TITLE: FOLDABLE ROOT VEGETABLE FOOD SHEET
FIELD
[0001] This application discloses a foldable root vegetable food sheet.
BACKGROUND
[0002] Food sheets have many uses. For example, wraps are typically
disc-shaped and folded around fillings, such as sliced vegetables, scrambled
egg or meat, to provide a convenient hand-held meal. A good wrap must be
foldable so that it can contain the filling to prevent it from dripping. Tortilla
wraps are a popular type of wrap, typically made from unleavened flatbread.
They are frequently used to make dishes such tacos, burritos and enchiladas,
with or without meat. Food sheets may also be used flat, as a base for
toppings, such for a pizza crust or a noodle such as a lasagne noodle. In
these uses, the food sheet may be rigid or foldable. Food sheets may also be
torn or cut into smaller pieces and dipped. These small pieces may be
foldable when dipped, similar to pieces of pita bread, or they may be baked or
fried until they are rigid chips, such as nacho chips.
[0003] Food sheets can be made out of many different ingredients, such
as wheat, corn, rice or potato. Wheat is one of the most commonly used
grains for breads, tortillas and flat noodles. Wheat flour contains wheat starch
and proteins which hold other ingredients together and add structure to
sheets. Wheat starch swells and gelatinizes when it is hydrated and heated.
Proteins such as gluten are typically fibrous, which adds texture and structure
to food (Y.H. Hui, Ed. Handbook of Food Science (2005, Marcel Dekker Inc)).
[0004] A concern with wheat is that many people have wheat intolerance,
making wheat difficult to digest, and potentially causing effects such as
nausea, diarrhea and vomiting. In some cases wheat is allergenic, causing
an immune response to wheat proteins that can lead to symptoms such as
upset stomach, vomiting, asthma and potentially anaphylaxis. Celiac disease
is one example of an autoimmune disorder triggered by components of wheat
flour. There is a need to make foldable food sheets (wraps) with nonallergenic
alternatives to wheat flour.
[0005] There is also a growing interest among some consumers in foods
made from vegetables that have undergone less processing. Grains used in
foldable sheets, such as corn, rice, wheat and potatoes are typically
processed into powdery, ground flours. Other times, the vegetable is
processed to mash or flakes, and may be dehydrated or extruded. One
example of a less processed food is a whole grain flour. However, there
remains an interest in using vegetable products made from more intact
vegetable components. A problem with using larger vegetable components is
that they can typically only be formed into relatively thick foods that are not
suitable for making wraps, chips or as a continuous base for supporting other
toppings on top. An omelet is one example of a carrier for large vegetable
components, but it is too soft to be hand-held and it is also allergenic to those
with egg allergies. Other carriers tend to be relatively rigid and thick, such as
potato cakes and latkes, and unsuitable for use as a wrap or hand-held food
product. There remains a need for a foldable food sheet that can replace
food sheets made from flour.
SUMMARY OF THE DISCLOSURE
[0006] The inventor has developed a food sheet made from vegetable
pieces that has the strength and flexibility to be used as a sheet in place of
conventional wraps and other breads, noodles and chips.
[0007] The food sheet typically includes a flexible layer that includes
vegetable pieces and a gelling composition (typically the gelling composition
includes a plurality of gelling agents, such as a starch composition including a
plurality of types of starches). The gelling composition forms a matrix in
conjunction with the vegetable pieces adhering the pieces in the form of a
sheet. The matrix is typically solid in order to hold the vegetable pieces
together, for example, when the food sheet is bent or folded (the solid matrix
is typically resilient to touch). Typically a sheet has shred uniformly disposed
therein. In one embodiment of the invention, the gelling composition is a
starch composition. The sheet is typically solid and resilient.
[0008] The vegetable pieces of the food sheet are optionally shreds, dices
or slices (ie. shredded vegetables or sliced vegetables), with and/or without
peel attached. In an embodiment, the vegetable shreds, dices or slices are
blanched. Suitable dimensions of shreds and slices will be readily apparent.
For example for potato and other root vegetables, suitable shreds are
optionally: 1 to 10 mm thick, 1 to 10 mm wide and 12 to 50 mm long. In
another embodiment, the shreds are 1 to 3 mm thick, 1 to 6 mm wide and 2 to
50 mm long.
[0009] In another embodiment, the vegetable pieces of the food sheet are
from a root vegetable. In another embodiment, the vegetable pieces are
potato. In a further embodiment, the vegetable pieces are sweet potato, yam,
yucca, cassava, onion, shallot, carrot or taro.
[00010] In a further embodiment of the invention, the flexible layer
comprises interlaced vegetable shreds. The food sheet is typically formed in
a continuous uniform layer, which helps it maintain shape and resist moisture
damage. It is also typically resiliently foldable such that it can be bent without
the continuous layer of shredded vegetable pieces breaking or tearing. The
food sheet can optionally be folded at least: 45, 90, 120, 150, 180, 200, 250,
300 or 360 degrees. In another embodiment of the invention, the food sheet
can be folded into a tube, such as a cylinder shape, or folded into a pair of
opposed semicircular surfaces.
[0001 1] The food sheet is typically 1 to 10 mm thick, 10 to 300 mm wide
and 20 to 200 mm long. In a further embodiment, the layer of the food sheet
is 1 to 5 mm in thickness. The layer is optionally 3 to 4 mm in thickness. In
yet another embodiment, the layer is circular and the ratio of the diameter to
height of the sheet is optionally: 1-2:100, 1-2:250 or 1-2:500.
