FIELD OF THE INVENTION

The present invention relates to edible devices and in particular to edible devices for engaging comestible goods. The invention further relates to methods of producing such edible devices. Embodiments of the invention have been particularly developed as pieces of cutlery and or tableware, which themselves can be consumed by the user and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

BACKGROUND OF THE INVENTION

Any discussion of the background art throughout the specification should in no way be considered as an admission that such art is widely known or forms part of common general knowledge in the field

Disposable single-use plastic items, such as disposable single-use plates, cutlery, straws and stirrers pose a great environmental burden due to their slow rate of decomposition. In particular, the accumulation of plastic waste from such disposable items in seas, oceans and on beaches as well as the contamination of major food sources with micro plastics has led many countries around the globe to enact bans on the sale and production of such products.

In addition, single-use plastic devices for engaging comestible goods contain several chemical complexes known to leach into the comestible goods, in particular into food and beverages. As such, use of plastic devices for engaging comestible goods bears the risk of ingestion of carcinogenic and neural-toxic compounds by the user.

Alternative non-plastic disposable devices for engaging comestible goods are well known. For example, disposable devices made out of wood, such as wooden cutlery, are being used by fast food and take-away food retailers in an attempt to circumvent the use of disposable plastic items. However, disposable wooden devices often have relatively rough surfaces and therefore suffer from unpleasant mouthfeel. In addition, such devices are regularly not taste-neutral. These deficiencies can only be avoided through further processing and machining of the wooden devices, which in turn leads to unfavourable production costs for mass-produced disposable items.

Furthermore, even the use of non-plastic disposable items adds to the general waste burden. As such, non-plastic disposable items, which are themselves edible, have been developed such that they may be consumed together with the comestible good that they are being used to engage. Notwithstanding, many edible devices are not suitable to engage a variety of comestible goods and suffer stability problems even during the duration of use. In addition, edible devices are often also not taste-neutral. Accordingly, there is a need in the art for improved non-plastic, disposable devices for engaging comestible goods as well as for improved methods of their production.

It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative. In particular, it is an object of the present invention to provide improved non-plastic, disposable devices for engaging comestible goods as well as for improved methods of their production.

SUMMARY OF THE INVENTION

To provide improved non-plastic, disposable devices for engaging comestible goods, the inventors have developed devices for engaging comestible goods, for example, cutlery, stirrers and paddle pop sticks, which can easily be mass produced and are themselves edible, such that they can be disposed of by consumption by the user.

Accordingly, in a first aspect, the present invention relates to an edible device for engaging comestible goods, preferably edible cutlery, comprising: a handling surface; and at least one comestible good engaging portion, characterised in that the device has a total moisture content of less than 4 % (w/w).

In a second aspect, the present invention relates to a process for the production of an edible device for engaging comestible goods, preferably edible cutlery, said process comprising the steps of:

(a) providing all solid ingredients in the form of a powder with a particle size of 75 to 115 pm, if required grinding solid ingredients to a particle size of 75 to 115 pm, wherein said solid ingredients comprise at least:

- 75 to 85 % (w/w) of a base material;

- 7.5 to 13 % (w/w) of a thickening and/or stabilising agent; and - 0.05 to 2.5 % (w/w) of a leavening agent;

(b) providing 0.5 to 4 % (w/w) of vegetable oil as a liquid ingredient;

(c) providing an amount of water, which corresponds in weight to 25 to 40 % (w/w) of all solid and liquid ingredients ingredients;

(d) mixing the solid and liquid ingredients with the water to form a dough mixture;

(e) rolling the dough mixture into one or more sheets of a first thickness,

(f) compacting the one or more sheets of a first thickness either prior to or during baking, wherein, i. when the sheets of a first thickness are compacted prior to baking, they are compacted such as to obtain compacted sheets of a second thickness, wherein said second thickness ranges between 60 and 87 % of the first thickness, the compacted sheets are subsequently placed into moulds corresponding to the shape of the device to be produced; and ii. when the sheets of a first thickness are compacted during baking, the sheets of a first thickness are placed into moulds corresponding to the shape of the device to be produced prior to baking and a predetermined pressure ranging from 2000 to 3250 N/m ² is applied to the moulds during baking; and

(g) baking at a temperature ranging between 120 and 250°C.

Finally, the edible device produced by the process of the second aspect is a device according to the first aspect.

FIGURES

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Fig. 1 shows a planar embodiment of the edible device of the present invention, namely, (a) a top view, (b) a side view and (c) a perspective view of an edible chip fork.

Fig. 2 shows another planar embodiment of the edible device of the present invention, namely, (a) a top view, (b) a side view and (c) a perspective view of an edible paddle pop stick.

Fig.3 shows yet a further planar embodiment of the edible device of the present invention, namely, (a) a top view, (b) a side view and (c) a perspective view of an edible, tapered paddle pop stick. Fig.4 shows a 3-dimensionally shaped embodiment of the edible device of the present invention, namely, (a) a top view, (b) a side view, (c) a bottom view and (c) a perspective view of an edible spoon.

Fig.5 shows another 3-dimensionally shaped embodiment of the edible device of the present invention, namely, (a) a top view, (b) a side view, (c) a bottom view and (c) a perspective view of an edible spork.

Fig.6 is a diagram illustrating the arrangement of a 3-dimensionally shaped embodiment of the edible device of the present invention, namely of an edible spoon, during the bend test applied to determine the breaking force of the device.

Fig.7 is a flow diagram illustrating the sequence of steps performed during an embodiment of the process of producing an edible device in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As already indicated above, to provide improved non-plastic, disposable devices for engaging comestible goods, the inventors have developed devices for engaging comestible goods, for example cutlery, stirrers and paddle pop sticks, which can be mass produced and are themselves edible, such that they can be disposed of by consumption by the user.

