Method for producing a multi-layer coated food product

Abstract

The present invention provides a method for producing a multi-layer coated edible snack product, comprising the following steps: a) providing an edible raw core having an outer surface; b) applying at least a first composite coating on the outer surface of the raw core; c) cooking the raw core covered with the at least first composite coating to form a first cooked layer having a first thickness; d) applying at least a second composite coating on the first cooked layer; e) cooking the at least second composite coating to form a second cooked layer. The product obtained by this method is crispy but has a soft texture, and the expansion of the at least second composite coating is greater than 35%.

Description

Field of the Invention

[0001] The present invention belongs to the field of product coatings. Specifically, it refers to a method for coating food products having a spherical or hemispherical, ovoid, oval, elliptical, etc. shape. Preferably, the method is applied to nuts, peanuts, seeds, etc. The method allows obtaining products with improved physical and sensory characteristics through an efficient, simple, and economical process. Background Art

[0002] Processes for coating food products with formulations based on solid mixtures (powders) composed of starch, flour, etc. and liquid mixtures such as syrups, honey, etc. are well-known in the prior art, as is the case for peanuts, nuts, and other types of seeds. Similarly, in coating methods or processes, it is well-known to use thermal operations such as baking, frying, or roasting after applying the coating, with the ultimate goal of drying or dehydrating it (also known as the "curing" step)) to ensure that the coating obtains the desired texture, usually crispy.

[0003] Generally, those products produced by applying a single coating followed by a frying step are called "Dutch" peanuts. On the other hand, "Japanese" peanuts are a type of peanut different from Dutch peanuts, which are baked to protect the coating.

[0004] There are also methods in the prior art for preparing food products coated with more than one layer of coating. The most relevant methods found are described below:

[0005] W02013009176 describes a method for preparing coated dried fruits, which basically includes applying at least one layer of coating on the product and then curing it by heat treatment, preferably by baking, roasting, or frying. In a preferred embodiment, the coated product is baked at 160°C for 25 minutes, then cooled at a temperature below 50°C, and then baked at 170°C for 20 minutes.

[0006] It should be emphasized that this document takes curing as the last step, that is, even if the product may be coated multiple times, only one curing is carried out, whether one or more heat treatments are performed, but no curing is carried out between coatings, as is the case in the present invention.

[0007] CN104013037 details a production method of fried peanuts baked with honey, including the following steps: pre-treating peanuts (A - B); coating the peanuts with a first formulation containing starch (C); frying (E) in a system controlled by a PLC with three temperature zones (105 - 110 °C; 150 - 165 °C and 180 - 190 °C, for 8 - 12 minutes, 5 - 8 minutes and 2 - 5 minutes respectively); cooling the peanuts (F); applying a second coating and baking (I) at 130 °C, and the second coating includes a solution containing honey (H).

[0008] In addition to presenting differences in the conditions related to the operation of the method, this document first fries the peanuts and then bakes them, which is the opposite of what is proposed in the present application. The said differences are important because the applicant knows that, following the step sequence disclosed in CN104013037, a product with the said characteristics cannot be obtained, mainly the crispy / crunchy properties.

[0009] Despite the above efforts, there is still a need to provide coated food products with improved physical and sensory characteristics through an efficient, simple and cost-effective process. Although the prior art has proposed various solutions, there is no method that combines the step sequence disclosed in the present invention, which results in a product with the characteristics described herein. Summary of the Invention

[0010] The present invention discloses a method for producing a multi-layer coated edible snack product, including the following steps: a) providing an edible raw core having an outer surface; b) applying at least a first composite coating on the outer surface of the raw core; c) cooking the raw core covered with the at least first composite coating to form a first cooked layer, the first cooked layer having a first thickness; d) applying at least a second composite coating on the first cooked layer; e) cooking the at least second composite coating to form a second cooked layer, the second cooked layer having a second thickness, and the second thickness of the second cooked layer is different from the first thickness of the first cooked layer; the layering process can be repeated multiple times as needed to control the thickness of the multi-layer shell around the edible core in this way; in addition, through this process, the processed raw edible core is transformed into a cooked edible core of a multi-layer coated edible snack product.