[00012] In a further embodiment of the invention, the food sheet optionally
contains up to 5%, and optionally 5-10%, 5-25% or 5-50% of a secondary
vegetable. In a further embodiment, the secondary ingredient is a root
vegetable, optionally sweet potato, garlic, ginger or onion. Secondary
vegetables are useful to add color, flavour or texture to the sheet. They are
also useful carriers for exogenous flavors.
[00013] In a further embodiment of the invention, the food sheet contains up
to 1%, optionally 1-2% or 1-5% by weight of a herb, seasoning or flavouring,
such as oregano, basil, fennel, cumin, mustard, whole grains, cilantro or
parsley.
[00014] In another embodiment of the invention, the food sheet contains up
to 10% fruit pieces or up to 10% fruit puree.
[00015] The starch composition of the invention optionally includes at least
one of the following starches: sago starch, waxy maize starch, maize starch,
rice starch, waxy rice starch, barley flour/starch, pea flour/starch, potato
starch, wheat starch, tapioca starch, lotus starch, sweet potato starch/flour or
starch/flour from millets, pulses or lentils. The flour/starches of the starch
composition can be native (unmodified) or modified by physical, chemical or
enzymatic methods. Optionally, the starches are instant starches or cook-up
starches.
[00016] In one embodiment, the starch composition includes a mixture of at
least two starches. In a further embodiment, the starch composition includes
sago starch and waxy maize starch. Optionally, the starch composition can
include 2 or more waxy maize starches. In yet another embodiment, the
starches of the starch composition are i) sago starch, ii) instant modified waxy
maize starch and iii) cook-up modified waxy maize starch. In a further
embodiment, the sago starch is modified sago starch.
[00017] In one embodiment of the invention, the food sheet comprises, or is
made (formed) from, the following ingredient amounts: 90 - 96% vegetable
pieces by weight, 0.05 - 3% sago starch by dry weight, 0.05 - 3% instant
modified waxy maize starch by dry weight and 0.05 - 3.5% cook-up modified
waxy maize starch by dry weight. In another embodiment, the food sheet
comprises, or is made from, 85 - 96% vegetable pieces by weight plus
second ingredients, typically so that dry starch is 10% by total weight or less
of the ingredients. Optionally the starch is 0.05 - 2.5% sago starch by dry
weight, 0.05 - 2.0% instant modified waxy maize starch by dry weight and
0.05 - 2.5% cook-up modified waxy maize starch by dry weight. In another
embodiment, the food sheet comprises, or is made from, 94 - 96% vegetable
pieces by weight, 1.7 - 2.5% sago starch by dry weight, 1.0 - 1.5% instant
waxy maize starch by dry weight and 1.7 - 2.5% cook-up waxy maize starch
by dry weight. The foregoing percentages are applicable to the raw sheet (ie.
raw ingredients) or the food sheet after cooking (i.e. cooked ingredients, with
adjustments to subtract water added to the gelling composition from the
weight percentages and adjusting for loss of water from the vegetable pieces
during cooking, such as 5-20% or more water loss). The chosen percentages
will vary depending on the properties desired in the food sheet and a skilled
person will appreciate that the percentages can be adjusted.
[00018] In a further embodiment of the invention, the food sheet is free of
gluten and/or any egg products.
[00019] The invention also relates to a wrapped food product comprising a
food wrap fully or partially wrapped around a filling. In a further embodiment
of the invention, the food sheet of the wrapped food product is fully folded
around the filling creating a food-tight seal that prevents the filling from
leaking through the body of the food sheet. The wrapped food product
contains the filling when upright, e.g. when held upright by a user.
[00020] In yet another embodiment, the invention includes a noodle, such
as a pasta-style noodle, formed from the food sheet. In a further
embodiment, the noodle is a lasagna style noodle or a cannelloni style
noodle.
[00021] In a further embodiment, the invention relates to a method of
forming a food wrap or a pasta noodle, comprising contacting vegetable
pieces with a food additive composition and gelling the food additive
composition to form a matrix around the vegetable pieces.
[00022] The invention also relates to the use of the food sheet and filling for
the preparation of a food product. The invention further relates to a method of
preparing a wrapped food product where the food sheet is fully or partially
folded around a filling. The filling of the food product or method optionally
comprises egg, burrito filling, tortilla filling, samosa filling, egg roll filling, spring
roll filling, sandwich meat, ground meat, vegetables, cheese, salad or fruit.
[00023] The invention also relates to food compositions per se (i.e. gelling
compositions or food additive compositions), not merely in combination with
vegetable pieces. In one embodiment, the food additive composition contains
sago starch and waxy maize starch. The starches can be modified or
unmodified. In a further embodiment, the food additive composition contains
i) sago starch, ii) instant modified waxy maize starch and iii) cook-up modified
waxy maize starch. In yet another embodiment of the food additive
composition, the sago starch, instant waxy maize starch and cook-up waxy
maize starch are in the ratio of :1:1 to 1.7: 1:1.7 by dry weight.
[00024] The invention further relates to the use of the food additive
composition for the preparation of a food sheet.
[00025] The invention also relates to a method of forming a food sheet,
using the following steps: (1) contacting root vegetable food pieces with the
food additive composition described above, (2) forming the root vegetable
food pieces into a raw sheet, and (3) gelling the food additive composition to
form a solid matrix around the root vegetable food pieces, thereby converting
the raw sheet to the food sheet.