Accordingly, in a first aspect, the present invention relates to an edible device for engaging comestible goods, preferably edible cutlery, comprising: a handling surface; and at least one comestible good engaging portion, characterised in that the device has a total moisture content of less than 4 % (w/w).

In some embodiments, the edible device of the first aspect is characterised in that it has a total moisture content of between 1 and 4 % (w/w) or between 1.5 and 4 % (w/w) or between 2 and 4 % (w/w) or between 2.5 and 4 %(w/w) or between 3 and 4 % (w/w) or between 3.5 and 4 % (w/w) or between 1.5 and 3.5 % (w/w) or between 1.5 and 3 % (w/w) or between 1.5 and 2.5 % (w/w) or between 1.5 and 2 % (w/w) or between 1.5 and 3.5 % (w/w) or between 2 and 3 % (w/w) or between 2.5 and 3 % (w/w).

Having a total moisture content in the above-described ranges provides the edible device with a favourable material strength. The edible device of the first aspect, in particular the embodiments described above, may further be characterised in that it has a material strength with a breaking force of at least 8 N per 66 mm ² area cross section. Typically, the breaking force ranges between 8 and 18 N per 66 mm ² area cross section or between 8 and 16 N per 66 mm ² area cross section or between 8 and 14 N per 66 mm ² area cross section or between 8 and 12 N per 66 mm ² area cross section or between 8 and 10 N per 66 mm ² area cross section or between 10 and 18 N per 66 mm ² area cross section or between 12 and 18 N per 66 mm ² area cross section or between 14 and 18 N per 66 mm ² area cross section or between 16 and 18 N per 66 mm ² area cross section or between 8 and 16 N per 66 mm ² area cross section or between 10 and 14 N per 66 mm ² area cross section or between 6 and 10 N per 36 mm ² area cross section or between 8 and 10 N per 36 mm ² area cross section.

The breaking force of the devices of the present invention is determined in a bending test, typically a three-point bend test. To this end, the device is mounted in longitudinal direction in a fixture such that the two opposing ends of the longitudinal axis are fixed and an increasing downward force is applied at about half the length of the device, i.e. substantially in the middle between the two fixed ends (see Figure 6), until the device breaks into two parts. The force at which the device breaks determines the breaking force. In devices having discernible horizontal and vertical dimensions, the device is fixed in the fixture such that the load is applied on to the broader/wider one. For example, a knife would be fixed such that the load is applied to one of its lateral sides. In devices, where the broader dimension has a discernible top and bottom side, wherein the top side is defined as the side of the device holding or receiving the comestible good during use, the downward force is applied to the top side.

Furthermore, the edible device of the first aspect, in particular the embodiments described above, may be characterised in that it has a density of at least 5 g per cm ³ . Typically, the device has a density of between 5 and 15 g per cm ³ , such as between 6 and 15 g per cm ³ or between 7 and 15 g per cm ³ or between 8 and 15 g per cm ³ or between 9 and 15 g per cm ³ or between 10 and 15 g per cm ³ or between 11 and 15 g per cm ³ or between 12 and 15 g per cm ³ or between 13 and 15 g per cm ³ or between 14 and 15 g per cm ³ or between 5 and 14 g per cm ³ or between 5 and 13 g per cm ³ or between 5 and 12 g per cm ³ or between 5 and 11 g per cm ³ or between 5 and 10 g per cm ³ or between 5 and 9 g per cm ³ or between 5 and 8 g per cm ³ or between 5 and 7 g per cm ³ or between 5 and 6 g per cm ³ or between 6 and 14 g per cm ³ or between 7 and 13 g per cm ³ or between 8 and 12 g per cm ³ or between 9 and 11 g per cm ³ . Such density adds to the device’s material strength, in particular when used to engage liquid comestible goods, and can be achieved by applying a predetermined pressure ranging from 2000 to 3250 N/m ² during the production process as will be further described below. In addition, the devices of the present invention, when produced under the application of pressure have a smooth surface finish and low porosity, such that the smooth surface finish is retained even when engaging liquid comestible goods. As a result, the devices of the present invention have a favourable mouth feel.

Furthermore, the devices of the present invention, in particular the embodiments described above, are neutral in taste in relation to the comestible good being engaged. As such, during the engagement of a comestible good for consumption by a user, the devices of the present invention of the first aspect, in particular the embodiments described above, do not alter or influence the taste of the comestible good and/or do not produce an aftertaste. Notwithstanding, when the edible device is itself chewed for consumption, the device’s own taste is released. This advantageous feature of the devices of the present invention allows flavouring of the device itself by adding flavouring agents during the device’s production as will be described below but ensures that this flavour is only released when the device is broken up such as through being chewed during consumption by the user.

As such, in the embodiments of the first aspect of this invention, a flavoured, edible device is advantageously provided, which does not leach its flavour when engaging with a comestible good but itself is tasty when consumed. For example, the edible device may be a chocolate or vanilla flavoured spoon, which can be used to engage a comestible good such as soup or ice cream to be consumed and which subsequent to the consumption of the comestible good by the user can itself serve as post-meal confectionary or dessert.