[0011] The multi-layer coated edible snack product obtained by the method of the present application is crispy on the outside and soft on the inside, presenting a pleasant coherence when bitten. The second composite coating exhibits a swelling of greater than 35%, typically in the range of about 35% to about 50%, and has a high porosity (in the range of about 60% to about 90%) between the two coatings, so that the first composite coating is found to be separated from the second composite coating, which helps to increase the volume and give the feeling of a large amount of product with a smaller supply, thereby reducing costs.

[0012] These and other aspects, embodiments, and advantages of the exemplary aspects and embodiments are discussed in detail below. This description provides illustrative examples of various aspects and embodiments of the invention and is intended to provide an overview or framework for understanding the nature and characteristics of the claimed aspects and embodiments. The inclusion of the drawings is to provide additional illustration and understanding of the various aspects and embodiments and is incorporated into and constitutes a part of this specification. The drawings, together with the description, are used to explain the described and claimed aspects and patterns. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The following drawings illustrate one or more embodiments of the invention and should not be considered as limiting the invention.

[0014] Figure 1a is a perspective view of the whole peanut kernel.

[0015] Figure 1b is a cross-section of the peanut kernel.

[0016] Figure 1c is a top view of half of the peanut kernel.

[0017] Figure 2 is a cross-sectional view of the multi-coated edible core.

[0018] Figure 3 is a flowchart of the method of the present invention. DETAILED DESCRIPTION

[0019] The following detailed description is merely exemplary and is not intended to limit the disclosed embodiments or the application and uses of the disclosed embodiments. As used herein, the word "exemplary" or "illustrative" means "serving as an example, instance, or illustration." Any embodiment described herein as "exemplary" or "illustrative" should not be construed as being better or superior to other embodiments. All of the embodiments described below are exemplary embodiments provided to enable those skilled in the art to make or use the embodiments of the present invention and are not intended to limit the scope of the present invention. For the purposes of this specification, the terms "top," "bottom," "left," "rear," "right," "front," "vertical," "horizontal," and derivatives thereof refer to the orientation of the present invention in the figures. Additionally, there is no intention to be bound by any explicit or implicit theory presented in the above technical field, background art, summary of the invention, or the following detailed description. It should also be understood that the specific apparatus and processes illustrated in the figures and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Accordingly, specific dimensions and other physical characteristics related to the embodiments described herein should not be construed as limiting, unless the claims expressly state otherwise.

[0020] It will be apparent to those skilled in the art that the method of the present invention can be applied to any product having a spherical or hemispherical, oval, ovoid, elliptical, etc. shape, particularly food products such as nuts, seeds, almonds, legumes such as chickpeas, peanuts, lima beans, etc.

[0021] For the present invention, the use of the term "about" provides an additional range of determination. The term is defined in the following manner. The additional range provided by the term is ±10%. By way of example, but not by way of limitation, if it reads "about 40 grams," the exact range is between 36 and 44 grams.

[0022] Likewise, unless otherwise stated, all percentages of ingredients or concentrations refer to weight.

[0023] In Figure 3 a flowchart of a method for producing a multi-layer coated edible snack product according to the present invention can be seen, where the process starts at block 20, which requires the addition and preparation of a raw edible core 10, as previously described, Figure 1a 、 1b 、1c show examples of the raw edible core 10, where peanuts are illustrated as an example of the edible core 10; the edible raw core 10 can be whole or in halves ( Figure 1c) are supplied to the process of the present invention and, depending on the type of the edible raw core 10, may or may not have an epidermal covering; another example of the edible raw core 10 may be nuts, legumes, grains such as corn, seeds, fruits, fruit derivatives, and the like. The edible core 10 is preferably provided in a raw state, which is an advantage of the process of the present invention because the edible raw core 10 is cooked during the layering process.

[0024] Before starting the method proposed herein, an edible raw core product 10 must be provided, which will be the basis for producing a multi-layer coated edible snack product according to the present invention.

[0025] Those skilled in the art will understand that the quantity of the edible raw cores 10 supplied in a continuous manner or in batches will depend on the capacity of the equipment used for the coating / layering process and the required quantity of the multi-layer coated edible snack product. The steps of the process are independent of the above-mentioned highlighted parameters.