[00026] In a further embodiment, the step of contacting root vegetable
shred with the food additive composition forms a dough. The forming step
can use pressure to form the dough into a raw sheet. Optionally, the forming
step is accomplished by applying 5 to 500PSI of pressure to the dough with a
press. In one embodiment, the pressure forming step is performed at ambient
temperature, optionally 16-25°C, 17-19°C or 18°C. In another embodiment,
the pressure forming step is performed below ambient temperature, optionally
4-1 8°C or 4-8°C. Alternatively, the dough may be contacted with a prescribed
heat treatment and a pressure of 5 to 500PSI.
[00027] In a further embodiment, the dough is sheeted by any other
sheeting method known in the art and cut into desired size and shape.
[00028] In another embodiment, the gelling step includes heating the raw
sheet to set the starches to bind with the food pieces to form the food sheet.
Optionally, the gelling step includes heating the raw sheet to 55-95°C,
optionally 65-90°C, 70-85°C or 80°C. In a further embodiment, the gelling
step includes heating the raw sheet until at least a portion of the vegetable
pieces turn darker, for example, golden or shades of brown, caused by
browning due to the heat.
[00029] The disclosure also shows use of the food additive (gelling)
compositions described herein and vegetable pieces for preparation of a food
sheet. The method of forming a food sheet optionally comprises:
contacting root vegetable food pieces with a food additive
composition;
forming the root vegetable food pieces into a raw sheet;
gelling the food additive composition to form a solid matrix around
the root vegetable food pieces, thereby converting the raw sheet to
the food sheet.
[00030] The step of contacting root vegetable shred with the food additive
composition typically forms a dough. The forming step typically involves
pressure forming the dough into the raw sheet, optionally by applying 5-
500PSI of pressure to the dough, such as with a press. The pressure forming
step is optionally performed at ambient temperature, for example 16-25°C,
17-19°C or 18°C or optionally at below ambient temperature, for example 4-
18°C or 4-8°C.
[00031] The gelling step typically comprises heating the raw sheet to set the
starches to bind with the food pieces to form the food sheet. Heating the raw
sheet is optionally at 200- 300°C, typically 230- 280°C. Typically, the gelling
step comprises heating the raw sheet to a core temperature of 55-95°C,
optionally 80°C and/or until at least a portion of the vegetable pieces become
darkened.
[00032] Other features and advantages of the present invention will become
apparent from the following detailed description. It should be understood,
however, that the detailed description and the specific examples while
indicating preferred embodiments of the invention are given by way of
illustration only, since various changes and modifications within the spirit and
scope of the invention will become apparent to those skilled in the art from the
detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[00033] Embodiments of the invention will be shown in relation to the
drawings in which:
Figure 1 shows (a) a top view of two potato food sheets and (b) a
close-up top view of one of the potato food sheets.
Figure 2 shows a potato food sheet folded at approximately a) 45,
b) 90, c) 150, d) 180, e) 360 degrees.
Figure 3 shows a potato food sheet formed into a tube.
DETAILED DESCRIPTION
[00034] The present application relates to a food sheet comprising a flexible
layer of vegetable pieces and a matrix formed from solidified gelling agents
that hold the pieces together (Figure 1). The food sheet is highly flexible and
strong such that it is useful as a wrap for food fillings, as a flat base for
toppings or for dipping into a sauce. The food sheet is designed to keep
potato closer to its natural state than is found in conventional, heavily
processed food sheets. The invention provides simplicity of design and an
absence of complicated food ingredients.
[00035] The inventor has developed a food sheet made from vegetable
pieces that has the strength and flexibility to be used as a sheet in place of
wraps and other breads, noodles and chips. The sheet also stays intact after
contact with water or oil from food fillings, such as liquid in sauces or fillings.
The sheet will not degrade and allow food to contact a user's hand if the sheet
is handheld. The sheet contains the food to prevent the food from dripping
out of the wrapped food product.
[00036] The term "gelling agent" refers to a semi-solid or solid, resilient
starch substance that adheres the vegetable pieces to one other. The gelling
agent may or may not need to be activated, for example, by contact with
water (heat may also be required for some gelling agents). Typically a "gelling
composition" comprising a plurality of gelling agents adheres the vegetable
pieces to one another. The gelling agent is typically a starch and the gelling
composition is typically a starch composition.
[00037] The term "starch" refers to an edible polysaccharide (natural,
processed or artificial) that adheres to root vegetable pieces, such as potato
pieces. The term "starch composition" typically includes a combination of 2 , 3
or more food starch products optionally in a carrier, such as water.
[00038] The term "matrix" generally refers to a flexible, solid substance in
which vegetable pieces are wholly or partially embedded.
[00039] The term "shred" generally refers to narrow strips cut from
vegetables. Typically, shred is in the form of uniform slices or splinters of
freshly cut vegetable material that optionally have an oval, square or crescent
shape. The individual shreds typically weigh approximately 1-2 grams and
usually have random dimensions of approximately 1-4 mm thick X 1-6 mm
wide X up to 70 mm long typically with tapering at the end of the shred. The
shreds optionally comprise peel or are free from peel. The vegetable shreds
may be used either i) raw, ii) blanched and partially cooked or iii) fully cooked.
Optionally the shreds are cooked then chilled, and used at room temperature
(20-25°C) or frozen.
[00040] The term "continuous" generally refers to an uninterrupted surface
with no liquid-permeable gaps, holes, or folds that would allow liquid to leak
through the surface.
[00041] The term "resiliently foldable" generally refers to a sheet can be
folded at least 180 degrees, optionally at least 360 degrees, without rupture.
