salt, oil and corn, as expected. Similarly, with respect to mouthcoat, no differences were observed relative to the control sample.

3. Impact of Holding Time and Manufacturing on Flavor Retention.

[00101] The sample microwave popcorn products prepared according to Example

Nos. 1 and 2 were popped in a microwave oven for about 2 minutes. Immediately after popping, the samples were placed in a 1 Liter vessel and covered with aluminum foil. The headspace above the popped samples was extracted using Solid-Phase Micro Extraction (SPME).

[00102] The extracted headspace samples were then analyzed using gas chromatography-mass spectrometry (GC-MS) to detect the presence of certain materials in the headspace above each sample. A 'blank' was run between each sample to minimize carryover between samples.

[00103] While GC-MS is able to detect the presence of certain materials in the headspace above each sample, it is difficult to draw conclusions about the amount or quantity of such materials present in the headspace. Nonetheless, flavor components from the cores of the flavor particles were detected in the headspace above each sample, indicating no significant signs of flavor loss due to holding time or the slurry

manufacturing process described in Section 4 above.

4. Process Conditions for Producing Double-Encapsulated Flavor Particles.

[00104] In Steps A - D of this Example, an exemplary process is set forth for producing double-encapsulated flavor particles. a. Step A: Preparing an Emulsion for Spray Drying.

[00105] Gum acacia is hydrated with water for 4 hours and then mixed until a solution is formed. Butter-based flavor components (which will form the core(s) of each flavor particle) are then blended and shear mixed with the hydrated gum acacia solution (which will form the first or inner layer(s) of each flavor particle) using a Ross High- Shear Impeller Mixer (Model HSMIOOL, S/N 100938) at about 5,000 rpm to 8,500 rpm for 10-15 minutes until a uniform emulsion is formed. The final solids content of the emulsion is 35%. b. Step B: Spray Drying the Emulsion.

[00106] The emulsion from Step A is atomized and spray dried to form the core(s) and the first or inner layer(s) of each flavor particle. This step involves atomizing the emulsion from Step A using a rotary atomizer and directing the atomized emulsion into a pilot plant-scale spray dryer. Both the rotary atomizer and the spray dryer are available from APV Nordic, Anhydro, of Soeborg, Denmark. The inlet temperature is maintained at about 190 °C (374 °F), and the outlet temperature is maintained at about 85 °C (185 °F). Material collected from the cyclone may be used for popcorn slurry preparation. c. Step C: Preparing a Dispersion for Spray Chilling.

[00107] Fully hydrogenated soybean oil is melted in a 2 Liter vessel that is maintained at a temperature of 82 °C (180 °F). Once completely melted, the oil (which will form the second or outer layer of each flavor particle) is gently mixed with a stainless steel spatula while the spray-dried, single-encapsulated flavor particles from Step B are charged into the vessel and uniformly dispersed by continuous mixing. d. Step D: Spray Chilling the Dispersion.

[00108] The dispersion from Step C is atomized and spray dried to form the second or outer layer of each flavor particle. The dispersion is atomized through a concentric fluid nozzle using compressed air with a source pressure of 45 psi. The dispersion is then gravity-fed into a Buchi B-295 lab-scale spray chiller available from Buchi Corporation of New Castle, Delaware, via a jacketed vessel that is maintained at a temperature of 180 °C (356 °F). The inlet temperature is maintained at 15 °C (59 °F) using a B-296 air conditioner and dehumidifier. Product is collected at the cyclone with an aspirator setting for 100%.

[00109] While this invention has been described as having exemplary designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A microwave popcorn product, comprising:

a container, including:

a quantity of unpopped popcorn kernels;

an amount of a fat blend, said fat blend being a solid form, co- crystallized blend of at least one solid fat component and at least one liquid fat component; and

encapsulated flavor particles present in an amount of less than 0.1 gram per 30 grams of a combined weight of said unpopped popcorn kernels and said fat blend.