In light of the above, it will be appreciated that the edible device of the above- described embodiments of the first aspect may further be characterised in that the device itself has a nutritional value of at least 200 kcal per 100 g. Typically, the device itself has nutritional value of between 200 and 500 kcal per 100g, such as between 240 and 440 kcal per 100g or between 240 and 400 kcal per 100g or between 240 and 380 kcal per 100g or between 240 and 360 kcal per 100g or between 240 and 340 kcal per 10Og or between 240 and 320 kcal per 10Og or between 240 and 300 kcal per 100g or between 240 and 280 kcal per 100g or between 240 and 270 kcal per 100g or between 240 and 250 kcal per 100g or between 250 and 400 kcal per 100g or between 260 and 400 kcal per 100g or between 280 and 400 kcal per 100g or between 300 and 400 kcal per 100g or between 320 and 400 kcal per 100g or between 340 and 400 kcal per 100g or between 360 and 400 kcal per 100g or between 380 and 400 kcal per 100g or between 250 and 430 kcal per 100g or between 260 and 420 kcal per 100g or between 270 and 410 kcal per 100g or between 280 and 400 kcal per 100g or between 290 and 390 kcal per 100g or between 300 and 380 kcal per 100g or between 310 and 370 kcal per 100g or between 320 and 360 kcal per 100g or between 330 and 350 kcal per 100g. In particular embodiments, the device itself has a nutritional value of about 265, of 340 or of 398 kcal per 100g. As such, the edible device itself is a food item and a source of nutrition for the user, thereby increasing the incentive for the user to consume the device while avoiding the production of waste or litter.

Further, the edible device of the above-described embodiments of the first aspect may be characterised in that the comestible good engaging portion is planar or is 3- dimensionally (3-D) shaped. As such, the comestible good engaging portion or the entire device - while being a three-dimensional portion or object perse, i.e. a portion or object having a length, a width and a height - may nevertheless be planar. In this context, “planar” means that the portion or object is substantially flat and not intentionally 3-dimensionally (3-D) shaped. For example, the well-known disposable chip fork or paddle pop stick resemble devices with a planar comestible good engaging portion, while a spoon resembles a device having a 3-D shaped comestible good engaging portion, preferably a portion suitable for scooping a liquid comestible good such as a soup.

Particularly, the edible device of the first aspect may be selected from the group consisting of: spoons; forks, preferably chip forks; knives; chopsticks; skewers; tongs; straws; stirrers, preferably coffee stirrers; picks; dippers; and sticks or spades, preferably dipping sticks, lollipop sticks, paddle pop sticks or popsicle sticks.

Additionally, the edible device of the first aspect may be a combination utensil having more than one engaging portions such as:

• chopforks - devices having an intermediary handling surface and a first comestible good engaging portion in the form of the comestible good engaging portion of a fork at one end and second and third comestible good engaging portions forming a pair of chopsticks/tongs at the other;

• pastry forks - devices, wherein the comestible good engaging portion is in the form of the comestible good engaging portion of a fork with a cutting/parting edge along one of the tines;

• chorks - devices, which are pointed and slightly curved tongs having two comestible good engaging portions with an intermediary handling surface and a further comestible good engaging portion at the other end, wherein this further portion is in the form of the comestible good engaging portion of a fork (in some embodiments, the chork may have a frangible portion such that it can be split/broken along its longitudinal axis to produce a pair of chopforks;

• forkchops - pairs of devices, which in general provide a pair of chopsticks each with an intermediary handling surface and a pointed comestible good engaging portion at one end and with each respective member of the pair having a further comestible good engaging portion at the other end, wherein one member has a further comestible good engaging portion in the form of a knife’s blade and the other has a further comestible good engaging portion in the form of the comestible good engaging portion of a fork;

• knorks - devices, wherein the comestible good engaging portion is in the form of the comestible good engaging portion of a fork with a cutting edge (often serrated) along one of the tines;

• spoon straws - devices, which are drinking straws having an additional spoon like comestible good engaging portion;

• sporfs - devices having an intermediary handling surface and two comestible good engaging portions at the opposing ends of the handling surface, wherein the first comestible good engaging portion is in the form of the comestible good engaging portion of a fork with a cutting edge (often serrated) along one of the tines and the second comestible good engaging portion is in the form of the comestible good engaging portion of a spoon;

• sporks - devices having a handling surface and a comestible good engaging portion generally in the form of the comestible good engaging portion of a spoon but wherein the distal end of the spoon portion also has a set of tines, thereby combining the features of a spoon and a fork;

• splaydes - devices having a handling surface and a comestible good engaging portion generally in the form of the comestible good engaging portion of a spoon but wherein the distal end of the spoon portion also has a set of tines with a cutting/parting edge along one of the tines, thereby combining the features of a spoon, a fork and a knife/blade; and

• spives - devices having either an intermediary handling surface and two comestible good engaging portions at the opposing ends of the handling surface, wherein the first comestible good engaging portion is in the form of the comestible good engaging portion of a spoon and the second comestible good engaging portion is in the form of the comestible good engaging portion of a knife or a handling surface and a single comestible good engaging portion at the one end wherein the single comestible good engaging portion is in the form of the comestible good engaging portion of a spoon with a cutting edge.

The edible device of the first aspect may be particularly adapted to maintain its material strength and/or density for at least the time of engaging the comestible good such as to allow a user to consume the comestible good using the device before consuming the device itself.

Specifically, in particular embodiments, the edible device of the first aspect is characterised in that the device:

- maintains its material strength and/or density for at least 15 minutes, typically for at least 15 to 60 minutes such as for 15 to 55 minutes or for 15 to 50 minutes or for 15 to 45 minutes or for 15 to 40 minutes or for 15 to 35 minutes or for 15 to 30 minutes or for 15 to 25 minutes or for 15 to 20 minutes, when engaging a comestible good, which has a temperature of from about -10°C to about +5°C, preferably the comestible good is ice cream about to be consumed; or

- after having been stored below 0°C, preferably at about -20°C, for at least 6 months such as for 12 months or more or for 6 to 18 months or for 9 to 18 months or for 12 to 18 months, maintains its material strength and/or density for at least 15 minutes, typically for at least 15 to 60 minutes such as for 15 to 55 minutes or for 15 to 50 minutes or for 15 to 45 minutes or for 15 to 40 minutes or for 15 to 35 minutes or for 15 to 30 minutes or for 15 to 25 minutes or for 15 to 20 minutes, when engaging a comestible good having a temperature of from about -10°C to about +5°C, preferably the comestible good is ice cream about to be consumed; or