[00042] As used herein, the term "root vegetable" generally refers to plant
tubers, such as stem tubers or root tubers used as vegetables. Root
vegetables can include, but are not limited to: potatoes, sweet potatoes,
yams, yucca, cassava, onions, shallots, carrots and taro. Therefore, the
vegetable pieces are optionally potato or other root vegetables. The sheet
can also be readily prepared free from allergens such as wheat (e.g. gluten)
and egg.
[00043] In a particularly advantageous embodiment, the food wrap is
principally made from potato simply cut in the form of a shred. Potato is a
staple food that is well tolerated and accepted in a wide distribution of cultures
and food styles as a source of nutrition. The present sheet is optionally
formed from shredded potato and gelling agents and has the ability to be
used as a food by itself or optionally folded and used as a food wrap. For
example, in an embodiment of the invention, the food sheet consists of
shredded potato and other non-glutinous gelling agents that yield a formable
sheet of potato with clearly identified shreds of potato. The process of
creating the sheet yields a flexible, foldable food wrapper that maintains the
integrity of the shredded potato from which it was created.
[00044] The food sheet typically includes a flexible layer that includes
vegetable pieces and gelling agents. The gelling agents form a matrix
interacting with and adhering the vegetable pieces in the sheet. In one
embodiment of the invention, the gelling agents are a plurality of starches.
[00045] The vegetable pieces of the food sheet are optionally shreds, dices
or slices (ie. shredded vegetables, diced vegetables or sliced vegetables).
Suitable dimensions of shreds, dices and slices will be readily apparent. The
dimensions of suitable shreds are varied depending on the desired
appearance and texture. For example for potato and other root vegetables,
suitable shreds are optionally: 1 to 4 , optionally 1 to 3 mm thick, 1 to 6 mm
wide, optionally 1 to 3 mm wide, and 2 to 70 mm long, optionally 2 to 5 mm, or
2 to 10 mm or 2 to 20 mm or 2 to 50 mm long. The length of the shred can
vary with the length of the root vegetable from which the shred is cut.
[00046] In a further embodiment of the invention, the flexible layer
comprises interlaced vegetable shreds. The food sheet is typically formed in
a continuous layer, which helps it avoid moisture leakage through the sheet
when used to contain a secondary food filling. It is also typically resilient and
bendable, optionally resiliency foldable and is readily bent without the
continuous layer breaking or tearing. The food sheet can optionally be folded
at least: 45, 90, 120, 150, 180, 200, 250, 300 or 360 or more degrees (see
Figure 1). In another embodiment of the invention, the food sheet is readily
folded into a tube (Figure 3), such as a cylinder shape, or folded into a pair of
opposed semicircular surfaces. When two opposed ends of the food sheet
meet, and are then viewed from the side, the two-dimensional shape of the
sheet optionally appears rounded, such as circular, oval, O-shaped, obround
or in an irregular shape having rounded portions. When the food sheet is
folded but the ends of the sheet do not meet, the shape optionally appears
arcuate, such as an arc, parabola, C-shape, U-shape (Figure 2(d)), J-shape,
S-shape or undulating shape. Dish or bowl shapes are also readily formed
which is useful, for example, to allow the sheet to adapt to accommodate the
shape of an underlying plate or bowl. It is also possible to fold the food sheet
to form sharper edges, so that, if two opposed ends of the food sheet meet,
the sheet optionally appears in a shape that is triangular or tetragonal, such
as a rectangle, square or an irregular shape having three or four angles.
When the food sheet is folded but the ends of the sheet do not meet, the
shape optionally appears to have at least one angle, such as an L-shape, VShape
or W-shape. Other shapes are also readily formed, such as conical
shape or pie-shape. Irregular shapes having combinations of arcuate and/or
angular portions are readily made by taking advantage of the flexibility of the
sheets described herein. The pasta sheet is optionally entirely flat or it may
be flat, with non-flat portions, such as crimped edges to help contain food or
undulating edges, similar to a lasagna-style noodle.
[00047] The food sheet is typically 1 to 3mm thick, 10 to 300 mm wide and
20 to 500 mm long. In another embodiment, the layer of the food sheet is 1 to
5 mm, optionally 2 to 4 mm or 3 to 4 mm, in thickness. Optionally, the sheet
is no thicker than the thickness of the interlaced vegetable shreds. In yet
another embodiment, the sheet is circular and typically 1 to 3 mm thick and 0
to 300 mm in diameter. The diameters that are common typically fall between
15 to 4 1 cm (6 to 16 inches). When the layer is circular, the ratio of the
diameter to height of the sheet is optionally: 1-2:100, 1-2:250 or 1-2:500.
According to one embodiment of the invention, the food sheet is a foldable
wrap that is similar in thickness, shape and use to a tortilla.
[00048] In a further embodiment of the invention, the food sheet contains up
to 5% of a secondary vegetable, typically also a root vegetable. In a further
embodiment, the secondary ingredient is optionally sweet potato, carrot,
garlic, ginger or onion. Secondary vegetables are useful to add flavour or
texture to the sheet. They can also act as carriers for exogenous flavors.
Secondary vegetables may either bind to the gelling agent (adherent
secondary vegetables) or not bind to the gelling agent (non-adherent
secondary vegetables). Adherent secondary vegetables are retained in the
matrix by the gelling composition whereas non-adherent vegetables are
retained in the matrix by the presence of the primary functional vegetable
(e.g. potato) which does bind to the gelling composition. Adherent secondary
vegetables bind well to the gelling agent, such that a sheet composed entirely
of the adhering vegetable is resilient and foldable at least 45 degrees, 90
degrees, 150 degrees, 180 degrees or 360 or more degrees without tearing of
the sheet.
