Vacuum packaged food products and methods of making same

Abstract

A packaged food article, comprising a package maintaining at least a partial vacuum and having at least a portion being flexible; and at least one food piece disposed therein in the form of a shaped solid composite mass comprising an aggregate base having a quantity of food particles, wherein at least a portion of the food piece is in conforming contact with the flexible package portion and wherein the food piece has a water activity of 0.45 or less is disclosed. In one embodiment the packaged food article further comprises binder. In most embodiments, the binder comprises 25% or less, by weight, of the product, resulting in a product that is less sweet than other grain-based handheld food products, yet retains a chewy texture. In another embodiment, highly oxygen sensitive ingredients are used as a food ingredient. The resulting product has a very long shelf life, maintaining its full color, texture and flavor for at least 3 months, up to about 12 months. Additionally, most of the frangible ingredients remain whole and there is minimal, if any, waste during manufacturing as no trimming is required.

What is claimed is:  
     
         1 . A packaged food article, comprising: 
 a package maintaining at least a partial vacuum, wherein at least a portion of the package is flexible; and    at least one food piece disposed therein in the form of a shaped solid composite mass comprising an aggregate base having a quantity of food particles, wherein at least a portion of the food piece is in conforming contact with the flexible package portion and wherein the food piece has a water activity of 0.45 or less.    
     
     
         2 . The packaged food article of  claim 1  further comprising a binder.  
     
     
         3 . The packaged food article of  claim 2  wherein the binder comprises less than 25%, by weight, of the package.  
     
     
         4  The packaged food article of  claim 2  wherein the binder comprises less than 10%, by weight, of the package.  
     
     
         5 . The packaged food article of  claim 3  wherein the food piece has a water activity ranging from about 0.15 to about 0.45.  
     
     
         6 . The packaged food article of  claim 3  wherein the binder is a sugar-protein binder.  
     
     
         7 . The package of  claim 2  having an internal pressure of less than about 150 millibars.  
     
     
         8 . The package of  claim 2  having a crush resistance of up to about 90 kPa.  
     
     
         9 . The package of  claim 2  containing less than 1 ppm of hexanal for at least 3 months.  
     
     
         10  The package of  claim 1  wherein the quantity of food particles includes a grain-based frangible food ingredient comprising a plurality of frangible pieces and the base further comprises a second dry ingredient.  
     
     
         11 . The packaged food article of  claim 10  wherein the plurality of frangible pieces are RTE cereal pieces.  
     
     
         12 . The packaged food article of  claim 10  wherein the plurality of frangible pieces are selected from the group consisting of chips, pretzels, crackers, and mixtures thereof.  
     
     
         13 . The packaged food article of  claim 10  wherein 90% or more of the plurality of frangible pieces are unbroken.  
     
     
         14 . The packaged food article of  claim 10  wherein at least a portion of the second dry ingredient includes a highly oxygen sensitive ingredient.  
     
     
         15 . The packaged food article of  claim 14  wherein the highly oxygen sensitive ingredient is fruit or dried fruit.  
     
     
         16 . The packaged food article of  claim 15  wherein the fruit and dried fruit are selected from the group consisting of cranberries, raisins, prunes, strawberries, raspberries, blueberries, cherries, pineapple, mangoes, apricots, bananas, apples, kiwi, peaches, tangerines, oranges and mixtures thereof.  
     
     
         17 . The packaged food article of  claim 15  wherein the dried fruit is freeze dried fruit.  
     
     
         18 . The packaged food article of  claim 2  wherein the package is made from a film having an oxygen barrier and a moisture barrier.  
     
     
         19 . The packaged food article of  claim 18  wherein the film is laminated.  
     
     
         20 . The packaged food article of  claim 19  wherein the package is puncture resistant.  
     
     
         21 . The packaged food article of  claim 18  wherein the package is translucent, opaque or clear.  
     
     
         22 . The packaged food article of  claim 2  wherein the composite mass has no cut surfaces.  
     
     
         23 . The packaged food article of  claim 18  wherein the food piece is fortified with vitamins or minerals.  
     
     
         24 . The packaged food article of  claim 23  wherein one of the minerals is calcium.  
     
     
         25 . The packaged food article of  claim 24  wherein the calcium is provided by calcium ingredients having a particle size of less than about 20 microns.  
     
     
         26 . The packaged food article of  claim 25  wherein the calcium is comprised of particles having a particle size of less than about five (5) microns.  
     
     
         27 . The packaged food article of  claim 2  wherein the food piece includes about 1% to about 40% by weight of a second dry food ingredient selected from the group consisting of dried fruit pieces, nuts, nut pieces, marshmallows, marshmallow bits, dried marshmallows, candies, candy pieces, cookies, cookie pieces, chocolates and chocolate products, including white and milk chocolates, peanut butter chips and butterscotch chips, and raisins and mixtures thereof.  
     