[0026] Once a batch of edible raw cores 10 is ready for processing, one batch of edible raw cores can range from 100 kg to 250 kg, depending on the capacity of the equipment to be used. The user must confirm whether the edible raw cores 10 have an epidermal covering or hull. If there is no epidermis, according to an alternative embodiment, the process includes the step of applying an adhesive layer (block 30) on the uncovered edible raw cores 10. The adhesive layer can follow any dough formula known in the art, preferably a dough formula having a liquid base such as syrup and dry ingredients such as a certain flour like corn flour, wheat flour, rice flour, etc.; the dough for the adhesive layer of this alternative embodiment will provide a layer with a thickness of 0.01 mm to 0.05 mm, preventing the edible raw cores from sticking to each other and allowing proper adhesion to at least the first composite coating 11; in addition to other coating methods available in the art, this alternative adhesive layer can be completed on a rinsing device, a conveyor tumbling drum, or a centrifuge barrel; once the edible raw cores 10 of this alternative embodiment have been coated, they are ready for the process of block 40.

[0027] In an alternative embodiment, when the provided edible raw cores 10 have no epidermis, an edible adhesive coating is added to ensure that the first composite coating 11 is fixed to the food product. Examples of suitable adhesives are gums or gelatin; however, various composites can be used to achieve this final goal.

[0028] The first composite coating 11

[0029] The raw edible cores are coated with at least one layer of the first composite coating.

[0030] In the case where the edible raw cores 10 have no epidermis but the adhesive layer of block 30 is not applied, the uncovered edible raw cores 10 are ready for the process of block 40.

[0031] In any case, with or without an epidermis, or with or without a square 30 adhesive layer, the edible raw core 10 is now ready for the first composite coating 11. The first starch content of the composite for this layer is approximately 10% to 30% by weight, and the first flour content is 40% to 70% by weight. The composite is prepared on a liquid base such as syrup and dry ingredients (square 50); the liquid base in the form of syrup to which starch is added, water, and other formulation-specific ingredients will be selected according to the type of the desired final product. The formulation-specific ingredients may include, but are not limited to: sugar, soybeans, edible oil, seasonings, protein, emulsifying stabilizers, etc.; the dry ingredients may include flour and other formulation-specific ingredients selected according to the type of the desired final product. The formulation-specific ingredients may be: any kind of flour such as corn flour, wheat flour, rice flour, etc., salt, condiments, etc.; the equipment suitable for performing the coating operation includes, but is not limited to, a elutriation device, a conveyor, a tumbling drum or a centrifuge barrel, a mixing container, a coating tube, a fluidized bed dryer, and other coating methods available in the art. The centrifuge barrel is the preferred method. Among them, the liquid base and dry ingredients prepared on square 50 can be added to the center of the barrel, and due to the centrifugal force, the liquid base and dry ingredients reach the edible raw core 10 that is radially accommodated on the circumferential wall of the barrel due to the centrifugal force; the approximate speed of the centrifuge barrel ranges from 100 rpm to 3000 rpm, and the centrifuge residence time ranges from 1 minute to 30 minutes; the speed and centrifuge residence time, the hourly net product processing volume, the specific formulation of the liquid base and dry ingredients prepared on square 50, and other variables related to engineering and technology will depend on the size of the batch of the edible raw core 10 to be processed.

[0032] In one embodiment, the application of at least the composite and the formulation-specific ingredient layer of the first composite coating 11 (square 50) is carried out in an automatic metering coating device, and the automatic metering coating device can be any commercially known device (for example, by dripping, centrifuging, spraying, soaking, etc.). A centrifugal coating device is preferably used.

[0033] In this embodiment, the device is programmed such that it can meter the powder and liquid ingredients bit by bit into an automatic metering coating device or a receiver containing the edible raw core 10, and in a preferred embodiment, the receiver is rotated at a high speed simultaneously, as is known to those skilled in the art. In any case, the automatic metering device containing the edible raw core 10 evenly distributes at least the first composite coating having the formulation-specific ingredients.

[0034] In another embodiment, in a suitable coating application device, such as in a centrifugal drum or a barrel, the dosing or addition of at least the first complex coating 11 of the formation of the first complex coating in block 50 is carried out manually; the edible nuclei 10 are introduced into a suitable coating application device, either manually or by means of a conveying device, such as a conveyor belt. The operator manually adds the first complex in block 50, the components of which have been pre-weighed.