[00049] In a further embodiment of the invention, the food sheet contains up
to 5% by weight of a herb, seasoning or flavouring ingredient, such as
oregano, basil, fennel, cumin, mustard, whole grains, cilantro or parsley.
[00050] In one embodiment of the invention, the gelling composition
optionally includes a starch composition that comprises a plurality of starches.
Typically, starches are combined to provide suitable adherence to root
vegetable pieces to form the sheet. In another embodiment, starch types are
blended to yield differing levels of flexibility in the food sheet.
[00051] Without wishing to be bound by theory, starch is a polysaccharide
carbohydrate consisting of a large number of glucose units joined together by
glycosidic bonds. Starch molecules normally arrange themselves in semicrystalline
granules and become soluble in water when heated. In order to
thicken (or "gelatinize") starches, heat is necessary to break down the
crystalline regions of the starch molecules in order to allow hydrogen bonding
sites to engage water. Two different types of starches produced by starch
manufacturers are "cook-up" starches and "instant" starches, which are
categorized depending on the type of further processing required by a user to
thicken a particular starch for use in food products. "Cook-up" starches
require heat to be applied to solubilize and thicken the starches. For
example, a finished food product manufacturer (eg. a company that sells to
restaurants, retail stores or directly to consumers) may buy a cook-up starch
from a starch manufacturer and the food product manufacturer then adds
water and heats the cook-up starch for use as a gelling agent in a starch
composition at the plant to make root vegetable food sheets. In "instant"
starches, the starch has typically been partially cooked and dried by a starch
manufacturer such that the starch is soluble in water without heating (e.g. cold
water or warm water with no heating requirement). For example, a starch
manufacturer may partially cook the starch and dry it for sale to a food
product manufacturer which then adds water to the instant starch for use as a
gelling agent in a starch composition for root vegetable food sheets. It will be
apparent that modified or unmodified starches are useful to make food
sheets. Modified starches have been physically, chemically or enzymatically
modified to allow the starch to function properly under conditions frequently
encountered during processing or storage, such as high heat, low pH,
freeze/thaw and cooling.
[00052] The starch composition of the invention optionally includes
synthesized starches or derivatives/fractions of starch such as amylose,
amylopectin or dextrins of various molecular weight. The sources of the
starch are optionally genetically modified or non-genetically modified
organisms that can be obtained through organic or conventional farming.
[00053] The starch composition in the food sheet optionally includes sago
starch and waxy maize starch. In a further embodiment, the starches include:
i) sago starch, ii) modified instant waxy maize starch and iii) modified cook-up
waxy maize starch. Examples of useful commercially available starches are
Advanta Gel®S, a modified sago starch manufactured by National Starch®,
UltraSperse ® M, a modified instant waxy maize starch manufactured by
National Starch®, and Col Flo®67, a modified cook-up waxy maize starch
manufactured by National Starch®.
[00054] Other useful starches are sago starch, waxy maize starch, maize
starch, rice starch, waxy rice starch, barley flour/starch, pea flour/starch,
potato starch, wheat starch, tapioca starch, lotus starch, sweet potato
starch/flour or starch/flour from millets, pulses and lentils. Further suitable
starches include unmodified sago starches such as Refined Sago Starch -
NX 1806 from Nex-US Ingredients, modified waxy maize starches such as
Polar-Tex® from Cargill Inc., CONSISTA ®, Clearam®, Instant TenderGel ®419,
Instant TenderGel ® 434, Instant TenderGel ® 479 from Tate & Lisle, and
Pregeflo® from Roquette, modified corn starches such as Hi-Form® from
Cargill Inc., modified tapioca starches such as Binasol™ 90C and 95 from
Tate & Lisle, and waxy potato starches such as Eliane™ from AVEBE.
[00055] Additional useful starches include starches that are viscoelastic in
nature (optionally highly viscoelastic), resistant to shear, able to rapidly
hydrate, resistant to retro-degradation and/or freeze-thaw stable. Useful
cook-up starches include cook-up starches that are able to rapidly hydrate
and have high viscoelastic properties. Optionally, the cook-up starches are
able to hydrate or solubilize at a temperature of at least 40°C, optionally 55-
95°C or 80°C. Useful instant starches optionally include instant starches that
are able to hydrate or solubilize at a temperature of 4-25°C.
[00056] The invention also relates to the food additive compositions per se
(i.e. gelling compositions), not merely in combination with vegetable pieces.
In one embodiment of the invention, the food additive composition contains a
plurality of starches such as sago starch and waxy maize starch. In a further
embodiment, the starches of the food additive composition include: i) sago
starch, ii) modified instant waxy maize starch and iii) modified cook-up waxy
maize starch.
[00057] The gelling or starch composition or food additive composition
optionally contains one or more gums such as agar, alginate, arabic,
carrageenan, carboxy methyl cellulose (CMC), gelatine, konjac flour, locust
bean gum (LBG), methyl cellulose and hydroxypropyl methyl cellulose
(MC/HPMC), microcrystalline cellulose (MCC), pectin and xanthan.
[00058] The invention also relates to a wrapped food product comprising a
food wrap fully or partially wrapped around a filling. In a further embodiment
of the invention, the food sheet of the wrapped food product is fully folded
around the filling creating a food-tight seal by a user that prevents the filling
from leaking through the sheet. The wrapped food product contains the filling
when held upright. The filling of the food product or method optionally
comprises egg, burrito filling, tortilla filling, samosa filling, egg roll filling, spring
roll filling, sandwich meat, vegetables or cheese. The food wrap of the
invention is useful as a breakfast meal where the wrap is formed around a
food, such as scrambled eggs and bacon and then frozen for reconstitution in
an appropriate oven or grill. The invention also relates to a method of
preparing a wrapped food product comprising fully or partially folding the food
wrap around a filling, wherein the food wrap contains the filling when held
upright.