- maintains its material strength and/or density for at least 3 minutes, preferably for at least 3 to 5 minutes, when engaging a hot liquid comestible good, preferably the hot liquid comestible good is a hot beverage, which has a temperature of up to 80°C; or

- maintains its material strength and/or density for at least 40 minutes, typically for between 40 to 50 minutes, when engaging a hot comestible good, preferably the hot comestible good is a deep fried comestible good such as French fries, which has a temperature of up to 80°C; or

- maintains its material strength and/or density for at least 10 minutes, typically for at least 10 to 40 minutes such as for 10 to 35 minutes, or for 10 to 30 minutes or for 10 to 25 minutes or for 10 to 20 minutes or for 10 to 15 minutes or for 15 to 40 minutes or for 20 to 40 minutes or for 25 to 40 minutes or for 30 to 40 minutes or for 35 to 40 minutes, when engaging a hot comestible good, which has a temperature of up to 100°C, preferably for at least 10 to 15 minutes the hot comestible good is a hot soup or for at least 30 to 40 minutes when hot comestible good is hot solid food.

In the second aspect, the present invention relates to a process for the production of an edible device for engaging comestible goods, preferably edible cutlery, said process comprising the steps of:

(a) providing all solid ingredients in the form of a powder with a particle size of 75 to 115 pm, if required grinding solid ingredients to a particle size of 75 to 115 pm, wherein said solid ingredients comprise at least:

- 75 to 85 % (w/w) of a base material;

- 7.5 to 13 % (w/w) of a thickening and/or stabilising agent; and

- 0.05 to 2.5 % (w/w) of a leavening agent;

(b) providing 0.5 to 4 % (w/w) of vegetable oil as a liquid ingredient;

(c) providing an amount of water, which corresponds in weight to 25 to 40 % (w/w) of all solid and liquid ingredients ingredients;

(d) mixing the solid and liquid ingredients with the water to form a dough mixture;

(e) rolling the dough mixture into one or more sheets of a first thickness,

(f) compacting the one or more sheets of a first thickness either prior to or during baking, wherein, i. when the sheets of a first thickness are compacted prior to baking, they are compacted such as to obtain compacted sheets of a second thickness, wherein said second thickness ranges between 60 and 87 % of the first thickness, the compacted sheets are subsequently placed into moulds corresponding to the shape of the device to be produced; and ii. when the sheets of a first thickness are compacted during baking, the sheets of a first thickness are placed into moulds corresponding to the shape of the device to be produced prior to baking and a predetermined pressure ranging from 2000 to 3250 N/m ² is applied to the moulds during baking; and

(g) baking at a temperature ranging between 120 and 250°C.

In some embodiments of the above process, in either step ((f)(i) or (f)(ii), a plurality of blanks of a desired shape are cut out of the sheets and, rather than placing sheets into the moulds, the blanks are placed into the moulds corresponding to the shape of the device to be produced.

Typically,

- the base material is selected from: wheat, corn, rice, sorghum, skinless mung beans, and combinations thereof;

- the thickening and/or stabilising agent is selected from: corn starch, pearl millet, tapioca, carboxy methyl cellulose, maltodextrin, edible gums such as xanthan and acacia gum, and combinations thereof; and

- the leavening agent is selected from: ammonium bicarbonate, sodium bicarbonate, and combinations thereof.

The solid ingredients are provided in the form of a powder with a particle size of 75 to 115 pm. In some embodiments, the particle size is: 75 to 110 pm; 75 to 105 pm; 75 to 100 pm; 75 to 90 pm; 75 to 85 pm; 75 to 80 pm; 75 to 100 pm; 80 to 115 pm; 85 to 115 pm; 90 to 115 pm; 95 to 115 pm; 100 to 115 pm; 105 to 115 pm; or 110 to 115 pm. With respect to the base material, it is typically provided in the form of pre-ground flour already having a particle size of the above-listed ranges.

The base material wheat is a rich source of various antioxidants, vitamins, minerals, and fibre. In the production process of the second aspect, wheat may be selected from hard wheat, soft/weak wheat and combinations thereof in order to adapt the gluten content of the edible device produced. Using soft/week wheat also aids the binding of all ingredients without unfavourably increasing the device’s hardness, i.e. without unfavourably affecting its chewability. Conversely, hard wheat is useful when the device’s hardness is to be increased. Wheat may constitute between 20 and 60 % or between 50 and 60 % or between 30 and 50 % or between 20 and 25 % of all solid and liquid ingredients

The base material corn is particularly rich in starch and zein. By varying the corn content in the overall recipe, the texture and surface finish of the device is varied. Corn may constitute between 2 and 17 % or between 12 and 17 % or between 2 and 5 % of all solid and liquid ingredients or may be absent.

The base material rice is particularly rich in amyloses. By varying the rice content in the overall recipe, the device’s hardness and thereby its chewability is varied. Rice may constitute between 3 and 25 % or between 3 and 4 % or between 12 and 16 % between 22 and 25 % of all solid and liquid ingredients.

The base material sorghum is substantially gluten-free. By varying the sorghum content in the overall recipe, and similar to varying the weak wheat content, the overall gluten content of the device is varied. In addition, sorghum adds nutritional value to the device as it contains antioxidants, vitamins and minerals. Sorghum may constitute between 5 and 32 % or between 5 and 7.5 % or between 15 and 20 % between 28 and 32 % of all solid and liquid ingredients.