2. The microwave popcorn product of Claim 1 , wherein said encapsulated flavor particles are double-encapsulated flavor particles, each particle comprising:

at least one core including at least one flavor component; an inner, water-soluble layer encompassing said at least one core; and an outer, water-insoluble layer surrounding said inner layer.

3. The microwave popcorn product of Claim 1, wherein said inner, water- soluble layer encompasses a plurality of said cores.

4. The microwave popcorn product of Claim 1 , wherein said outer, water- insoluble layer includes at least one lipid having a melting point of at least 145 °F.

5. The microwave popcorn product of Claim 1, having a total fat content of less than 8 grams per 30 grams of said combined weight.

6. The microwave popcorn product of Claim 1 , having a total saturated fat content of less than 2 grams per 30 grams of said combined weight.

7. The microwave popcorn product of Claim 1 , having a total trans fat content of less than 0.05 gram per 30 grams of said combined weight.

8. The microwave popcorn product of Claim 1 , wherein said at least one solid fat component is present in an amount of between 6 wt.% and 15 wt.% and said at least one liquid fat component present in an amount of between 65 wt.% and 78.5 wt.%, based on the total weight of said fat blend.

9. The microwave popcorn product of Claim 1 , wherein said fat blend further includes salt present in an amount of between 5 wt.% and 25 wt.%, based on the total weight of said fat blend.

10. A microwave popcorn product, comprising :

a container, including:

a quantity of unpopped popcorn kernels;

an amount of at least one fat; and

double-encapsulated flavor particles, each particle comprising: at least one core including at least one flavor component; an inner, water-soluble layer encompassing said at least one core; and

an outer, water-insoluble layer surrounding said inner layer.

11. The microwave popcorn product of Claim 10, wherein said amount of at least one fat provides a total saturated fat content of less than 2 grams per 30 grams of a combined weight of said unpopped popcorn kernels and said at least one fat.

12. The microwave popcorn product of Claim 10, wherein said double- encapsulated flavor particles are present in an amount of less than 0.1 gram per 30 grams of a combined weight of said unpopped popcorn kernels and said at least one fat.

13. The microwave popcorn product of Claim 10, wherein said outer, water- insoluble layer includes at least one lipid having a melting point of at least 145 °F.

14. The microwave popcorn product of Claim 11 , having a total fat content of less than 8 grams per 30 grams of said combined weight.

15. The microwave popcorn product of Claim 10, having a total trans fat content of less than 0.05 gram per 30 grams of a combined weight of said unpopped popcorn kernels and said at least one fat.

16. The microwave popcorn product of Claim 10, wherein said at least one fat is a solid form, co-crystallized blend of at least one solid fat component and at least one liquid fat component, said at least one solid fat component present in an amount of between 6 wt.% and 15 wt.% and said at least one liquid fat component present in an amount of between 65 wt.% and 78.5 wt.%, based on the total weight of said fat blend.

17. The microwave popcorn product of Claim 10, further comprising salt present in an amount of between 5 wt.% and 25 wt.%, based on the total weight of said at least one fat.

18. A method of producing a microwave popcorn product, comprising the steps of:

producing a fat blend that includes at least one solid fat component, at least one liquid fat component, and double-encapsulated flavor particles, each double- encapsulated flavor particle having an outer, oil-soluble layer; and

introducing said fat blend into a container, said container further including a quantity of unpopped popcorn kernels.

19. The method of Claim 18, wherein said producing step further comprises: heating said at least one solid fat component to an elevated temperature to melt said at least one solid fat component; and

blending said melted solid fat component, said at least one liquid fat component, and said double-encapsulated flavor particles, said outer, oil-soluble layer of each double-encapsulated flavor particle withstanding said elevated temperature.

20. The method of Claim 19, wherein said producing step further comprises co-crystallizing said melted solid fat component and said at least one liquid fat component into a solid form.