[00059] In yet another embodiment, the invention includes a noodle, such
as a pasta style noodle, formed from the food sheet. In a further embodiment,
the noodle is a lasagna noodle or a cannelloni noodle. In a further
embodiment, the invention relates to a method of forming a food wrap or the
food wrap in the form of a pasta noodle, comprising contacting root vegetable
food pieces with the food additive composition and gelling the food additive
composition to form a matrix around the food pieces.
[00060] A primary and compelling use for is to facilitate the functional
inclusion of a potato product in the style of other bread wraps/tortillas for use
in hand held wrapped food applications. The unique properties of the
invention allow for use in "hand held" food wrap products such as a burrito or
breakfast wrap where the filling would optionally contain eggs in one of
several forms according to desired tastes. The filling of the potato wrap
optionally includes, but is not limited to, egg, burrito filling, tortilla filling,
samosa filling, egg roll filling, spring roll filling, sandwich meat, sliced cooked
meats including beef, pork and chicken, vegetables or cheese.
EXAMPLES
[00061] Embodiments of the food sheet and methods of preparation will be
illustrated in a non-limiting way by reference to the examples below.
Example 1. Process for making potato food sheet.
[00062] An example of a process is described, without limiting the scope of
the process, since variations will be readily apparent. The process described
below is also useful for other root vegetables, with adaptations as will be
readily apparent to those of skill in the art.
[00063] 1. Shreds of potato are prepared from sound, whole potatoes that
have been washed, steam peeled, sorted for defects and sorted for suitability
of further size reduction. The potatoes are optionally blanched to a
temperature of 60° to 80°C, then cooled for a period of time to facilitate the
development of a suitable texture for shredding and thereafter shredded by a
mechanical shredder. Shreds are optionally uniform slices / splinters of
freshly cut potato material that have a consistent shape, weigh approximately
1 to 2 grams and have random dimension consistent with an oval or crescent
shape cut of potato shred, for example, dimension of approximately 3 mm
thick X 3 to 6 mm wide X 10 to 70 mm long with a tapering at the end of the
shred. The root vegetable shreds are optionally used fresh, chilled or frozen.
[00064] 2 . Shreds of potato are optionally mixed with three or more food
starch products each of which imparts a unique textural effect to the mixture
and to the outcome. The unique formulation of the shreds and food starch
ingredients are mixed to a dough of uniform viscosity that is similar to loose
bread dough or like a loose cookie dough with inclusions such as a macaroon
dough.
[00065] 3. The specific quantity of shred mixture desired to yield the
finished food piece is weighed and portioned into a ball, then the ball of shred
mixture is optionally pressure formed without heat to form a raw sheet. The
pressure forming is optionally done by contacting the shred mixture with a
pressure of 5 to 500 PSI. The pressure forming step is optionally conducted
at ambient temperature, for example 16-25°C, 17-19°C or 18°C. In another
embodiment, the pressure forming step is optionally conducted at a
temperature below ambient temperature, for example 4-1 8°C, preferably 4-
8°C. Alternatively depending on the nature of the potato shred substrate, the
raw material is contacted with a prescribed heat treatment and a pressure of 5
to 500 PSI. The shred mixture may be pressure formed between two pieces
of parchment paper. In this embodiment, the raw sheet is released from the
paper prior to cooking. The formed piece (raw sheet) is cooked gently to a
temperature of approximately 80°C. This step surface cooks and set the
starch so that it binds with the shredded potato to form the continuous
seamless food sheet matrix, thereby forming the foldable food sheet, which
typically turns light brown on portions of its surface. The cooking is optionally
done after forming using a surface-heating device such as a belt cooker
consisting of two independent non-stick (e.g. Teflon™) belts that convey the
formed shred dough piece between two heated plates, to ensure the proper
texture of the set under a slight compression. Alternately the cooking may be
done using a continuous flat sheet cooking device such as a serpentine oven
commonly used for the cooking of tortilla shells, or a stainless steel
continuous belt cooker, typically with a 180° flip part-way (eg. halfway)
through the cooking process. Alternately the cooking device may be a
continuous fry pan in the style of a "Brat Pan."
[00066] 4 . The resulting formed heated wrap may be frozen for storage,
optionally between two pieces of non-stick parchment paper. The frozen
shred wrap piece is typically brittle because of the unique texture of the
shredded potato substrate, and protective packaging such as cardboard helps
to maintain integrity. The frozen piece is readily reheated, for example, on a
flat top grill common to any foodservice kitchen, or a fry pan, then used for the
above-mentioned food wrapping uses. It is alternatively reheated in a
microwave oven, typically until the surface of the sheet is warm or hot to
touch. The resulting warmed food-ready shredded wrap becomes foldable
and flexible for a variety of culinary uses and food wrapping applications.
Example 2. Formula - Food sheet
[00067] The food wrap is optionally created by mixing frozen shredded
potato that is allowed to thaw in a mixing device. To the shredded potato,
optionally three or more non-glutinous starches are added, typically in
succession, to bind and create the unique shred wrap dough. The starches
are optionally pre-mixed in a composition and then added to the shred. The
starches are readily prepared for use as known in the art, for example, the Col
Flo® 67 cook-up starch is typically heated before addition to the shred. The
proportions of this Example are optionally as follows:
Ingredient Quantity Broad Useful Range Typical Range
Shredded Potato 85-96% 94 -96 %
UltraSperse ® M 0.05 - 2.00% 1.0-1 .5%;
optionally 1.26%
Advanta Gel® 0.05 - 2.5% 1.7 -2.5%
Col Flo® 67 0.05 - 2.5% 1.7 - 2.5%
A broad range is specified to show the flexibility of the process for making
food sheets. Other ranges are also useful depending on the desired
properties of the food sheet.