The base material skinless mung beans (also known as skinless green gram) is particularly rich in protein. By varying the skinless mung bean content in the overall recipe, the nutritional value, in particular the protein content, of the device is varied. Skinless mung beans may constitute between 2 and 6.5 % or between 2 and 4 % or between 4 and 6.5 % of all solid and liquid ingredients or may be absent.

Corn starch is used as a thickening agent, which acts like an adhesive or binder keeping the ingredients together and, ultimately, increases the stability of the final device produced. Corn starch may constitute between 2 and 10 % or between 2 and 4 % or between 7 and 10 % of all solid and liquid ingredients or may be absent.

Similarly, pearl millet acts as an adhesive or binder but also contains useful amounts of phytates and polyphenols. By varying the pearl millet content in the overall recipe, the shelf life of the device is varied. Pearl millet may constitute between 1 and 7 % or between 4 and 7 % or between 1 and 3 % of all solid and liquid ingredients or may be absent.

Again similarly, maltodextrin is a thickening agent, which affects the shelf life of the device produced. Therefore, by varying the maltodextrin content in the overall recipe, the shelf life of the device is varied. Maltodextrin may constitute between 2 and 3.5 % of all solid and liquid ingredients or may be absent.

Tapioca is used as a thickening agent, which acts similar to corn starch and also increases the crispiness and chewability of the device produced. Tapioca may constitute between 2 and 7 % or between 4 and 7 % or between 2 and 4 % of all solid and liquid ingredients or may be absent.

Carboxy methyl cellulose acts as an emulsifier, which aids in stabilising the device being produced. Carboxy methyl cellulose may constitute between 0.01 and 0.05 % of all solid and liquid ingredients or may be absent.

Edible gums act as thickening agents while also aiding emulsification and binding of the ingredients. In particular, xanthan gum predominantly acts as a binder and stabilising agent increasing the device’s stability and acacia gum acts as thickening agent and emulsifier, which is particularly useful for binding and emulsifying the ingredients. In particular, acacia gum is useful to bind and emulsifying flavouring agents during the production process. Xanthan gum may constitute between 0.5 and 1 % of all solid and liquid ingredients or may be absent and acacia gum may constitute between 0.1 and 0.5 % of all solid and liquid ingredients or may be absent.

The leavening agent is preferably selected from: ammonium bicarbonate, sodium bicarbonate, and combinations thereof. Ammonium bicarbonate may constitute between 0.01 and 0.5 % or between 0.01 and 0.05 % or between 0.1 and 0.5 % of all solid and liquid ingredients or may be absent and sodium bicarbonate may constitute between 0.3 and 3 % or between 0.3 and 0.7 % or between 1.5 and 3 % of all solid and liquid ingredients or may be absent.

Preferably, regarding the solid and liquid ingredients provided in the process of all of the above-described embodiments of the second aspect,

- wheat constitutes between 20 and 60 % (w/w) of the solid and liquid ingredients; and/or

- corn constitutes present between 0 and 17 % (w/w) of the solid and liquid ingredients; and/or

- sorghum constitutes between 5 and 35 % (w/w) of the solid and liquid ingredients; and/or

- skinless mung beans constitute between 0 and 6.5 % (w/w) of the solid and liquid ingredients; and/or - corn starch constitutes between 0 and 10 % (w/w) of the solid and liquid ingredients; and/or

- pearl millet constitutes between 0 and 7 % (w/w) of the solid and liquid ingredients; and/or

- tapioca constitutes between 0 and 7 % (w/w) of the solid and liquid ingredients; and/or

- carboxy methyl cellulose constitutes between 0 and 0.05 % (w/w) of the solid and liquid ingredients; and/or

- maltodextrin constitutes between 0 and 3.5 % (w/w) of the solid and liquid ingredients; and/or

- xanthan gum constitutes between 0 and 1 % (w/w) of the solid and liquid ingredients; and/or

- acacia gum constitutes between 0 and 0.5 % (w/w) of the solid and liquid ingredients.

In some of the above-described embodiments, the solid ingredients further comprise: a nutritional component, preferably selected from: seeds, leaves, roots, and combinations thereof; dietary fibre, preferably wheat bran; and/or a flavouring agent, preferably selected from: salt, pepper, sugar vanilla, chocolate, paprika and combinations thereof.

Adding nutritional components increases the nutritional value of the device such that it may itself serve as food upon consumption.

Adding dietary fibre increases the overall stability of the product and provides dietary fibres to the user upon consumption of the device. In some embodiments of the production process of the second aspect, especially in the above-described embodiments thereof, between 0.25 and 9.5 % of wheat bran is added as a solid ingredient. Typically, between 0.3 and 9.5, between 0.4 and 9.5 %, between 0.5 and

9.5 %, between 1 and 9.5 %, between 1.5 and 9.5 %, between 2 and 9.5 %, between

2.5 and 9.5 %, between 3 and 9.5 %, between 3.5 and 9.5 %, between 4 and 9.5 %, between 4.5 and 9.5 %, between 5 and 9.5 %, between 5.5 and 9.5 %, between 6 and 9.5 %, between 6.5 and 9.5 %, between 7 and 9.5 %, between 7.5 and 9.5 % between 8 and 9.5 %, between 8.5 and 9.5 %, between 9 and 9.5 %, between 0.25 and 9, between 0.25 and 8.5 %, between 0.25 and 7 %, between 0.25 and 6.5 %, between 0.25 and 6%, between 0.25 and 5.5 %, between 0.25 and 5 %, between 0.25 and 4.5 %, between 0.25 and 4 %, between 0.25 and 3.5 %, between 0.25 and 3 %, between 0.25 and 2.5 %, between 0.25 and 2 %, between 0.25 and 1.5 %, between 0.25 and 1 %, between 0.25 and 0.75 %, between 0.4 and 0.6 %, between 0.25 and 9.5 % between 0.25 and 9.5 %, between 0.25 and 9.5 %, between 0.25 and 9.5 %, between 2 and 4 % or between 8 and 9 %of wheat bran is added as a solid ingredient.

