Heat and moisture resistant edible containers and methods of making same

Abstract

An edible container is made from upgraded brewer's grains, upgraded oat protein, and starch. A dough containing upgraded brewer's grains, upgraded oat protein and starch is placed in a mold and baked under high temperature and pressure conditions to form an upgraded, nutritional, edible container that can hold hot liquids, including boiling liquids, for an extended period of time without degradation and without the addition of a separate coating.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. non-provisional patent application No. 17 / 833,727, filed on June 6, 2022, entitled “Thermal and Moisture-Resistant Edible Container and Method of Making the Same,” the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present invention relates to edible containers for holding liquids for consumption. In particular, the present invention relates to edible containers made from upcycled components that are capable of withstanding hot liquids, such as boiling water, for extended periods of time while maintaining structural integrity and not leaking. Background Art

[0004] Disposable cups made of plastic or plastic-lined paper are a common alternative to reusable drinking cups due to their low cost and convenience. Both plastic and paper cups can hold hot liquids for long periods of time. However, disposable cups are not good for the environment. Because they are not biodegradable, they clutter the environment or fill up landfills. In addition, the plastic used in disposable cups comes from fossil fuels.

[0005] Edible cups are an alternative to disposable cups and are better for the environment. Edible cups do not create the hazardous waste of disposable cups because they are eaten or quickly biodegrade if thrown away. The most common type of edible cup is made from baked dough or batter and is made by, for example, pouring the batter into a mold and then baking it, or forming the dough around a mandrel and then baking it.

[0006] However, these types of edible cups cannot hold liquids for long periods of time because they are not waterproof. One solution to this problem is to apply a waterproof layer to the baked cup. Petrini, U.S. Pat. No. 6,068,866, discloses an edible cup made of a twice-baked pastry with a waterproof layer made of sugar, water, starch and gum that can hold hot and cold drinks without leaking or losing its structural integrity. However, this additional layer requires an additional coating process, the cup is still limited by the structural integrity of the baked dough, and the time such a cup can hold hot liquids is limited and relatively short.

[0007] Another edible cup is made of dehydrated fruit or vegetables. U.S. Patent No. 6,423.357 to Woods discloses an edible container made of dehydrated fruit or vegetables formed into strips and wrapped around a mold rod. However, dehydrated fruits and vegetables tend to rehydrate when exposed to liquid. In addition, a cup like this is limited by the strength of the dehydrated fruit or vegetable and it is difficult to form the dehydrated material into a cup shape.

[0008] Another problem with some conventional edible containers is that they must be constantly supported. That is, the user cannot place the container upright on a flat surface.

[0009] Additionally, most traditional edible containers are made from raw grains, which require the use of precious and dwindling resources such as fertile land and water to plant and grow, rather than recycled food assets obtained through upcycling. This has a negative impact on the environment.

[0010] Therefore, it is necessary to improve the existing disposable containers. Summary of the invention

[0011] The present invention relates to an upgraded edible container that can hold and contain hot and cold liquids for a long time.

[0012] In a general aspect of the invention, an edible container is comprised of brewers spent grain, upcycled oat protein and starch. In this aspect, brewers spent grain comprises 13% to 17.5%, upcycled oat protein comprises 11.6% to 13.8%, and starch comprises 6.1% to 10.4%, by weight of the edible container.

[0013] In another general aspect of the present invention, a method for making an edible container is provided. The method comprises: (1) forming a dough by mixing ingredients including water, 13 wt % to 17.5 wt % of brewer's grains, 11.6 wt % to 13.8 wt % of upcycled oat protein, and 6.1 wt % to 10.4 wt % of starch; (2) placing the dough into a baking mold; and (3) baking the dough to form an edible container.

[0014] In another aspect of the present invention, the edible container further comprises unbleached flour, sugar, fat and salt. Preferably, the concentration of unbleached flour is 35.6 wt % to 63 wt %, the concentration of sugar is 9.2 wt % to 12.4 wt %, the concentration of fat is 4.8 wt % to 5.5 wt %, and the concentration of salt is 0.3 wt % to 0.8 wt %.

[0015] In another aspect of the present invention, the upcycled oat protein in the edible container is oatmilk flour, and the oatmilk flour preferably contains about 20% fiber and 50% protein. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more example aspects of the disclosure and, together with the detailed description, serve to explain their principles and implementations.

[0017] Figure 1 is a side view of an edible container according to an embodiment of the present invention.

[0018] Figure 2 yes Figure 1 A top view of the edible container is shown.

[0019] Figure 3 is a flow chart showing a manufacturing process according to a preferred embodiment of the present invention. DETAILED DESCRIPTION

[0020] Exemplary aspects of the present invention are described herein. Those of ordinary skill in the art will recognize that the following description is illustrative only and is not intended to be limiting in any way. Other aspects will readily occur to those skilled in the art who benefit from this disclosure. Reference will now be made in detail to the implementation of the exemplary aspects as shown in the accompanying drawings. In all drawings and the following description, the same reference numerals will be used as much as possible to refer to the same or similar items.