Example 3. Specifications of Shredded Potato
[00068] Shreds of potato are prepared from sound, whole potatoes that
have been washed, steam peeled, sorted for defects, pre-heated to a
temperature of 60° to 80°C and then shredded and blanched at 60° to 85°C
for 10 to 15 minutes. Alternatively, shreds of potato are prepared from sound
whole potatoes that have been washed, steam peeled, sorted for defects, pre
heated to a temperature of 60° to 85°C, blanched for 10 to 20 minutes at 60 to
85°C, cooled at a temperature of 4° to 6°C for 30 to 50 minutes to create a
potato texture that will facilitate shredding, then shredded. Shreds are
optionally uniform slices / splinters of freshly cut potato material that have a
consistent shape, weigh approximately 1 to 2 grams and have random
dimension consistent with an oval or crescent shape cut of potato shred,
dimension of approximately 2 to 4 mm thick X 3 to 6 mm wide X 2 to 70 mm
long - the length dependent on the length of the root vegetable shredded -
with a tapering at the end of the shred. The root vegetable shreds are
optionally used chilled or frozen and used later. Other shreds are also useful
depending on the desired properties of the food sheet.
Example 4. Preparation of a potato food sheet
[00069] Russet Burbank potatoes were peeled, blanched to a temperature
of 74°C for 30 minutes, and then cooled for 45 minutes at a temperature of
5°C and then shredded. Potato shreds were then mixed with three starches
and water in a manner that produced a dough and imparted minimal damage
to the potato shreds. The three non-glutinous starches were added in
succession to bind and create the unique shred wrap dough. Shreds are
visibly apparent in the dough. The proportions of the shred wrap dough
ingredients were as follows:
Ingredient Quantity
Shredded Potato 900 g 94.54 %
UltraSperse ® M 12 g 1.26%
Advanta Gel® 20 g 2.10%
Col Flo® 67 20_g 2.10%
Total 952 g 100%
[00070] This Example uses two modified waxy maize starches and a sago
starch. Other starch combinations are useful. UltraSperse ® M is a cold water
swelling (instant) starch, while Col Flo® 67 was cooked. About 50g of shred
dough mixture was weighed and formed into a ball. The ball of shred mixture
was pressure formed without heat using a tortilla press to achieve a disc
shape, like a tortilla. Thickness of the raw sheet was about 2mm. The
formed piece was cooked on a Garland commercial griddle set at 185°C. The
disc was cooked to a temperature believed to be approximately 80°C to
surface cook and set the starches that bind with the shredded potato to form
the continuous seamless food sheet matrix. The food sheet was light brown
on a portion of its surface. The individual food sheets were then frozen using
a forced air blast freezer, and packaged between layers of silicone baking
paper, and stored at -18°C. A food sheet prepared according to this Example
is shown in Figure 2(a) to (d). Other potatoes, vegetables and parameters
are also useful depending on the desired properties of the food sheet.
[00071] It is to be understood that the invention is not limited in its
application to the details set forth in the preceding description or exemplified
by the Examples. The invention is capable of other embodiments or of being
practiced or carried out in various ways. Also, it is to be understood that the
phraseology and terminology employed herein is for the purpose of
description and should not be regarded as limiting.

WE CLAIM:
1. A food sheet comprising a flexible layer of vegetable pieces and a
gelling composition, the gelling composition forming a matrix
adhering the pieces in the sheet.
2 . The food sheet of claim 1, wherein the gelling composition
comprises a starch composition.
3. The food sheet of claim 1, wherein the pieces comprise shreds,
dices or slices with and without peel attached.
4 . The food sheet of claim 1, wherein the layer comprises a
continuous layer.
5. The food sheet of claim 1, wherein the flexible layer is resiliently
foldable.
6 . The food sheet of claim 1, folded at least 180 degrees or at least
360 degrees.
7 . The food sheet of claim 1, folded into a tube or a pair of opposed
semicircular surfaces.
8. The food sheet of claim 1, wherein the layer comprises interlaced
shreds.
9. The food sheet of claim 3, wherein the pieces, shreds, dices or
slices comprise root vegetable pieces, shreds, dices or slices,
optionally with peel attached.
10. The food sheet of claim 1, wherein the vegetable is a root
vegetable.
11. The food sheet of claim 10, wherein the root vegetable comprises
potato.
12. The food sheet of claim 1, wherein the potato comprises potato
shreds, optionally with peel attached.
13. The food sheet of claim 10, wherein the root vegetable comprises
sweet potatoes, yams, yucca, cassava, onions, shallots, carrots or
taro.
14. The food sheet of claim 3, wherein the pieces, shreds, dices or
slices comprise blanched pieces, shreds, dices or slices.
5. The food sheet of claim , wherein the pieces are 1 to 3 mm thick, 1
to 6 mm wide and 2 to 50 mm long.
16. The food sheet of claim 1, wherein the layer is 1 to 5 mm in
thickness.
17. The food sheet of claim 1, wherein the layer is 3 to 4 mm in
thickness.
18. The food sheet of claim 1, wherein the layer is circular and the ratio
of the diameter to height of the sheet is optionally: 1-2:100, 1-2:250
or 1-2:500.
