Process of producing rottable thin-walled shaped bodies made of

Details Process of producing rottable thin-walled shaped bodies made of Process of producing rottable thin-walled shaped bodies made of

1992-07-30

1994-12-27

Kuhns, Allan R.

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

By mechanically introducing gas into material

264232, 264259, 264300, B29C 6724

Patent

active

053763203

DESCRIPTION:

BRIEF SUMMARY
This invention relates to a process of producing rottable thin-walled shaped bodies, in which a baking composition made of starch is applied to the lower mold half of a composite, preferably bipartite, mold, the closed mold is heated to bake the shaped body, and the baked product is subsequently conditioned.
The process in accordance with the invention can be used to make, e.g., the following shaped bodies: Cups, plates, fast-food packages, package inserts, so-called trays, paper- and cardboardlike sheets and webs-e.g. for use as insert sheets in boxes of chocolates-or for retaining lumps in packages or as a basic material for composite materials to be used for packaging, e.g., as more or less regularly shaped small bodies for use in combination with plastics, e.g., as a filling material for protecting packaged goods against shocks, like the known Styropor chips.
For the purposes of the present invention the term "thin-walled" indicates the thickness of a wall which resists fracture and cracking in its intended use and which can still be baked between two mold halves on conventional automatic wafer-baking machines (see, e.g., U.S. Pat. Nos. 4,438,685 and 4,648,314 and Published German Patent Application 3,346,970).
Those products of the above-mentioned kind which are presently on the market consist mainly of plastic and/or paper and are made from a raw material consisting of petroleum or wood. Rapidly growing plants, such as starch or oil plants, have not yet been used as a main raw material for making such products, which in a broader sense might be described as packaging materials. For instance, plant starches, plant oils and plant fats are globally available as industrial raw materials beyond nutritional requirements.
Specifically, starch is an interesting starting material, which can be reacted to swell and to be cross-linked and can be heated in physical and chemical processes to form consolidated structures, such as are known from baked products, e.g., in the crust of bread.
In the field of durable baked products, edible wafers made in the form of sheets (flat wafers, paper-thin wafers), cornets, cups, etc. constitute products which may be used for packaging functions, e.g., for ice cream, but owing to their typical properties-they are crisp, fragile, brittle and susceptible to moisture and to oxidation-cannot comply with several essential requirements to be met by a package as regards stability and protective function.
Edible wafers are made in accordance with various recipes, which are known from the patent literature and the technical literature (see, e.g., DE 17 82 502; DE 29 29 496; DE 32 39 871; P.E. Pritchard, A. H. Emery, D. J. Stevens (1975) The Influence of Ingredients on the Properties of Wafer Sheets in FMBRA Report No. 66; D. J. R. Manley, Technology of Biscuits, Crackers and Cookies, Ellis Horwood Limited, 1983, pages 222 et seq.; E. Winter, CCB Rev. Chocolate, Confectionary & Baking, 5 (3), 19; (1980).
In the recipes for the baking of wafers, wheat flour and water are called for in major amounts in addition to a number of minor ingredients, which are essential for the making of that product:
Leavening: Sodium hydrogen carbonate is used in an amount of 0.2 to 0.8% of the flour employed. Part of it may be replaced by ammonium hydrogen carbonate, or yeast may also be used.
Fats: Fats/oils must be used in an amount of 1 to 3% based on the amount of flour in order to facilitate the removal of the wafers from the baking mold (release agent). Magnesia is also sometimes recommended for that purpose but owing to its basic nature may give rise to problems regarding the stability of the baked products.
Lecithin: Lecithin is used in the making of wafers as an emulsifying agent and when used in a larger amount may also be regarded as a release agent.
In such recipes, oils and fats are used mainly not for reasons of taste but are required to prevent a sticking to the baking mold. Lecithin also facilitates the removal from the mold and emulsifies the oil/fat content in the aqueous wafer-baking compos

REFERENCES:
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patent: 3268338 (1966-08-01), Strobel
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Chem. Abstract, vol. 107, 1987, p. 107.
Chem. Abstract, vol. 96, 1982, p. 574.

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