Heat- and moisture-resistant edible container and method for making same

Abstract

An edible container made from upcycled brewer's grains, upcycled oat protein, and starch. The dough including the upcycled brewer's grains, upcycled oat protein, and starch is placed in a mold and baked under high heat and pressure conditions to form an upcycled, nutritious, edible container that can hold hot liquids, including boiling liquids, for extended periods of time without deterioration and without the addition of a separate coating.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of U.S. Non-Provisional Patent Application No. 17 / 833,727, filed 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.

[0002] FIELD OF THE INVENTION The present invention relates to edible containers for holding liquids for consumption. Specifically, the present invention relates to edible containers made from upcycled ingredients that can withstand high temperatures, such as boiling water, for extended periods of time while maintaining their structural integrity and being leak-proof. [Background technology]

[0003] Disposable cups made from plastic or plastic-lined paper are commonly used instead of 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 end up littered in the environment or buried in landfills. In addition, the plastic used in disposable cups is derived from fossil fuels.

[0004] Edible cups are an alternative to disposable cups and are better for the environment. Edible cups do not produce the harmful waste of disposable cups because they can be eaten or quickly biodegraded when discarded. The most common type of edible cup is made from a baked dough or batter, for example, by pouring the batter into a mold and then baking it, or by forming the dough around a mandrel and then baking it.

[0005] However, these types of edible cups are not waterproof and cannot hold liquids for long periods of time. One solution to this problem is to coat the baked cup with a waterproof layer. U.S. Patent No. 6,068,866 to Petrini discloses an edible cup made from twice-baked pastry with a waterproof layer made from sugar, water, starch, and gum, allowing the cup to contain hot and cold beverages without leaking or losing its structural integrity. However, this additional layer requires an additional coating process, and the cup is still limited by the structural integrity of the baked dough, so the time such a cup can hold hot liquids is limited and relatively short.

[0006] Another type of edible cup is made from dried fruits or vegetables. U.S. Patent No. 6,423,357 to Woods discloses an edible container made from dried fruits or vegetables formed into a strip and wrapped around a mandrel. However, dried fruits and vegetables tend to rehydrate when exposed to liquid. Additionally, cups such as these suffer from both the limited strength of dried fruits or vegetables and the difficulty of forming dried materials into a cup shape.

[0007] Another problem with some conventional edible containers is that they must be continuously supported, i.e., the user cannot place the container upright on a flat surface.

[0008] Additionally, most conventional edible packaging is made from virgin grains rather than recovered food resources obtained through upcycling, which require the use of precious and dwindling resources such as fertile land and water to cultivate and grow, which has a negative impact on the environment.

[0009] Therefore, improvements to existing disposable containers are needed. Summary of the Invention

[0010] The present invention is directed to an upcycled edible container that can hold and contain hot and cold liquids for extended periods of time.

[0011] In a general embodiment of the present invention, the edible container is comprised of brewers spent grain, upcycled oat protein, and starch. In this embodiment, the edible container comprises 13% to 17.5% brewers spent grain, 11.6% to 13.8% upcycled oat protein, and 6.1% to 10.4% starch by weight.

[0012] In another general aspect of the invention, a method for making an edible container is provided, the method including: (1) forming a dough by mixing ingredients including water, 13% to 17.5% by weight of brewer's spent grains, 11.6% to 13.8% by weight of upcycled oat protein, and 6.1% to 10.4% by weight of starch; (2) placing the dough into a baking pan; and (3) baking the dough to form an edible container.

[0013] In another embodiment of the present invention, the edible container further comprises unbleached wheat flour, sugar, fat, and salt, preferably with a concentration of 35.6% to 63% by weight of unbleached wheat flour, 9.2% to 12.4% by weight of sugar, 4.8% to 5.5% by weight of fat, and 0.3% to 0.8% by weight of salt.

[0014] In another embodiment of the invention, the upcycled oat protein in the edible container is oat milk powder, which preferably contains about 20% fiber and 50% protein. [Brief explanation of the drawings]

[0015] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more exemplary aspects of the disclosure and, together with the detailed description, serve to explain the principles and implementations thereof.

