Sprouted popcorn and method for making sprouted popcorn

Patent metadata

Field	Value
Publication number	US-12089622-B2
Application number	US-202318500725-A
Country	US
Kind code	B2
Filing date	Nov 2, 2023
Priority date	Dec 21, 2018
Publication date	Sep 17, 2024
Grant date	Sep 17, 2024

Abstract

Systems and methods for producing sprouted popcorn kernels are provided, which can be popped into sprouted popped popcorn having unique organoleptic qualities. In an embodiment, a system incorporates a germination unit having one or more sensors to track the germination progress of unsprouted popcorn kernels and to automatically transition sprouted popcorn kernels to a drying process to provide dried sprouted popcorn kernels suitable for popping as a ready to eat product or for packaging for consumer popping preparation. The system promotes the preparation of commercial scale sprouted popcorn kernels through tracking of moisture content of the popcorn kernels through one or more processes of sprouted popcorn kernel production.

First claim

What is claimed is:

1. A method for producing sprouted popcorn kernels comprising:
receiving a charge of at least 100 lbs. of unsprouted popcorn kernels and a volume of soaking fluid;
covering the charge of unsprouted popcorn kernels with the soaking fluid until a moisture content of the charge of unsprouted popcorn kernels by weight is from about 25% to about 35%;
separating the soaked unsprouted popcorn kernels from the soaking fluid;
germinating the soaked unsprouted popcorn kernels in a germination unit to produce sprouted popcorn kernels without acrospire formation;
detecting a germination progress of the popcorn kernels in the germination unit with a germination sensor;
generating an output signal from the germination sensor in response to detection of the germination progress;
transmitting the output signal from the germination sensor to a computer controller;
comparing, via computer controller, the output signal to reference germination thresholds to determine whether the output signal meets or exceeds at least one reference germination threshold; and
drying the sprouted popcorn kernels to a moisture content by weight from about 14% to about 16% responsive to instructions from the computer controller when the output signal from the germination sensor meets or exceeds at least one reference germination threshold.

2. The method of claim 1 , further comprising transmitting an output signal from a moisture sensor measuring the moisture content of the charge of unsprouted popcorn kernels to the computer controller.

3. The method of claim 2 , wherein the computer controller initiates separation of the soaked unsprouted popcorn kernels from the soaking fluid when the output signal from the moisture sensor indicates a moisture content of the charge of unsprouted popcorn kernels by weight from about 29% to about 33%.

4. The method of claim 1 , wherein germinating the soaked unsprouted popcorn kernels in a germination unit to produce sprouted popcorn kernels includes germinating the soaked unsprouted popcorn kernels in the germination unit to produce sprouted popcorn kernels having a moisture content by weight from about 30% to about 35%.

5. The method of claim 1 , wherein detecting a germination progress of the popcorn kernels in the germination unit with a germination sensor includes measuring an opacity of a hull of popcorn kernels held within the germination unit, and wherein the reference germination thresholds include a hull opacity measurement prior to acrospire formation.

6. The method of claim 1 , wherein detecting a germination progress of the popcorn kernels in the germination unit with a germination sensor includes measuring a moisture content of popcorn kernels held within the germination unit, and wherein the reference germination thresholds include a moisture content of sprouted popcorn kernels prior to acrospire formation.

7. The method of claim 1 , wherein detecting a germination progress of the popcorn kernels in the germination unit with a germination sensor includes measuring an opacity of a hull of popcorn kernels held within the germination unit, and when the computer controller determines the output signal meets or exceeds at least one reference germination threshold, the computer controller instructs a moisture sensor to measure a moisture content of popcorn kernels held within the germination unit.