[0035] Contrary to the exemplary embodiment with an automatic dosing device, in this exemplary embodiment, it is necessary to allow the edible nuclei 10 to remain between the addition of each batch of complex in block 50 and the formulation-specific components, with the ultimate goal of achieving a uniform coating. The residence time should depend on the formulation-specific components and the experience of those skilled in the art.

[0036] At the end of this step, edible nuclei 10 coated with at least the first complex coating 11 are obtained.

[0037] Once this batch of edible nuclei 10 is coated with at least the first complex coating and dried, it is subsequently removed from the coating device and transferred to a heating device for the first cooking process, preferably baking. Suitable heating devices include but are not limited to gas or electric convection heating ovens, retorts, chain flat ovens or even frying pans, or other air or fluid gas heating devices known in the art; this batch of coated edible nuclei 10 is preferably heated to about 150 °C to 200 °C, with a heating exposure time of 5 minutes to 12 minutes; the temperature and heating exposure time, as well as the number of edible nuclei 10 in the batch, the type of heating device, the type of final product specifications, and other engineering and process variables will depend on the specific formulation of the liquid-based and dry components of the preparation in block 50; once the heated batch of edible nuclei 10 coated with the first complex coating 11 leaves the heating operation 70, the first complex coating 11 is cooked, preferably baked, and dried, having a first thickness; additionally, it should be noted that the temperature and heating exposure time of the first complex coating 11 do not cook the edible nuclei 10, so they still retain their raw characteristics.

[0038] In an alternative embodiment, the edible nuclei 10 can be conditioned before the heating of at least the first complex coating 11 (block 70), which can be done in a conditioning drum or a conveyor belt oven, a traditional batch oven, and other heating / baking devices commercially available in the art, where the residence time will vary between about 1 minute and 1 hour, preferably between about 1 minute and 40 minutes, depending on the heating / baking device used, to equalize the quantity of product supplied to the heating / baking device and avoid temperature variations therein.

[0039] The heating of at least the first composite coating 11 (box 70) on the edible raw nucleus can have two purposes. The first is to dry the coating and the edible raw nucleus 10 without changing the food product. The second purpose is to reach a point or cooking (preferably baking) condition where the ingredients on at least the first composite coating of box 50 undergo a chemical transformation, which results in special edible sensory characteristics such as the texture, flavor, and color of the coated product, as well as mechanical characteristics such as crack resistance, which ensures good handling in the subsequent steps of the process in both cases. In the same way, the cooking, preferably baking, of the first composite coating 11 (box 70) step is the reason for the crispy / crunchy properties of the obtained multi-layer coated edible snack product.

[0040] At the end of this step, an edible raw nucleus 10 with a first cooking layer 11 is obtained.

[0041] In an alternative embodiment, depending on the desired thickness and edible characteristics of the final multi-layer coated edible snack product, the step sequence of the first composite coating 11 and its cooking (box 70), preferably baking, can be repeated the necessary number of times.

[0042] Second composite coating 12

[0043] After the cooking (preferably baking) of the first composite coating 11 (box 70), at least a second composite coating is added to the product on the cooked first layer 11 to form a second composite coating 12 (see Figure 2 ). The addition of at least the second composite coating of box 60 is preferably carried out immediately after the product is still hot at the end of the box 70 step.

[0044] Once a batch of baked edible nuclei 10 having at least a first composite coating exits the cooking (preferably baking) apparatus, it is transferred to a second layering operation (block 80) where it is coated with at least a second composite coating 12, the second starch content of the composite for this layer being about 30% to 60% by weight and the second flour content being 10% to 40% by weight, the at least second composite coating being prepared on a liquid base such as syrup and dry ingredients (block 60); the liquid base in the form of syrup with added starch, water and other formulation-specific ingredients will be selected according to the type of the desired final product, and the formulation-specific ingredients may include but are not limited to: edible sugar, sucrose soy, edible oil, seasonings, proteins, emulsifying stabilizers, etc.; the dry ingredients may include flour and other formulation-specific ingredients selected according to the type of the desired final product, and the formulation-specific ingredients may include but are not limited to: any kind of flour such as corn flour, wheat flour, rice flour, etc., salt, dry spices, chili powder, citric acid powder, flavorings, low humidity and fine-grained flour, etc.; in a preferred embodiment of the second composite in block 60, the dry ingredient is preferably wheat flour having a fine particle size (90 μm to 180 μm), and this flour helps to avoid adhesion during heating in the at least second composite coating process in block 90. The at least second composite coating 12 operation is carried out on an apparatus suitable for performing the coating operation, and the apparatus suitable for performing the coating operation includes but is not limited to a elutriation device, a conveyor, a tumbling drum or a centrifuge barrel, a mixing container, a coating tube, a fluidized bed dryer and other coating methods available in the art; an example of a preferred method is a centrifuge barrel, where the liquid base and dry ingredients prepared in block 60 can be added to the center of the barrel, and due to the centrifugal force, the liquid base and dry ingredients reach the edible nuclei 10 coated with the first composite that are radially received on the circumferential wall of the barrel due to the centrifugal force; the approximate speed of the centrifuge barrel ranges from 100 rpm to 3000 rpm; the speed and the centrifuge residence time, the hourly net product processing volume, the specific formulation of the liquid base and dry ingredients prepared in block 60 and other variables related to engineering and technology will depend on the size of the batch of edible nuclei 10 coated with the first composite to be processed.