[0016] [Figure 1] FIG. 1 is a side view of an edible container according to one embodiment of the present invention. [Figure 2] FIG. 2 is a top view of the edible container shown in FIG. [Figure 3] 1 is a flowchart illustrating a manufacturing process according to a preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] Exemplary aspects of the present invention are described herein. Those skilled in the art will understand that the following description is illustrative only and is not intended to be limiting in any way. Other aspects will readily suggest themselves to those skilled in the art having the benefit of this disclosure. Reference will now be made in detail to embodiments of the exemplary aspects as illustrated in the accompanying drawings. Wherever possible, the same reference indicators will be used throughout the drawings and the following description to represent the same or similar items.

[0018] The present invention is directed to an edible, biodegradable container made from upcycled grain that can hold hot or cold liquids for extended periods of time. The container can be easily molded into different shapes and sizes and does not require a separate coating process to extend the time it maintains its structural integrity when exposed to liquids. The container is made essentially from natural materials that are safe to eat, making it a tasty alternative to disposable containers that would otherwise be sent to landfills. The container can be eaten while consuming its contents. The edible container can be used at parties and events in place of disposable containers, or in other situations where disposable containers are typically used or where additional nutritional intake is desired.

[0019] The edible container, an example of which is configured as a drinking cup, is made from brewer's grains, upcycled oat protein, and starch. The starch is preferably selected from wheat starch, potato starch, tapioca starch, corn starch, arrowroot starch, and the like. The edible container may also further comprise unbleached wheat flour, sugar, fat, and salt. The fat is preferably selected from partially hydrogenated vegetable oil, coconut oil, palm kernel oil, avocado oil, olive oil, grapeseed oil, sunflower oil, almond oil, hemp seed oil, hazelnut oil, butter, and the like.

[0020] In a preferred embodiment, the brewer's spent grains have a fiber fraction of 40-60% and a protein fraction of 20-30% of the total brewer's spent grains, and the upcycled oat protein is preferably oat milk powder. Essential amino acids may comprise approximately 30% of the total protein in the brewer's spent grains.

[0021] In addition, brewer's grains preferably contain significant amounts of vitamins, including folic acid, niacin, biotin, thiamine, choline, pantothenic acid, riboflavin, and pyridoxine, as well as tocochromanols, such as tocotrienols and tocopherols (commonly known as vitamin E). Preferably, the most abundant minerals in brewer's grains are calcium (e.g., at 3600 mg / kg), magnesium (e.g., at 1900 mg / kg), phosphorus (e.g., at 6000 mg / kg), and sodium (e.g., at 2900 mg / kg). Other minerals present in brewer's grains may include iron, copper, potassium, and manganese.

[0022] Brewer's grains are preferably low in carbohydrates, with most of the sugars removed during the initial mashing process for fermentation. As a result, brewer's grains preferably have 12 times the fiber, twice the protein, and one-third the carbohydrates compared to standard all-purpose flour. When baked, brewer's grains develop a malty brown color and have flavors like nuts, caramel, and almonds.

[0023] In a preferred embodiment, the upcycled oat protein is oat milk powder, a high-protein, high-fiber, gluten-free product made from the nutritious oat pulp left over from oat milk production, which, when baked, develops a light brown, oaty, slightly sweet, butterscotch-like flavor.

[0024] The oat milk powder preferably contains about 20% fiber and approximately 50% protein.

[0025] In a typical embodiment, the edible container comprises 18% to 30% by weight of brewer's spent grains, 7% to 13% by weight of upcycled oat protein, and 5% to 7% by weight of starch.

[0026] In a preferred embodiment, the total weight of the brewer's spent grains and the upcycled oat protein is 26% by weight or more, preferably 26% to 77% by weight, and most preferably 26% to 35% by weight of the total weight of the edible container. In a further embodiment, the unbleached wheat flour described above can be excluded and replaced with an additional proportion of the brewer's spent grains and the upcycled oat protein. In such a further embodiment, the total weight of the brewer's spent grains and the upcycled oat protein can be 77% by weight or less of the total weight of the edible container.

[0027] In another preferred embodiment, the ratio of brewer's grains to oat protein is about 11:9.

[0028] Unlike other edible containers that require coatings to be liquid-resistant, the edible container of the present invention achieves its moisture-resistant barrier properties by using a combination of materials and baking under high heat and pressure to form a glass-like structure. As used herein, "glass-like structure" refers to a crystalline structure created by a combination of pressure, heat, and steam that causes a chemical reaction between the lignin and hemicellulose in the brewer's grains. To achieve a sufficiently high degree of crystallinity, and therefore a structure with glass-like properties, a baking temperature of 356°F to 392°F is most preferred, and the moisture level of the finished edible container is preferably 10% or less.

