FIELD OF TECHNOLOGY:

[0001] The present invention relates to a novel edible film which is not only thinly metalized with an edible metal but is also water resistant thereby imparting longer shelf life and better protection of the edible products, the said novel edible film is used as a wrapper or packaging and the process for the preparation of the said novel ultrathin water resistant metalized edible film.

[0002] Disclosed herein is an ultrathin metalized water resistant edible film comprising sodium corboxy methyl cellulose or methyl cellulose or mixture thereof; wherein thickness of the metal coating is in the range of about 0.01 micron to about O. lmicron and that of edible film ranges from about 0.5 micron to about 8 microns. The invention also relates to a process for making the said novel ultrathin water resistant metalized edible film comprising deposition of precious ultra thin metal film on to a water resistant edible film that will not only support metalized film but will also prevent cracking of the ultra thin metal film and could be used for wrapping and packing of edibles thereby prolonging shelf life by protecting the food products from bacterial and germs attack, protects from film dissolution and also enhancing aesthetics of the food products wrapped or packed therein.

[0003] Disclosed herein is an ultra thin metalized water resistant edible film comprising sodium carboxy methyl cellulose or methyl cellulose or pullulan or mixture thereof and process thereof comprising vaporization of edible metal of desired ultra thickness over the substantially thin water resistant edible film replacing conventionally used thick metallic foil thereby reducing the quantity of metal used in conventional methods for making precious metal leaf (e.g. gold or silver) thereby providing an economical and health friendly edible film with enhanced productivity. [0004] Disclosed herein is a composition for the product under the subject invention comprising pullulan or sodium corboxy methyl cellulose or methyl cellulose or tapioca starch or soy protein or zien or amylomize starch or mixture thereof which constitute about 55% to about 60% quantum of the said edible film, glycerol or sodium alginate or sodium oleate or potassium oleate or xylitol or citric acid or agar or pectin or sorbitol or sugar or magnesium hydroxide or aluminum hydroxide or mixture thereof which constitute about 10 to about 20% quantum ofedible film and edible metal selected from silver or gold or other edible metals which constitute about 10 to about 20% of the said edible film.

BACKGROUND OF THE INVENTION:

[0005] Along with the continuously ongoing development and demand for new, different, and desirable characteristics and properties of health friendly edible films there has been emergence of new polymers to accomplish the new needs. From adding additional sought after characteristics that some products demand, creating environmentally friendly alternatives, or simply producing a film for consumer pleasure, the advancements that have been, and continue to be made in the field are numerous.

[0006] Edible films and coatings have received considerable attention in recent years because of their advantages including use as edible packaging materials over synthetic films. This greatly contributes to the reduction of environmental pollution. An edible film is defined as a thin layer, which can be consumed, coated on a food or placed as barrier between the food and the surrounding environment. For the past 10 years, research on edible films and coatings in food products is driven by food engineers due to the high demand of consumers for longer shelf-life and better quality of fresh foods as well as of environmentally friendly packaging. By functioning as barriers, such edible films and coatings can feasibly reduce the complexity and thus improve the recyclability of packaging materials, compared to the more traditional environmentally unfriendly packaging materials, and maybe able to substitute such synthetic polymer films. Edible films and coatings enhance the quality of food products by extending their shelf live and improving food's safety by protecting them from threats such as chemical, biological, and physical deterioration.

[0007] However, it is to be noted that although the edible films can be used to provide a barrier to protect the products, but moisture from the packed material will collect inside the film. An edible packaging film gradually absorb the moisture from the product stored or wrapped therein or from the environment making it soft and weak thus reducing the shelf life of the food product wrapped or packed therein. This would lead to increase risk of mold growth. Eventually the moisture absorbed may cause the film to dissolve.