19. The food sheet of claim 1, wherein the layer comprises up to 10%
of a second ingredient.
20. The food sheet of claim 19, wherein the second ingredient is a root
vegetable.
2 1. The food sheet of claim 19, wherein the second ingredient is onion.
22. The food sheet of claim 19, wherein the second ingredient is sweet
potato.
23. The food sheet of claim 1, wherein the layer comprises up to 5% of
a flavouring or seasoning.
24. The food sheet of claim 1, wherein the layer comprises up to 10%
fruit pieces.
25. The food sheet of claim 1, wherein the layer comprises up to 10%
fruit puree.
26. The food sheet of claim 2, wherein the starch composition
comprises sago starch, waxy maize starch, maize starch, rice
starch, waxy rice starch, barley flour/starch, pea flour/starch, potato
starch, wheat starch, tapioca starch, lotus starch, sweet potato
starch/flour or starch/flour from millets, pulses or lentils.
27. The food sheet of claim 2 , wherein the starch composition
comprises at least two starches.
28. The food sheet of claim 27, wherein the starch composition
comprises sago starch and waxy maize starch.
29. The food sheet of any one of claims 26 to 28, wherein the starch
composition comprises a modified or unmodified starch.
30. The food sheet of any one of claims 26 to 29, wherein the starch
composition comprises i) sago starch, ii) instant modified waxy
maize starch and iii) cook-up modified waxy maize starch.
3 1. The food sheet of claim 30, wherein the food sheet is formed from
90-96% vegetable pieces by weight, 0.05-3% sago starch by dry
weight, 0.05-3% instant modified waxy maize starch by dry weight
and 0.05-3.5% cook-up modified waxy maize starch by dry weight.
32. The food sheet of claim 3 1, wherein the food sheet is formed from
94-96% vegetable pieces by weight, 1.7-2.5% sago starch by dry
weight, 1.0-1 .5% instant waxy maize starch by dry weight and 1.7-
2.5% cook-up waxy maize starch by dry weight.
33. The food sheet of any one of claims 30-32 wherein the sago starch
is modified.
34. The food sheet of claim 1, wherein the product is free of gluten.
35. The food sheet of claim 1 wherein the product is free of egg.
36. A wrapped food product comprising the food sheet of claim 1, fully
or partially folded around a filling to contain the filling.
37. The wrapped food product of claim 36, wherein the food sheet is
fully folded around the filling creating a food-tight seal that prevents
the filling from leaking through the sheet.
38. The wrapped food product of claim 37, wherein the product
contains the filling when upright.
The wrapped food product of claim 36, wherein the filing comprises
egg, burrito filling, tortilla filling, samosa filling, egg roll filling, spring
roll filling, deli-style sliced meat, vegetables, cheese, salad or fruit.
A noodle comprising the food sheet of claim 1
The noodle of claim 40, wherein the sheet is shaped as a lasag
noodle or a cannelloni noodle.
The use of the food sheet of claim 1 and filling for preparation of a
wrapped food product.
A method of preparing a wrapped food product comprising fully or
partially folding the food sheet of claim 1 around a filling, wherein
the food sheet contains the filling when held upright.
The method of claim 43, wherein the filing comprises egg, burrito
filling, tortilla filling, samosa filling, egg roll filling, spring roll filling,
deli-style sliced meat, vegetables, cheese, salad or fruit.
A food additive composition comprising sago starch and waxy
maize starch.
46. The food additive composition of claim 45, wherein the starches are
modified or unmodified.
47. The food additive composition of claims 45 or 46, wherein the food
additive composition comprises i) sago starch, ii) instant modified
waxy maize starch and iii) cook-up modified waxy maize starch.
48. The food additive composition of claim 47, wherein the food
additive composition comprises sago starch, instant modified waxy
maize starch and cook-up modified waxy maize starch in the ratio
of 1: 1 : 1 to 1.7:1 : 1 .7 by dry weight.
49. The food additive composition of claim 47 or 48, wherein the sago
starch is modified.
50. The use of the food additive composition of any one of claims 45 to
49 and vegetable pieces for preparation of a food sheet.
5 1. A method of forming a food sheet, comprising:
contacting root vegetable food pieces with the food additive composition of
any one of claims 45 to 49;
forming the root vegetable food pieces into a raw sheet;
gelling the food additive composition to form a solid matrix around the root
vegetable food pieces, thereby converting the raw sheet to the food
sheet.
52. The method of claim 5 1, wherein the step of contacting root
vegetable shred with the food additive composition forms a dough.
53. The method of claim 5 1, wherein the forming step comprises
pressure forming the dough into the raw sheet.
54. The method of claim 53, wherein the pressure forming step
comprises applying 5-500PSI of pressure to the dough with a press.
55. The method of claim 53, wherein the pressure forming step is
performed at ambient temperature.
56. The method of claim 53, wherein the pressure forming step is
performed at 16-25°C.
57. The method of claim 53, wherein the pressure forming step is
performed at below ambient temperature.
58. The method of claim 53, wherein the pressure forming step is
performed at 4-1 8°C.
59. The method of claim 58, wherein the pressure forming step is
performed at 4-8°C.
60. The method of claim 5 1, wherein the gelling step comprises heating
the raw sheet to set the starches to bind with the food pieces to
form the food sheet.
6 . The method of claim 5 1, wherein the gelling step comprises heating
the raw sheet to 55-95°C.
62. The method of claim 5 1, wherein the gelling step comprises
heating the raw sheet at least until a portion of the vegetable pieces
become darkened.