     
         28 . The packaged food article of  claim 2  wherein the composite mass has less than about 0.5%, by weight, of one or more humectants.  
     
     
         29 . The packaged food article of  claim 28  wherein the humectants include polyhydric alcohol.  
     
     
         30 . The packaged food article of  claim 29  wherein the polyhydric alcohol is glycerol or sorbitol.  
     
     
         31 . The packaged food article of  claim 2  wherein the composite mass is substantially free of humectants.  
     
     
         32 . The packaged food article of  claim 2  wherein the composite mass is cured.  
     
     
         33 . The packaged food article of  claim 32  wherein the composite mass has a water activity of between about 0.2 to 0.5.  
     
     
         34 . The packaged food article of  claim 32  wherein the package is an active package that forms the composite mass into a final shape.  
     
     
         35 . The packaged food article of  claim 34  wherein the final shape is a substantially rectangular shape.  
     
     
         36 . The packaged food article of  claim 34  wherein the final shape is a substantially log shape or circular shape.  
     
     
         37 . The packaged food article of  claim 34  wherein the final shape is a complex shape.  
     
     
         38 . The packaged food article of  claim 37  wherein the complex shape is selected from a group consisting of regular geometric shapes, patterned irregular shapes and unpatterned irregular shapes.  
     
     
         39 . The packaged food article of  claim 2  wherein the composite mass is uncured.  
     
     
         40 . The packaged food article of  claim 39  wherein the temperature of the composite mass is above a glass transition temperature of the binder.  
     
     
         41 . A food product comprising: 
 a base having RTE cereal pieces, wherein most of the RTE cereal pieces are whole cereal pieces;    a binder adapted to hold the base together to form a workable composite mass, wherein the binder comprises less than 25%, by weight, of the product, and the workable composite mass is vacuum packaged in a package.    
     
     
         42 . The food product of  claim 41  wherein at least 90% of the RTE cereal pieces are whole cereal pieces.  
     
     
         43 . The food product of  claim 41  wherein at least 99% of the RTE cereal pieces are whole cereal pieces.  
     
     
         44 . The food product of  claim 41  wherein the RTE cereal pieces are selected from the group consisting of o-rings, flakes, shreds, biscuits, rings, spheres, squares, rounds, triangles, convex-shapes, hexagonals, tubes, bugles, oblongs, pillows and mixtures thereof.  
     
     
         45 . The food product of  claim 41  wherein the product has no cut surfaces.  
     
     
         46 . The food product of  claim 41  further comprising fruit or dried fruit.  
     
     
         47 . The food product of  claim 46  wherein the dried fruit is freeze-dried.  
     
     
         48 . The food product of  claim 46  wherein the fruit or dried fruit retains a fresh smell for at least 3 months.  
     
     
         49 . The food product of  claim 41  wherein release additives are included in the food product.  
     
     
         50 . The food product of  claim 49  wherein the release additives are selected from the group consisting of cheese, peanut butter and meat paste.  
     
     
         51 . The food product of  claim 41  wherein the food product is a savory seasoned snack.  
     
     
         52 . The food product of  claim 41  wherein the food product further comprises a stick embedded in the food product for holding the food product.  
     
     
         53 . The food product of  claim 41  further comprising a coating.  
     
     
         54 . The food product of  claim 41  further comprising a filling.  
     
     
         55 . The food product of  claim 41  wherein the binder is swirled together with the RTE cereal pieces.  
     
     
         56 . The food product of  claim 41  wherein the food product contains fluid milk or powdered milk.  
     
     
         57 . The food product of  claim 41  wherein the food product is shelf stable for at least 3 months.  
     
     
         58 . A method of forming a vacuum packaged food product comprising: 
 preparing a workable composite mass containing a grain-based food ingredient and a low water activity binder;    placing a quantity of the workable composite mass into a flexible packaging material;    applying a vacuum to the flexible packaging material;    sealing the flexible packaging material to form a flexible sealed package; and    allowing the workable composite mass to cure within the flexible sealed package to form a vacuum packaged food product.    
     
     
         59 . The method of  claim 58  wherein the composite mass cures within about 4 minutes to 48 hours.  
     
     
         60 . The method of  claim 58  wherein the grain-based food ingredient is a frangible ingredient.  
     
     
         61 . The method of  claim 58  wherein the composite mass is subdivided prior to being placed into the package.  
     
     
         62 . The method of  claim 61  wherein the composite mass is subdivided with a wire cutter.  
     
     
         63 . The method of  claim 61  wherein a vacuum of 50 millibar or less is applied to the package.  
     
     
         64 . The method of  claim 58  wherein the composite mass comprises less than 25% binder, by weight.  
     
     
         65 . The method of  claim 64  wherein the food product contains one or more highly oxygen sensitive ingredients.  
     
     
         66 . The method of  claim 65  wherein the one or more highly oxygen sensitive ingredients is fruit or dried fruit.