Soft shaped tortillas

Abstract

The present invention encompasses edible carriers for foods that are soft but still hold a preformed shape. Specifically encompassed are soft shaped tortilla products that can be used to hold food fillings. Exemplary shapes and sizes are provided for the products. Also encompassed are methods of making, packaging, and using the products.

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         31 . A packaged food article, comprising:
 a hermetically sealed food package having a headspace;   at least one baked soft shaped tortilla piece having a thickness ranging from about 1-5 mm disposed therein said soft shaped tortilla pieces having a water activity of 0.88 or less; and,   a headspace gas.   
     
     
         32 . The packaged food article of  claim 31  wherein the food piece ranging from about 40-60 g in weight. 
     
     
         33 . The packaged food article of  claim 32  wherein the food piece is fabricated from a cooked farinaceous tortilla dough having a finished moisture content of 25% or less. 
     
     
         34 . The packaged food article of  claim 33  wherein the dough additionally comprises:
 about 1%-10% sugar;   about 4%-15% humectant;   about 1%-15% fat;   about 1%-5% salt;   about 1%-3% of a chemical leavening system including at least one baking acid and soda.   
     
     
         35 . The packaged food article of  claim 34  wherein the dough comprises at least 51% wheat flour. 
     
     
         36 . The packaged food article of  claim 35  wherein the sealed food package is fabricated at least in part from a flexible packaging film. 
     
     
         37 . The packaged food article of  claim 36  wherein the food package has an oxygen permeability of less than 2.5 ccO 2 /cm 2 /day and wherein the headspace gas has an oxygen level of less than 4%. 
     
     
         38 . The packaged food article of claim wherein the headspace gas includes N 2  and CO 2 . 
     
     
         39 . The packaged food article of  claim 38  comprising a plurality of soft shaped tortilla pieces each of a nestable configuration arranged in nested stacked relationship to form at least one stack. 
     
     
         40 . The packaged food article of  claim 33  wherein the stack is mounted within a supplemental support carrier. 
     
     
         41 . The packaged food article of  claim 40  wherein the pieces are arranged in at least two stacks. 
     
     
         42 . The packaged food article of  claim 31  having a shelf life of at least six months at room temperature storage and wherein the piece has a water activity ranging less than about 0.88. 
     
     
         43 . The packaged food article of  claim 42  wherein the headspace has an oxygen level of less than 1%. 
     
     
         44 . The packaged food article of  claim 43  wherein the shaped tortillas are in the form of a boat. 
     
     
         45 . A meal kit for use in making a Mexican soft shaped tortilla, comprising:
 an outer package;   a first soft shaped tortilla base pieces package food article disposed within the outer package including:
 a hermetically sealed food package having a headspace; 
 a quantity of baked soft shaped tortilla pieces disposed therein said soft shaped tortilla pieces fabricated from a farinaceous dough having a water activity of 0.88 or less; and, 
 a headspace gas having an oxygen level of less than 4%; and, 
   a second packaged food article disposed within the outer package that is either a pouch of dry seasoning mixture or a pouch of a wet sauce.   
     
     
         46 . The meal kit of  claim 45  wherein the seasoning mix includes seasoning for flavoring meat. 
     
     
         47 . The meal kit of  claim 46  wherein the outer package is a carton wherein the carton includes a front major panel and a rear major panel. 
     
     
         48 . The meal kit of  claim 47  additionally including an instructions legend for preparing Mexican tortilla using the meal kit. 
     
     
         49 . The meal kit of  claim 48  wherein the instruction legend is on rear major panel of the carton. 
     
     
         50 . The meal kit of  claim 49  wherein the second packaged food article is a pouch of dry seasoning mixture for meat. 
     
     
         51 . The packaged food article of  claim 50  wherein the first food package article has an oxygen permeability of less than 2.5 cc O 2 /cm 2 /day and a headspace oxygen level of less than 2%. 
     
     
         52 . A method of preparing a baked soft shaped tortilla piece packaged food article, comprising the steps of:
 A. providing a quantities of a chemically leavened gluten plastic dough;   B. forming the quantities into shaped heat set three dimensional pieces having a thickness of about 1-5 mm;   C. baking the shaped heat set pieces to form finished soft shaped tortilla piece having a moisture content of about 25% or less and having a water activity value of about 0.88 or less; and,   D. packaging a number of finished soft shaped tortilla piece within a modified atmosphere package to form soft shaped tortilla piece packaged food article having a shelf life of at least six months at room temperature storage.   
     
     
         53 . The method of  claim 52  wherein the dough is a worked farinaceous dough, comprising:
 about 55 to 80% (dry weight basis) of the dough as flour and wherein at least a majority of the flour is wheat flour;   about 1%-10% sugar;   about 4%-15% humectant;   about 1%-3% of a chemical leavening system including at least one baking acid and soda;   about 10%15% fat;   about 1%-5% salt; and,   about 30%-35% moisture.   
     
     
         53 . The method of  claim 52  wherein the dough is a rested farinaceous dough. 
     
     
         54 . The method of  claim 53  wherein each quantity of dough in step
 A ranges from about 40-60 g and wherein the dough has a Brabender value ranging from about 500 to 1000 BU.   
     
     
         55 . The method of  claim 54  wherein the forming step is practiced in a mold heated to about 190° C. to 205° C. 
     
     
         56 . The method of  claim 55  wherein forming step is practiced to form a par-baked intermediate food item and the baking step is practiced in a belt oven.