[0008] The increased consumer demand for high quality, extended shelf life, ready to eat foods has initiated the development of several innovative techniques to keep their natural and fresh appearance as long as possible and at the same time render them safe decorative and attractive. Packaging has been an important element in these preservation concepts for providing the appropriate (mechanical and functional) protection to the commodity. One of the more popular innovations that have taken place in the recent past is the introduction of metalized films. With the application of a layer of aluminum to a polymer's surface, the finished product proves to be more resistant to both water and oxygen transmission as well as providing a metallic and glossy appearance much like that of aluminum foil. The said aluminum foil used for the storage of food products keep the food product stored therein fresh prolonging the shelf life but being non edible has to be removed and is discarded as a waste leading to environmental pollution. The ability to provide some of the key properties possessed by aluminum foil, for a considerably lower cost and tare weight makes edible metalized films a popular choice in the food and confectionary fields. Since the creation of metalized films, the packaging industry has been propelled to astonishing heights. Through the development and utilization of these films, manufacturing practices, and continual innovations, the field of packaging has been able to grow and evolve to adapt to the needs of products around the globe. Metalized films have an illustrated history in packaging, and there are regular enhancements and improvements, as well as new products being marketed. The popularity of utilizing metalized packaging and films for packaging is largely based on the numerous technical developments that have been made in the field. Metalized packaging and film possess good barrier properties on their own, but with the aid of coatings, film types, and manufacturing methods, the positive attributes skyrocket.

[0009] Development of edible metal coating over the edible films made another big boost in the food industry. This type of metalized edible films not only protects the food product from the polluted environment but also extend the shelf life of the product. However, there is a limitation that metal like aluminum being not edible cannot be used for making metalized edible film. It has been observed that metalized edible films also get exposed to the moisture thereby reducing the shelf life of the edible films and making them soft and sticky.

[00010] Conventionally edible films are produced using cellulose. Recently there have been advancements wherein whey proteins (a component of milk) have been used replacing cellulose. Whey has advantages over cellulose like whey can be processed to make films that are either water-soluble or water-resistant, whey offer high oxygen and aroma barrier properties, or whey is glossy, transparent, and is devoid of strong smell or taste. Whey protein based films without addition of any plasticizer are very brittle, therefore, it is desirable to use plasticizer which provides flexibility to the Whey based films and also increases said film's water vapour permeability (one of the favorable cause for the microbial decay). Increased concentration of plasticizers in edible whey protein based films decreased tensile strength and Young's modulus, but increased elongation (M. J. Food Sci. 2002, 67, 164-167). The water vapor permeability can also be improved by the incorporation of hydrophobic materials such as lipids (M. J. Food Sci. 1999, 64, 695-698). However, the incorporation of lipid materials into edible film formulations could adversely affect the sensory characteristics of films. The incorporation of antimicrobial agents into edible coating formulations is needed to obtain stronger inhibitory effect against microbial growth.

[00011] During the development on the metalized edible film it has been observed that edible films coated with edible metals also gets softened due to the absorption of the moisture from the packed product and environment and thus allows the microbial growth thereby reducing the shelf life of the food product wrapped or packed therein. [00012] Gold and silver leaf has been used for centuries, not only for decoration of fine art objects but also for the decoration and protection of food products like wedding cakes, Indian sweets, chocolates, fruit, marzipan, champagne cocktails, and the likes. Edible leaf is manufactured with extreme care and controls and adheres to the FDA guidelines of edibility. Edible leaf has no taste or smell but enhances appearance considerably along with prolonging shelf life of the food product packed or wrapped therein. Precious metal in suitable quantity has a medicinal property and if taken in excess of medically permitted limit then it has adverse effects on human health. The ultrathin metal coating of the instant invention addresses this issue.

[00013] A water resistant edible film coated with edible metal is long lasting and accordingly also increases the shelf life of the food product wrapped or packed therein.

[00014] In view of above there is a dire need to develop a very thin precious metal film supported by an substantially thin water resistant edible film that will not only prevent cracking of the ultra thin metal film to be used for packing of the edibles but will also remain water resistant without getting dissolved or soft thereby increasing the shelf life of the food product wrapped or packed therein besides enhancing the aesthetic look. Thickness of the metal film can be adjusted up to level which shall be permitted by the regulatory bodies and will not impact human health adversely. Disclosed herein is a novel ultra thin metalized water resistant edible film comprising a removable carrier substance which can be removed while final packaging. Ultra thin coating of precious metal in a health friendly quantity not even reduces the metal consumption over the conventional methods but also the ultrathin metalized edible film produced there from is health friendly and is devoid of any health hazard related to excessive quantity of edible film material and metal.