[0045] Once at least a second composite coating is applied to the batch of edible nuclei 10 coated with at least a first composite coating 11 and dried, the product is then removed from the coating apparatus and transferred to cooking (preferably frying) for cooking, preferably frying, the second layer operation (block 90), and suitable cooking apparatuses for the second layer operation of cooking (preferably frying) block 90 include, but are not limited to, batch fryers, conveyor oil fryers, kettle and agitator fryers, and other types of deep fry or edible oil fryers or methods known in the art; the batch of the second composite layer 12 on the first cooked layer 11 of edible nuclei 10 is preferably immersed in an edible frying liquid, which includes, but is not limited to: canola oil, corn oil, palm oil, safflower oil, sunflower oil, coconut oil, sesame oil, animal oil, lard, butter, and other frying liquids; the frying liquid temperature varies between approximately 150 °C and 200 °C, and the frying exposure time is approximately 8 minutes to 20 minutes; the temperature and frying exposure time depend on the specific formulation of the liquid-based and dry ingredients prepared in block 60, also depend on the amount of the second composite coating 12 on the first cooked composite layer 11 of edible nuclei 10 present in the batch, and the type of frying apparatus depends on the type of the final multi-layer coated edible snack product specifications and other engineering and process variables; once the batch of the second composite coating 12 on the first baked composite layer 11 of edible nuclei 10 that has been cooked (preferably fried) leaves the cooking (preferably frying) operation 90, at least the second composite coating 12 is cooked (preferably fried) and dried, forming a layer with a thickness of approximately 0.30 mm to 1.00 mm, and the thickness of the second composite coating 12 is thicker than that of the first composite coating 11. It should also be noted that the temperature of the second composite in block 60, cooking (preferably frying), exposure time, and the second starch and second flour content form at least the second composite coating 12, which can accommodate the steam generated during the second cooking (preferably frying) operation, resulting in the cooking of the edible nuclei 10, so that the edible nuclei 10 have lost their moisture and have acquired the cooked edible commercial characteristics.

[0046] As in the case of at least the first composite coating 11, commercially available automatic metering coating apparatuses can be used for the application of at least the second composite coating 12, for example, by dripping, centrifuging, spraying, soaking, and the like. A centrifuge apparatus is preferably used.

[0047] As an exemplary embodiment, the apparatus is programmed such that it can meter dry and liquid ingredients bit by bit into an automatic metering coating apparatus or receiver containing the edible nuclei 10 with the first heated (block 70) first composite coating 11.

[0048] In another exemplary embodiment, the metering or addition of the second complex of block 60 is carried out manually in a suitable layer application device, such as in a centrifugal drum or a bucket.

[0049] In this exemplary embodiment, the edible core 10 with the first complex-coated (block 70) first complex coating 11 is introduced into a suitable layer application device, either manually or with the aid of a conveying device, such as a conveyor belt. The suitable layer application device is started, and the operator manually adds the components of the second complex of block 60, which have been pre-weighed.

[0050] Contrary to the exemplary embodiment with an automatic metering device, in this exemplary embodiment, it is necessary to allow the edible core 10 with the first cooked (block 70) first complex coating 11 to stay between the additions of batches of the second complex of block 60, with the ultimate goal of achieving a uniform coating. The residence time should depend on the experience of those skilled in the art as well as the formulation-specific ingredients.