[0021] The present invention relates to an edible and biodegradable container made from upcycled grains that can hold hot or cold liquids for a long time. The container can be easily molded into different shapes and sizes and does not require a separate coating process to increase the time it maintains structural integrity when exposed to liquids. The container is made substantially of natural materials that are safe to eat and is a delicious alternative to disposable containers that end up in landfills. The container can be eaten as the contents it contains are ingested. The edible container can be used at parties and events in place of disposable containers, or in other situations where disposable containers are normally used or additional nutrition is needed.

[0022] An example of the edible container is configured as a drinking cup, such as Figure 1 and 2As shown, it is made of brewer's grains, upgraded oat protein and starch. The starch is preferably selected from wheat starch, potato starch, tapioca starch, corn starch, arrowroot starch, etc. The edible container may also contain unbleached flour, sugar, fat and salt. The fat is preferably selected from partially hydrogenated vegetable oils, coconut oil, palm kernel oil, avocado oil, olive oil, grape seed oil, sunflower oil, almond oil, hemp seed oil, hazelnut oil, butter, etc.

[0023] In a preferred embodiment, the spent grains have a fiber fraction of 40% to 60% and a protein fraction of 20% to 30%, based on the total amount of spent grains, and the upcycled oat protein is preferably oat milk powder. Essential amino acids may constitute approximately 30% of the total protein in spent grains.

[0024] In addition, brewer's grains preferably contain a considerable amount of vitamins, including folic acid, niacin, biotin, thiamine, choline, pantothenic acid, riboflavin and pyridoxine, and tocochromanols such as tocotrienols and tocopherol (commonly known as vitamin E). Preferably, the most abundant minerals in brewer's grains are calcium (e.g., 3600 mg / kg), magnesium (e.g., 1900 mg / kg), phosphorus (e.g., 6000 mg / kg) and (e.g., 2900 mg / kg) and sodium (e.g., 137 mg / kg). Other minerals present in brewer's grains may include iron, copper, potassium and manganese.

[0025] The spent grains are preferably low in carbohydrates, and most of the sugars are removed during the saccharification process of the initial spent grain fermentation. Thus, the spent grains preferably have 12x the fiber, 2x the protein, and 1 / 3 the carbohydrates compared to standard all-purpose flour. The spent grains produce a malty brown color when roasted, with nutty, caramel, and almond flavors.

[0026] In a preferred embodiment, the upcycled oat protein is oat milk powder. Oat milk powder is a high-protein, high-fiber, gluten-free product made from the nutritious oat pulp leftovers from oat milk production. When baked, it develops a light tan color and develops an oaty, slightly sweet, butterscotch flavor.

[0027] Oat milk powder preferably contains approximately 20% fiber and approximately 50% protein.

[0028] In a typical embodiment, the edible container comprises 18 wt% to 30 wt% brewer's spent grains, 7 wt% to 13 wt% upcycled oat protein; and 5 wt% to 7 wt% starch.

[0029] In a preferred embodiment, the total weight of brewer's grains and upcycled oat protein is 26% or more, preferably 26% to 77%, most preferably 26% to 35%, by total weight of the edible container. In another embodiment, the above-mentioned unbleached flour may be excluded and replaced with an additional percentage of brewer's grains and upcycled oat protein. In such further embodiments, the total weight of brewer's grains and upcycled oat protein may be 77% or less, by total weight of the edible container.

[0030] In another preferred embodiment, the ratio of brewer's spent grains to oat protein is about 11:9.

[0031] Unlike other edible containers that require coatings to resist liquids, the edible container of the present invention achieves its moisture barrier properties by producing a glassy structure using a combination of ingredients and baking at high temperature and pressure. As used herein, "glassy structure" is a crystalline structure formed by a chemical reaction between lignin and hemicellulose in brewer's grains caused by a combination of pressure, heat, and steam. In order to obtain a structure with a sufficiently high degree of crystallinity, and therefore obtain glass-like properties, baking temperatures between 356°F and 392°F are most preferred, and the moisture content of the final edible container is preferably less than or equal to 10%.

[0032] Now refer to Figure 3 The flowchart in describes the method for forming an edible container. First, dough is formed by mixing the ingredients including water, 25% to 35% by weight of brewer's grains, 9.7% to 20% by weight of the upgraded oat protein and 4.5% to 6.5% by weight of starch. The dough can also include unbleached flour at a concentration of 28% to 40% by weight, sugar at a concentration of 6% to 8% by weight, fat at a concentration of 3.3% to 4% by weight and salt at a concentration of 0.2% to 0.5% by weight. As mentioned above, if unbleached flour is not included, the brewer's grains and the upgraded oat protein are replaced with additional percentages. In such further embodiments, the total weight of brewer's grains and the upgraded oat protein can be up to 58%, by the total weight of the dough.