8. The method of claim 1 , wherein covering the charge of unsprouted popcorn kernels with the soaking fluid until a moisture content of the charge of unsprouted popcorn kernels by weight is from about 25% to about 35% includes an activation step and a steeping step, wherein the activation step includes soaking the charge of unsprouted popcorn kernels in the soaking fluid at a temperature of between about 30° ° C. to about 60ºC for a duration of about 15 minutes to about 120 minutes, and wherein the steeping step includes soaking the charge of unsprouted popcorn kernels in the soaking fluid at a temperature of between about 20° C. to about 30° C. for a duration of about 4 hours to about 8 hours.

9. The method of claim 1 , wherein receiving a charge of at least 100 lbs. of unsprouted popcorn kernels includes receiving a charge of at least 100 lbs. of unsprouted popcorn kernels having a moisture content by weight of about 10% to about 16%.

10. The method of claim 1 , further comprising decontaminating the charge of unsprouted popcorn kernels prior to covering the charge of unsprouted popcorn kernels with the soaking fluid.

11. A method for producing sprouted popcorn kernels comprising:
receiving a charge unsprouted popcorn kernels and a volume of soaking fluid;
covering the charge of unsprouted popcorn kernels with the soaking fluid until a moisture content of the charge of unsprouted popcorn kernels by weight is from about 25% to about 35%;
separating the soaked unsprouted popcorn kernels from the soaking fluid;
germinating the soaked unsprouted popcorn kernels in a germination unit to produce sprouted popcorn kernels without acrospire formation;
detecting a germination progress of the popcorn kernels in the germination unit with a germination sensor by measuring an opacity of a hull of popcorn kernels held within the germination unit;
generating an output signal from the germination sensor in response to detection of the germination progress;
transmitting the output signal from the germination sensor to a computer controller;
comparing, via computer controller, the output signal to reference germination thresholds to determine whether the output signal meets or exceeds at least one reference germination threshold, wherein the reference germination thresholds include a hull opacity measurement prior to acrospire formation; and
drying the sprouted popcorn kernels to a moisture content by weight from about 14% to about 16% responsive to instructions from the computer controller when the output signal from the germination sensor meets or exceeds at least one reference germination threshold.

12. The method of claim 11 , further comprising transmitting an output signal from a moisture sensor measuring the moisture content of the charge of unsprouted popcorn kernels to the computer controller.

13. The method of claim 12 , wherein the computer controller initiates separation of the soaked unsprouted popcorn kernels from the soaking fluid when the output signal from the moisture sensor indicates a moisture content of the charge of unsprouted popcorn kernels by weight from about 29% to about 33%.

14. The method of claim 11 , wherein germinating the soaked unsprouted popcorn kernels in a germination unit to produce sprouted popcorn kernels includes germinating the soaked unsprouted popcorn kernels in the germination unit to produce sprouted popcorn kernels having a moisture content by weight from about 30% to about 35%.

15. The method of claim 11 , wherein when the computer controller determines the output signal meets or exceeds at least one reference germination threshold, the computer controller instructs a moisture sensor to measure a moisture content of popcorn kernels held within the germination unit.

16. The method of claim 11 , wherein covering the charge of unsprouted popcorn kernels with the soaking fluid until a moisture content of the charge of unsprouted popcorn kernels by weight is from about 25% to about 35% includes an activation step and a steeping step, wherein the activation step includes soaking the charge of unsprouted popcorn kernels in the soaking fluid at a temperature of between about 30° ° C. to about 60ºC for a duration of about 15 minutes to about 120 minut

Assignees

• Conagra Foods Rdm Inc

Inventors

• Castrale Melissa
• Wassinger Andrew
• Pedro Aghogho
• David Jairus R D

Classifications

• A23L7/161

  Puffed cereals, e.g. popcorn or puffed rice · CPC title

• G01N27/223

  for determining moisture content, e.g. humidity (rain detectors on vehicle windows B60S1/0825) · CPC title

• A23L7/20

  Malt products (preparation of malt for brewing C12C) · CPC title

• A23P30/30

  Puffing or expanding · CPC title

• A23P30/38

  by heating (combined with pressure release or vacuum treatment A23P30/32) · CPC title