As already indicated, in any of the described embodiments of the process of the second aspect, a flavouring agent or a combination of flavouring agents is added such as to influence and determine the devices own taste when being consumed by a user. While all possible flavours can be envisaged, particularly suitable flavouring agents are salt, pepper, sugar, vanilla, chocolate, capsicum and/or cookie flavour.

During the production process of the second aspect, especially in the above- described embodiments thereof, the total moisture content of the dough mixture ranges between 37 and 45 % (w/w), preferably between 39 and 43 % (w/w), more preferably the total moisture content of the dough mixture is about 41 %.

During the production process of the second aspect, especially in the above- described embodiments thereof, routinely, the dough mixture is compacted using a rammer or a press.

In some embodiments of the production process of the second aspect, especially in the above-described embodiments thereof, the second thickness in step (f)(i) ranges between 65 and 87 %, between 65 and 84 %, between 65 and 80 %, between 65 and 75 %, between 65 and 70 %, between 65 and 67 %, between 80 and 87 %, between 75 and 85 %, between 70 and 85 % or between 82 and 84 % of the first thickness or wherein said second thickness is 83.3 % or 66.6 % of the first thickness. In particular, the first thickness ranges from 5 to 6 mm and the second thickness is about 4 mm.

In some embodiments of the production process of the second aspect, especially in the above-described embodiments thereof, the predetermined pressure in step (f)(ii) typically ranges from 2000 to 3000 N/m ² , from 2000 to 2750 N/m ² from 2000 to 2500 N/m ² , from 2000 to 2250 N/m ² , from 2250 to 3250 N/m ² , from 2500 to 3250 N/m ² , from 2750 to 3250 N/m ² or from 3000 to 3250 N/m ² .

In some embodiments of the production process of the second aspect, especially in the above-described embodiments thereof, the temperature typically ranges between 130 and 250°C, between 140 and 250°C, between 150 and 250°C, between 160 and 250°C, between 170 and 250°C, between 180 and 250°C, between 190 and 250°C, between 200 and 250°C, between 210 and 250°C, between 220 and 250°C, between 230 and 250°C, between 240 and 250°C, between 120 and 240°C, between 120 and 230°C, between 120 and 220°C, between 120 and 210°C, between 120 and 200°C, between 120 and 190°C, between 120 and 180°C, between 120 and 170°C, between 120 and 160°C, between 120 and 150°C, between 120 and 140°C or between 120 and 130°C.

In some embodiments of the production process of the second aspect, especially in the above-described embodiments thereof, the sheets are generally baked for a duration sufficient to reduce the total moisture content to less than 4 % (w/w).

In some embodiments of the production process of the second aspect, especially in the above-described embodiments thereof, during the step of baking, the total moisture content of the edible device produced is reduced to between 1 and 4 % (w/w), to between 1.5 and 4 % (w/w), to between 2 and 4 % (w/w), to between 2.5 and 4 %(w/w), to between 3 and 4 % (w/w), to between 3.5 and 4 % (w/w), to between 1.5 and 3.5 % (w/w), to between 1.5 and 3 % (w/w), to between 1.5 and 2.5 % (w/w) or to between 1.5 and 2 % (w/w). Generally, the baking lasts for a duration ranging from 2 to 5 minutes.

Finally, the edible device produced by the process of the second aspect, in particular in the embodiments of this process described above, is a device according to above- described embodiments of the first aspect.

In order to provide a clear and consistent understanding of the specification and claims, and the scope to be given such terms, the following definitions are provided.

In order to provide a clear and consistent understanding of the specification and claims, and the scope to be given such terms, the following definitions are provided.

Definitions

In the context of this application, the term “edible" is to be understood in its plain English meaning, namely to describe the devices of the present invention as being suitable for human consumption. As such, the material from which the devices of the invention are made is a food itself. That is in contrast to other materials of which devices for engaging comestible goods may be made, ingestion of which may not be detrimental, e.g. organic materials such as wood, bamboo or straw, but which are not food. Non-edible materials such as plastics or poisonous or unpalatable organic materials are expressly not included in this definition. In the context of this application, the term “device for engaging comestible goods” refers to utensils used to engage edible items, in particular food items. Such engagement may be, and without limitation, for consumption, for holding or for handling comestible goods. As such, the term is understood to include but not being limited to tableware, again including but not limited to cutlery, cups, plates, bowls etc. In the context of this application, the term “cutlery” is not limited to cutting utensils but is to be understood to include: all eating utensils, including but not limited to spoons, forks, chopsticks, and combination eating utensils; as well as cooking utensils, such as ladles, kitchen scrapers, spatulas, cake servers, dippers, picks, spoons, skimmers, sieves, etc.

Devices of the present invention include a “handling surface”. In the context of this application, the term refers to any surface of a device handled by a user. For example, the outer surface of a handle-less cup, which is gripped by a user when handling the cup, constitutes the handling surface of the cup (device) in this context. Similarly, the surface of a chopstick, which is is in contact with a users hand during use of the chopsticks constitutes the handling surface of the device. Of course, in devices with handles the handling surface will typically be an outer surface of the handle.

In contrast to the “handling surface” defined above, the devices of the present invention also comprise at least one “comestible good engaging portion". This is the portion of the device, which is meant to engage, i.e. which is meant to come into contact with, the comestible good during use. For Example, the cutting edge is the comestible good engaging portion of a knife, the hollow part (bowl) is the comestible good engaging portion of a spoon or the tines of a fork form the comestible good engaging portion of a fork.