[0051] In any given embodiment, the liquid ingredients can be added at room temperature or heated as required, with the ultimate goal of facilitating their application.

[0052] In an alternative embodiment, during the coating with the first complex (block 40) and the first cooking (block 70) step, the water vapor generated by the evaporation of the water contained in the liquid ingredients contributes to the pre-cooking of the food product by utilizing the latent heat.

[0053] It is important to note that there is a significant humidity gradient between the first heating (block 70) of at least the first complex coating 11 and at least the second complex coating 12, which helps to ensure that the two coatings do not adhere to each other, thus allowing at least the second complex coating 12 to expand during the cooking (preferably frying) process.

[0054] At the end of this step, an edible core 10 with a first cooked layer under the second complex coating 12 is obtained.

[0055] The ultimate goal of carrying out the second cooking step, preferably frying (block 90), is to impart a soft texture to the final product, because, in addition to the humidity discussed earlier, the oil entering the product will also allow the second complex coating 12 to expand, filling the space between the first cooked layer 11 and the second cooked layer 12 with air bubbles, which creates a pleasant sensation when biting.

[0056] The second cooking step (block 90) also allows the edible core 10 with at least the second complex coating 12 on the first cooked layer to complete cooking, with the cooking of the first layer starting in the first layer heating step of block 70.

[0057] Finally, once the edible core 10 has been heated through the second layer operation of the square 90, it is cooked and cooled to obtain an edible core 10 product with a multi-layer shell.

[0058] The next step of the method of the present invention is to check whether the shell composed of multiple layers arranged on the edible core 10 has reached the required thickness. The total shell thickness depends on the type of the final product sought. Therefore, based on this and the specific formula followed, the user can determine the total thickness of the shell. If the required total shell thickness is reached, the layering process ends. If the required total shell thickness is not reached, the layering process (from square 40 to square 90) is repeated.

[0059] Flavor enhancer

[0060] The next step is to check whether the formula of the specified multi-layer edible product requires a flavor enhancer coating. If so, a flavor enhancer complex is prepared according to the type of the final product required (square 100). The formula of the specific components of the flavor enhancer coating includes but is not limited to: sugar, sucrose soybeans, edible oil, seasonings, chili powder, colorants, salt, spices, etc. in dry ingredient form. In a preferred embodiment of the flavor enhancer coating formula in square 100, the thickness of the dry ingredients is preferably about 0.001 mm to 0.30 mm, and is thinner than the first complex coating 11 in any implementation. Therefore, the flavor enhancer coating has a dusty property.

[0061] The application of the flavor enhancer coating occurs at square 110. The equipment suitable for performing the coating operation at square 110 includes but is not limited to a elutriation device, a conveyor, a tumbling drum or a centrifuge barrel, a mixing container, a coating tube, a fluidized bed dryer, and other coating methods available in the art. The application of the flavor enhancer coating on the second cooking layer is carried out at ambient temperature. Once this operation expires, the whole process ends.

[0062] Characteristics of the obtained product

[0063] The multi-layer shell dough snack prepared according to the above method presents the following sensory characteristics and properties:

[0064] The edible core 10 is fully cooked, so the taste is pleasant. The multi-layer shell dough snack presents a crispy and brittle characteristic in the center of the product provided by the first baking layer 11. The soft feeling when biting into the multi-layer coated edible snack product is due to the expansion of the second cooking layer.

[0065] In addition, compared with the traditional process of Dutch peanuts, the expansion of the second complex coating 12 is achieved with a smaller supply. As is known to those skilled in the art, in the traditional process of Dutch peanuts, only the first coating process and subsequent frying exist.

[0066] Tests conducted by the applicant have shown that multi-layer coated edible snack products prepared according to the method proposed herein have a percentage of expansion of the second composite layer coating 12 by frying that is higher than approximately 35%, typically between approximately 35% and 50%, and a porosity of approximately 60% - 90% between the first and second composite coatings (11, 12), such that the first composite coating 11 is found to be separated from the second composite coating 12, which confers a higher volume and a perception of providing more product with a smaller serving size, thus reducing costs.

[0067] In addition, the surface of the second cooking layer is uneven, which makes its appearance different from those existing in the prior art, and this also makes it easy for any subsequent liquid or powder or dust-like flavor enhancer layer to adhere.