[0029] A method for forming an edible container will now be described with reference to the flowchart of FIG. 3. First, a dough is formed by mixing ingredients including water, 25% to 35% by weight of brewer's spent grains, 9.7% to 20% by weight of upcycled oat protein, and 4.5% to 6.5% by weight of starch. The dough may also include 28% to 40% by weight of unbleached wheat flour, 6% to 8% by weight of sugar, 3.3% to 4% by weight of fat, and 0.2% to 0.5% by weight of salt. As mentioned above, if the unbleached wheat flour is omitted, it is replaced with additional percentages of brewer's spent grains and upcycled oat protein. In such further embodiments, the total weight of the brewer's spent grains and upcycled oat protein may reach 58% by weight of the total weight of the dough.

[0030] The dough is then formed into an appropriately sized ball and placed into a baking mold. This process is called "dosing." For example, for a 100 ml cup, the dosing ranges from 28 grams to 30 grams. If the mass of the dough ball exceeds this range, overdosing occurs, resulting in too much pressure in the mold, creating a large hole in the cup and causing the dough to blow out of the mold. If the mass of the dough ball falls below this range, underdosing occurs, resulting in the mold cavity not being filled and an incomplete cup being formed. Those skilled in the art will understand that the shape of the baking mold will substantially correspond to the desired finished shape of the edible container, and the amount of dough used will be selected based on the shape and size of the mold.

[0031] After being placed in a mold, the dough is baked under high heat and pressure to form an edible container. Preferably, the baking temperature ranges from 356°F to 392°F, the pressure ranges from 90 to 120 psi, and the baking time ranges from 150 to 180 seconds. This high-heat, high-pressure process used to form the edible container effectively converts the components in the brewer's grains, such as hemicellulose, cellulose, and lignin, into a glass-like structure. This glass-like structure allows the edible container to retain liquid for up to 24 hours without structural deterioration and resulting leakage, providing a structure that can retain hot liquids, having an initial temperature of 185°F to 212°F, for at least 4 hours, preferably at least 24 hours, before the edible container's structural integrity deteriorates and the liquid can no longer be held therein. The finished edible container preferably has a moisture level of 10% or less.

[0032] Figure 1 is a side view and Figure 2 is a top view of a formed edible container according to a preferred embodiment of the present invention. While the above has been described in conjunction with exemplary embodiments, it is understood that the term "exemplary" is meant merely as an example. Those skilled in the art can appreciate from the above description that the present invention can be embodied in a variety of forms. For example, the doughs and corresponding molds described herein can be used to make a variety of edible and degradable articles, such as kitchen utensils (forks, spoons, knives, etc.), drinking straws, travel covers for containers, plates, etc.

[0033] Thus, while embodiments of the present invention have been described in connection 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 review of this specification. Such modifications and variations are considered to be within the scope and range of the appended claims and their equivalents.

Claims

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

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

3. 2. The edible container of claim 1, wherein the ratio of the brewer's spent grains to the upcycled oat protein is about 11:

9.

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

5. 5. The edible container of claim 4, wherein the unbleached wheat flour has a concentration of 35.6% to 63% by weight, the sugar has a concentration of 9.2% to 12.4% by weight, the fat has a concentration of 4.8% to 5.5% by weight, and the salt has a concentration of 0.3% to 0.8% by weight.

6. 2. The edible container of claim 1, wherein the brewer's spent grains have a fiber fraction of 40-60% and a protein fraction of 20-30% of the total brewer's spent grains.

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

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

9. 10. The edible container of claim 1, wherein the container is capable of containing liquids at an initial temperature ranging from 185°F to 212°F for at least four hours before deteriorating.

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

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

12. 11. The method for producing an edible container according to claim 10, wherein the ratio of the brewer's spent grains to the upcycled oat protein is about 11:

9.

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

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

15. 11. The method for producing an edible container according to claim 10, wherein the brewer's spent grains have a fiber fraction of 40-60% and a protein fraction of 20-30% of the total brewer's spent grains.

16. 11. The method of manufacturing an edible container of claim 10, wherein the upcycled oat protein is oat milk powder.

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

18. 11. The method of manufacturing an edible container according to claim 10, wherein the container is capable of containing liquids at an initial temperature ranging from 185°F to 212°F for at least four hours before deteriorating.

19. 11. The method of manufacturing an edible container of claim 10, wherein said baking of said dough is conducted under pressure and temperature sufficient to form said dough into a glass-like structure.

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