In addition to the above definitions, and unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

Further, reference throughout this specification to “one embodiment”, “some embodiments" or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment”, “in some embodiments” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

As used herein, unless otherwise specified the use of the ordinal adjectives ’first", "second", "third", etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

As used herein, the term “exemplary "is used in the sense of providing examples, as opposed to indicating quality. That is, an “exemplary embodiment "is an embodiment provided as an example, as opposed to necessarily being an embodiment of exemplary quality.

Devices of the invention

Referring to the drawings, Figures 1 to 5 schematically illustrate the edible device for engaging a comestible good (1) in accordance with the first aspect of the present invention comprising a handling surface (2) and at least one comestible good engaging portion (3).

The comestible good engaging portion (3) of the exemplary edible device (1) of Figure 1 , i.e. an edible chip fork having two tines (4), is substantially planar, while the comestible good engaging portions (3) of the exemplary edible devices (1) of Figures 4 and 5, i.e. of an edible spoon and an edible spork, respectively, are 3- dimensionally (3-D) shaped. The 3-D shaped devices of Figures 4 and 5 have an enforced region (5) at their under/bottom side.

Process of the invention

Figure 7 illustrates the steps of the process of the present invention. Specifically, the process of the present invention comprises grinding all solid ingredients to a particle size of 75 to 115 pm in step (a) and providing the base materials, thickening and/or stabilising agents and leavening agents in step (a-1). Adjusting the particle size of the solid ingredients significantly affects the surface finish of the device produced. Typically, these materials and agents are provided at (w/w) percentages of 75 to 80 %, 7.5 to 13 % and 0.05 to 2.5 %, respectively. The liquid ingredients are provided in step (b) and an amount of water, which corresponds in weight to 25 to 40% (w/w) of all solid and liquid ingredients, is provided in step (c). Adjusting the amount of water affects the stability of the device produced.

In step (d) the solid and liquid ingredients are mixed in with the water to form a dough mixture. At this point, flavouring agents may be added and mixed/kneaded into the dough mixture. The dough mixing of (d) can be performed manually or in a kneader.

In one particular embodiment wheat between 50 and 62 % (w/w) of all solid and liquid ingredients, wheat bran between 0.1 and 2 % (w/w) of all solid and liquid ingredients, corn between 12 and 17 % (w/w) of all solid and liquid ingredients, rice between 3 and 4 % (w/w) of all solid and liquid ingredients, sorghum between 5 and 7.5 % (w/w) of all solid and liquid ingredients, skinless mung beans between 2 and 4 % (w/w) of all solid and liquid ingredients, pear millet between 4 and 7 % (w/w) of all solid and liquid ingredients, tapioca between 1.5 and 4 % (w/w) of all solid and liquid ingredients, sunflower oil between 1 and 4 % (w/w) of all solid and liquid ingredients, ammonium bicarbonate between 0.01 and 0.05 % (w/w) of all solid and liquid ingredients, sodium bicarbonate between 0.03 and 0.07 % (w/w) of all solid and liquid ingredients, maltodextrin between 2 and 3.5 % (w/w) of all solid and liquid ingredients, carboxy methyl cellulose between 0.01 and 0.05 % (w/w) of all solid and liquid ingredients and acacia gum between 0.2 and 0.5 % (w/w) of all solid and liquid ingredients is mixed with an amount of water corresponding in weight to between 33 and 38 % (w/w) of all solid and liquid ingredients. In this embodiment an amount of flavours corresponding in weight to between 0.5 and 1.5 % (w/w) of all solid and liquid ingredients may optionally also be included during the mixing.

In another particular embodiment wheat between 30 and 44 % (w/w) of all solid and liquid ingredients, wheat bran between 1.5 and 3.5 % (w/w) of all solid and liquid ingredients, corn between 2 and 4.5 % (w/w) of all solid and liquid ingredients, rice between 12 and 17 % (w/w) of all solid and liquid ingredients, sorghum between 14.5 and 20 % (w/w) of all solid and liquid ingredients, skinless mung beans between 4 and 7.5 % (w/w) of all solid and liquid ingredients, pear millet between one and 3 % (w/w) of all solid and liquid ingredients, tapioca between 4 and 7.5 % (w/w) of all solid and liquid ingredients, sunflower oil between 0.5 and 1.5 % (w/w) of all solid and liquid ingredients, ammonium bicarbonate between 0.1 and 0.5 % (w/w) of all solid and liquid ingredients, sodium bicarbonate between 1 and 3 % (w/w) of all solid and liquid ingredients, maltodextrin between 2 and 4 % (w/w) of all solid and liquid ingredients, carboxy methyl cellulose between 0.01 and 0.05% (w/w) of all solid and liquid ingredients and xanthan gum between 0.5 and 1.2 % (w/w) of all solid and liquid ingredients is mixed with an amount of water corresponding in weight to between 26 and 32 % (w/w) of all solid and liquid ingredients. In this embodiment an amount of flavours corresponding in weight to between 20 and 26 % (w/w) of all solid and liquid ingredients may optionally also be included during the mixing.

In yet another particular embodiment wheat between 21 and 25 % (w/w) of all solid and liquid ingredients, wheat bran between 7 and 10 % (w/w) of all solid and liquid ingredients, rice between 22 and 26 % (w/w) of all solid and liquid ingredients, sorghum between 28 and 33 % (w/w) of all solid and liquid ingredients, sunflower oil between 0.5 and 1.5 % (w/w) of all solid and liquid ingredients, ammonium bicarbonate between 0.1 and 0.5 % (w/w) of all solid and liquid ingredients, acacia gum between 0.01 and 0.05 % (w/w) of all solid and liquid ingredients, acidic acid between 0.1 and 0.5 % (w/w) of all solid and liquid ingredients and glycerine between 2.5 and 4 % (w/w) of all solid and liquid ingredients is mixed with an amount of water corresponding in weight to between 33 and 38 % (w/w) of all solid and liquid ingredients. In this embodiment an amount of flavours corresponding in weight to between 1.5 and 4 % (w/w) of all solid and liquid ingredients may optionally also be included during mixing.