[0068] In another embodiment, the first cooking layer is cooked by frying and the second cooking layer is cooked by baking.

[0069] The accompanying drawings of this specification illustrate the above method applied to peanuts. Nevertheless, those skilled in the art will understand that these should not be construed as limitations on the present invention.

[0070] Those skilled in the art can anticipate changes to the invention described herein. However, it must be understood that this specification relates to the preferred embodiments of the present invention, which are for illustrative purposes only and should not be construed as limitations on the present invention. All obvious modifications within the spirit of the present invention, such as changes to the shape, material, and dimensions of the features constituting the present invention, must be considered to fall within the scope of the appended claims.

Claims

1. A method for producing a multi-coated edible snack product, comprising the steps of: Providing an edible core having an outer surface and formed from raw materials; Applying a first layer on the outer surface of the edible core, the first layer comprising a first cookable ingredient and water; Cooking the first layer to form a cooked first layer on the edible core; Applying a second layer on the cooked first layer, the second layer being formed from a second cookable ingredient that expands upon cooking; and Cooking the second layer to form an expanded second layer, which provides a greater volume to the snack product; Wherein the cooking of the first layer results in a humidity gradient between the cooked first layer and the overlying second layer, which helps prevent the second layer from adhering to the cooked first layer during the cooking and expansion of the second layer.

2. The method according to claim 1, wherein the step of cooking the second layer comprises cooking the second layer in an edible frying liquid to facilitate the formation of air bubbles between the expanded second layer and the cooked first layer.

3. The method according to claim 2, wherein the step of cooking the second layer comprises frying the second layer.

4. The method according to claim 2, wherein the edible frying liquid is cooking oil.

5. The method according to claim 1, wherein the step of cooking the second layer comprises frying the second layer in cooking oil to generate air bubbles between the expanded second layer and the cooked first layer.

6. The method according to claim 1, wherein the step of cooking the first layer comprises baking the first layer, and the step of cooking the second layer comprises frying the second layer.

7. The method according to claim 1, wherein the second cookable ingredient has a higher starch-to-flour ratio than the first cookable ingredient to facilitate the expansion of the second layer during cooking.

8. The method according to claim 7, wherein the second cookable ingredient has a starch content of 30% to 60% by weight and a flour content of 10% to 40% by weight.

9. The method according to claim 1, wherein the first cookable ingredient has a starch content of 10% to 30% by weight and a flour content of 40% to 70% by weight.

10. The method according to claim 1, wherein, The edible core is selected from the group consisting of nuts including almonds and peanuts, nut derivatives, seeds, legumes including chickpeas and lima beans, whole grains, corn, fruits, dried fruits, fruit derivatives, dried vegetables, and any combination or mixture of the foregoing.

11. The method according to claim 1, wherein the step of cooking the first layer comprises sealing the edible core.

12. The method according to claim 1, further comprising applying an adhesive layer on the edible core before the step of applying the first layer to enhance the adhesion of the cooked first layer to the edible core.

13. The method according to claim 1, further comprising applying a flavor enhancer on the expanded second layer.

14. The method according to claim 1, wherein the cooked first layer has a thickness, and the expanded second layer has a thickness greater than the thickness of the cooked first layer.

15. A method for producing a multi-coated edible snack product, comprising the steps of: Providing an edible core having an outer surface and formed from raw materials; Apply a first layer on the outer surface of the edible core, the first layer being formed from a first cookable ingredient and water; Cook the first layer to form a cooked first layer on the edible core; Apply a second layer on the cooked first layer, the second layer being formed from a second cookable ingredient that expands upon cooking; And Deep-fry the second layer in an edible frying liquid to form an expanded second layer and create air bubbles between the expanded second layer and the cooked first layer; wherein cooking of the first layer results in a humidity gradient between the cooked first layer and the overlying second layer, which helps prevent the second layer from adhering to the cooked first layer during frying and expansion of the second layer, and the edible frying liquid helps form air bubbles between the expanded second layer and the cooked first layer.

16. The method according to claim 15, wherein the edible frying liquid is cooking oil.

17. The method according to claim 15, wherein the second cookable ingredient has a higher starch-to-flour ratio than the first cookable ingredient.

18. The method according to any one of claims 1 to 17, wherein the step of cooking the first layer forms a crispy layer on the edible core.

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