[0033] Next, the dough is formed into balls of appropriate size and placed into the baking mold. This process is called "dosing". For example, for a 100ml cup, the dosing range is 28 grams to 30 grams. When the mass of the dough ball is above this range, over-dosing occurs, resulting in excessive pressure in the mold, creating a large hole in the cup, and the dough blows out of the mold. When the mass of the dough ball is below this range, under-dosing occurs, resulting in insufficient filling of the mold cavity and poor cup forming. As will be understood by those skilled in the art, the shape of the baking mold substantially corresponds to the desired final shape of the edible container, and the amount of dough used is selected based on the shape and size of the mold.

[0034] Once the dough is in the mold, it is baked at high temperature and high pressure to form an edible container. Preferably, the baking temperature range is 356°F to 392°F, the pressure range is 90 to 120psi, and the baking time range is 150 to 180 seconds. This high temperature and high pressure process for forming an edible container effectively converts the components (such as hemicellulose, cellulose and lignin) in the brewer's grains into a glassy structure. This glassy structure formed allows the edible container to hold liquid for up to 24 hours without structural degradation and leakage caused, and provides a structure that holds hot liquids with an initial temperature of 185°F to 212°F for at least 4 hours, preferably at least 24 hours, and then the structural integrity of the edible container is degraded to the extent that it can no longer hold liquid. The moisture content of the final edible container is preferably less than or equal to 10%.

[0035] Figure 1 is a side view of a shaped edible container according to a preferred embodiment of the present invention, Figure 2 is a top view. Although the foregoing has been described in conjunction with exemplary embodiments, it should be understood that the term "exemplary" is merely meant as an example. Those skilled in the art can understand from the foregoing description that the present invention can be implemented in various forms. For example, the dough described herein and the corresponding molds can be used to make various edible and degradable items, such as kitchen utensils (forks, spoons, knives, etc.), straws, travel covers for containers, plates, etc.

[0036] Therefore, although the embodiments of the present invention have been described in conjunction with specific examples thereof, the true scope of the embodiments of the present invention should not be so limited, since other modifications and variations will become apparent to those skilled in the art upon study of this specification. Such modifications and variations are considered to be within the authority and scope of the appended claims and their equivalents.

Claims

1. An edible container, comprising: 13 to 17.5% by weight of brewer's grains; 11.6 wt. % to 13.8 wt. % upcycled oat protein; and 6.1 wt% to 10.4 wt% starch.

2. The edible container of claim 1, wherein the total weight of the brewer's spent grains and the upcycled oat protein is 26% or more, based on the total weight of the edible container.

3. The edible container according to claim 1, wherein the ratio between the spent grains and the upcycled oat protein is about 11:

9.

4. The edible container of claim 1, further comprising unbleached flour, sugar, fat and salt.

5. The edible container according to claim 4, wherein the concentration of the unbleached flour is 35.6 wt% to 63 wt%, the concentration of the sugar is 9.2 wt% to 12.4 wt%, the concentration of the fat is 4.8 wt% to 5.5 wt%, and the concentration of the salt is 0.3 wt% to 0.8 wt%.

6. The edible container according to claim 1, wherein the brewer's spent grains have a fiber portion of 40% to 60% and a protein portion of 20% to 30%, based on the total amount of the brewer's spent grains.

7. The edible container of claim 1, wherein the upcycled oat protein is oat milk powder.

8. The edible container of claim 1, wherein the oat milk powder has 20% fiber and about 50% protein.

9. The edible container of claim 1, wherein the container is capable of containing a liquid having an initial temperature ranging from 185°F to 212°F for at least 4 hours before degradation.

10. A method of making an edible container, the method comprising: forming a dough by mixing ingredients including water, 13 wt% to 17.5 wt% brewer's spent grains, 11.6 wt% to 13.8 wt% upcycled oat protein, and 6.1 wt% to 10.4 wt% starch; placing the dough into a baking mold; and The dough is baked to form an edible container.

11. The method of making an edible container according to claim 10, wherein the total weight of the brewer's spent grains and the upcycled oat protein is 26% or more based on the total weight of the edible container.

12. The method of making an edible container according to claim 10, wherein the ratio between the spent grains and the upcycled oat protein is about 11:

9.

13. The method of making an edible container according to claim 10, wherein the dough further comprises unbleached flour, sugar, fat and salt.

14. The method of manufacturing an edible container according to claim 13, wherein the concentration of the unbleached flour is 35.6 wt% to 63 wt%, the concentration of the sugar is 9.2 wt% to 12.4 wt%, the concentration of the fat is 4.8 wt% to 5.5 wt%, and the concentration of the salt is 0.3 wt% to 0.8 wt%.

15. The method of manufacturing an edible container according to claim 10, wherein the brewer's spent grains have a fiber portion of 40% to 60% and a protein portion of 20% to 30% based on the total amount of the brewer's spent grains.

16. The method of making an edible container according to claim 10, wherein the upcycled oat protein is oat milk powder.

17. The method of making an edible container of claim 10, wherein the oat milk powder has 20% fiber and about 50% protein.

18. The method of making an edible container of claim 10, wherein the container is capable of containing a liquid having an initial temperature ranging from 185°F to 212°F for at least 4 hours before degradation.

19. The method of making an edible container according to claim 10, wherein the baking of the dough is carried out at a pressure and temperature sufficient to form a glass-like structure in the dough.

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