Once sufficiently mixed the dough mixture is rolled into one or more sheets of a first thickness in step (e). The compacting of the sheets in step (f) can either be performed prior to or during baking.

If compacted prior to baking the sheets of a first thickness may be contacted using a rammer or a press, which supply a vertical old until the second thickness ranging between 60 and 87 % of the first thickness is reached. The compacting is required such that the device produced retains its shape during baking and increases the time in which the device becomes usable to engage either hot or cold comestible goods, in particular liquid comestible goods. Without the compacting, the consistency of the device would allow absorption of undesirable amounts of liquid leading to the device becoming soft and/or soggy prematurely. After having been compacted, the sheets are subsequently placed into moulds corresponding to the shape of the device to be produced. Typically, the moulds are arranged in a tessellating fashion to optimise use of the compacted dough sheets and to avoid wastage. Notwithstanding, as the surplus sheet material can only be removed after baking, a certain amount of baked dough wastage is generated.

Alternatively, if the sheets of the first thickness are compacted during baking, they can be cut into blanks of the appropriate shape prior to being placed into the moulds and any dough sheet wastage can again be fed into the dough rolling of step (e) of the process. Furthermore, the cutting can be performed by an automatic cutter adapted to cut the sheets precisely into blanks matching according the shape of the mould, further minimising dough wastage. The blanks are then compacted by the application of a predetermined pressure ranging from 2000 to 3250 N/m ² to the moulds during baking, i.e. are exposed to “compressed baking”. In either case, the sheets or the blanks are baked at a temperature ranging between 120 and 250°C. in addition, of the devices produced are then cooled in step (h), which preferably occurs naturally by placing the baked devices at room temperature, and are packaged for storage and/or sale in step (i).

A further advantage of the process of the present invention described here is that it allows the production of edible devices for engaging comestible goods, which do not alter or influence the taste of the comestible good itself and/or do not produce an aftertaste. Notwithstanding, when the edible device is itself chewed for consumption, the device’s own taste is released. This advantageous feature of the devices produced by the process of the present invention allows flavouring of the device itself by adding flavouring agents as described above while at the further steps of the process ensure that the flavour is sealed into the device produced.

Examples

The invention is further described by the following non-limiting Examples.

Example 1:

A planar device of the present invention was produced using the following recipe:

Devices prepared with this recipe can be used to engage (a) comestible goods of temperatures below 15°C while maintaining their stability for more than 30 min, and/or (b) liquid comestible goods of a temperature of up to 80°C while maintaining their liquids for 2 to 5 min.

The baking duration at a temperature of about 160°C is about 3 minutes. The nutritional value of a device produced with this recipe is about 340 kcal per 100 grams.

The breaking force as determined in a bending test between 6 to 10 N per 66 mm ² . Of course, flavouring agents may be added when mixing the dough to produce a device of a particular flavour.

Example 2: A 3-dimensionally (3-D) shaped device of the present invention, namely the 3-D spoon of Figure 4, was produced using the following recipe:

Devices prepared with this recipe can be used to engage (a) comestible goods of temperatures below 15°C while maintaining their stability for more than 30 min, and/or (b) liquid comestible goods of a temperature of up to 80°C while maintaining their liquids for 20 to 30 min.

The baking duration at a temperature of about 170°C is about 4.5 minutes.

The nutritional value of a device produced with this recipe is about 265 kcal per 100 grams.

The breaking force as determined in a bending test between 8 to 14 N per 66 mm2.

Of course, flavouring agents may be added when mixing the dough to produce a device of a particular flavour.

Example 3:

A 3-dimensionally (3-D) shaped device of the present invention, namely a 3-D fork, was produced using the following recipe: The baking duration at a temperature of about 170°C is about 4.5 minutes.

The nutritional value of a device produced with this recipe is about 398 kcal per 100 grams.

The breaking force as determined in a bending test between 12 to 18 N per 66 mm2.

Of course, flavouring agents may be added when mixing the dough to produce a device of a particular flavour.

Example 4

To determine the breaking force of a device prepared according to the recipes of Examples 1 to 3, and with reference to the illustration of Figure 6, the respective device is fixed by its respective ends in a three-point bend test fixture.

The distance between the two ends, i.e. the length of the device, is 140 mm, while the point at which the downward force is applied is 68 mm from the distal end of the comestible good engaging portion of the spoon, i.e. is substantially in the middle between the two ends. The cross sectional area of the devices tested at the point where the downward force is applied is indicated in the table below.

The downward force is gradually increased until the spoon breaks in two i.e. up until the breaking force. Using a pressure gauge dynamometer, the downward force is measured and the breaking force is determined:

Example 5

Five paddle pop sticks produced according to the process of the present invention (using the recipe of Examples 1 and 2) and five commercially available ice cream cone wafers were stored in a freezer (i.e. at a temperature of about -20°C) for up to 4 weeks. Microbial analysis of both products was performed to comparatively determine possible levels of microbial growth and similar results were obtained for both products, i.e. the commercially available BRAND product, which indicates to be suitable for storage of at least up to 18 months at below -15°C, substantially displayed the same microbial growth as the device of the present invention. Accordingly, it is concluded that the devices of the present invention can be stored at temperatures of about -20°C for up to 18 months.

Many modifications and other embodiments of the invention set forth herein will come to mind to the one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.