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.

We claim: 
     
         1 . 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 piece having a water activity of 0.88 or less, said soft shaped tortilla piece being flexible and pliable; and,   a headspace gas, wherein the soft shaped semi-rigid tortilla has a packaged shelf life of at least 6 months at room temperature storage during which the soft shaped semi-rigid tortilla remains flexible and pliable.   
     
     
         2 . The packaged food article of  claim 1  wherein the soft shaped tortilla piece has a 3-dimensional shape in the form of a cup, bowl, U- or square bottomed-shaped taco shell, boat or canoe, pita, flower, pie, tube, envelope, pod, bun, or cone. 
     
     
         3 . The packaged food article of  claim 2  wherein the soft shaped tortilla piece is fabricated from a cooked farinaceous tortilla dough having a finished moisture content of 25% or less. 
     
     
         4 . The packaged food article of  claim 3  wherein the cooked farinaceous tortilla dough additionally comprises:
 about 55 to 80% by dry weight flour; 
 about 1%-10% sugar; 
 about 4%-15% humectant; 
 about 1%-15% fat; 
 about 1%-5% salt; and 
 about 1%-3% of a chemical leavening system including at least one baking acid and soda. 
 
     
     
         5 . The packaged food article of  claim 4  wherein the dough comprises at least 51% wheat flour. 
     
     
         6 . The packaged food article of  claim 5  wherein the sealed food package is fabricated at least in part from a flexible packaging film. 
     
     
         7 . The packaged food article of  claim 6  wherein the food package has an oxygen permeability of less than 2.5 cc O 2 /cm 2 /day and wherein the headspace gas has an oxygen level of less than 4%. 
     
     
         8 . The packaged food article of  claim 7  wherein the oxygen level of the headspace gas is less than 1%. 
     
     
         9 . The packaged food article of  claim 6  wherein the headspace gas includes N 2  and CO 2 . 
     
     
         10 . The packaged food article of  claim 1  wherein the at least one baked soft shaped tortilla piece comprises multiple tortilla pieces arranged nested in a stacked relationship within the hermetically sealed food package. 
     
     
         11 . The packaged food article of  claim 10 , further comprising a supplemental support carrier in which the multiple tortilla pieces are nested. 
     
     
         12 . The packaged food article of  claim 11 , wherein the multiple tortilla pieces are arranged in at least two stacks within the hermetically sealed food package. 
     
     
         13 . The packaged food article of  claim 1  wherein the tortilla piece is in the form of a boat. 
     
     
         14 . The packaged food article of  claim 1  further comprising, in combination, a pouch of dry seasoning mixture for meat or a wet sauce, the hermetically sealed food package and the pouch being contained in a common outer package to establish a meal kit. 
     
     
         15 . A packaged food article comprising:
 a hermetically sealed package containing a soft shaped semi-rigid tortilla which is set into a preformed 3-dimensional shape adapted to hold edible fillings, wherein the shape is other than flat and is selected from a cup, bowl, U- or square bottomed-shaped taco shell, boat or canoe, pita, flower, pie, tube, envelope, pod, bun and cone, said soft shaped tortilla being both pliable and sufficiently rigid to maintain its shape at room temperature, wherein the soft shaped semi-rigid tortilla is baked, has a moisture content of between 23% and 28%, a thickness ranging from 1 to 5 mm, a fat content of from 1 to 15%, and a water activity of 0.88 or less; and   a headspace gas within the hermetically sealed package having an oxygen level of 4% or less, wherein the packaged food article has a shelf life of at least 6 months at room temperature storage with the soft shaped semi-rigid tortilla remaining flexible and pliable within the hermetically sealed food package.   
     
     
         16 . The packaged food article of  claim 15 , wherein the soft shaped semi-rigid tortilla comprises:
 1%-10% sugar;   4%-15% humectant;   1%-15% fat;   1%-5% salt;   1%-3% of a chemical leavening system including at least one of baking acid and soda; and   at least 51% flour.   
     
     
         17 . The packaged food article of  claim 15 , wherein the food package has an oxygen permeability of less than 2.5 cc 0 2 /cm 2 /day. 
     
     
         18 . The packaged food article of  claim 17 , wherein the headspace gas includes N 2  and CO 2 .