[00015] US4710228 discloses edible film coating composition of low moisture permeability and their methods of preparation. The composition comprises cross linked, refined shellac and an edible member. The molten mixture is dissolved in a food grade solvent, applied to a substrate and dried. The coating is useful as a moisture barrier in composite food articles having phases in contact which differ substantially in water activity. [00016] US4915971 discloses an edible film for retarding water transfer among components of multi component food product. The film includes a base film having a hydrophilic polymer layer and the base film lipid layer. The base lipid layer has a hydrophobic surface presented away from the hydrophilic polymer layer. An additional lipid layer is laminated to the hydrophobic surface of the base film lipid layer. The invention further includes a method of making the edible film and a food product incorporating it.

[00017] US5401518 discloses an emulsion which provides an edible moisture barrier coating for foods. The resultant film is thick. The emulsion is coated onto a food product and cold-set using refrigeration, where the coating serves as a moisture barrier.

[00018] US6165521 discloses a method of making an edible film with a thickness upto print paper size and a method of utilizing such edible films with various food products.

[00019] US4493872 discloses an improved process for the adhesion of metal over the plastic films comprising the metalized technique resulting into a product that is used for as a packaging material.

[00020] US5631066 discloses a metalized packaging film comprising a biodegradable poly (hydroxy acid) film having a thickness of 25-125 micrometers (microns) having adhered to one side thereof with a metal coating having a thickness of 20-50 nanometers characterized by a process comprising sputtering a metal, such as aluminum, gold, silver, copper, platinum, nickel, titanium or tantalum onto a biodegradable poly (hydroxy acid), preferably poly(lactic acid) film, which may then be adhered to a cellulosic. The thickness of the biodegradable poly (hydroxy acid) film is very high and a person skilled in the art neither gets any teaching nor gets any motivation in respect of reducing the thickness of the substrate film to about 1 micron which in itself has a strength and can be coated with any metal. [00021] US7252878 discloses a high oxygen barrier, multilayer flexible packaging structure having a vacuum metalized, bi-axially oriented polypropylene (met-BOPP) or metalized polyester (met-PET) film substrate; a high barrier ethylene vinyl alcohol layer coextruded or laminated directly on the metal-containing layer wherein said metal-containing layer has an optical density of about 1.5 to 5.0.; and optionally an adjacent layer of anhydride modified polyolefin and anhydride modified adhesive resin on the ethylene vinyl alcohol layer.

[00022] US5827615 discloses a metalized film substrate having a core layer and a metal receiving skin layer of ethylene vinyl alcohol. The ethylene vinyl alcohol surface is metalized with aluminum. A low temperature sealable layer is coated to the aluminum surface. For the adhesion of ethylene vinyl alcohol, the core layer may either be blended with a maleic anhydride modified polyolefin or have an adhesion-promoting tie layer.

[00023] US 6616958 Bl discloses an edible film , method of making and using same for decorating foodstuffs, in particular baked goods, wherein anyone can easily, inexpensively and artistically decorate foodstuffs.

[00024] US 5286502 A discloses a method of prolonging the shelf life of stick chewing gum, and a shelf-stable chewing gum prepared according to the method, are provided. Chewing gum sheet is coated on both sides with an aqueous solution of an edible film forming agent which, when partially dried, serves as an adhesive. A layer of wax is then applied to each of the layers of edible film forming agent. Stick chewing gum prepared according to the method of the invention does not absorb or lose moisture as fast as conventional, uncoated chewing gum sticks.

[00025] The conventional methods for making the metal films popularly known as metal leaf comprises the following steps and are associated with certain drawbacks as illustrated herein low: i) manual or electrical hammering of the metal piece to desired size and weight resulting into thin films having the thickness of about 0.3 microns which requires more metal as an input. ii) These films are bundled manually to form a booklet during which many of them go waste due to curling and cracking because of their delicate nature. iii) In case when the shredding is required these sheets are required to subject to the vibro sieve to achieve the desired size.

[00026] The present invention have been successful in eliminating the problems associated with the conventional method by incorporating a substance that will impart water resistance characteristic in the edible film and also providing metal film having uniform thickness in the range of about 0.01 micron to about O. lmicronachieved by deposition by vaporization technique under vacuum thereby consuming less metal but with increased productivity in comparison to that of 0.3 microns obtained by conventional methods.

[00027] The present invention has also eliminated the problem of curling and cracking of the metal film by using edible film as support which is further mounted on the carrier base film. Moreover the thickness of the edible film ranges from about 0.5 to about 8 microns.

[00028] The present invention has also eliminated the problem of softening of the metalized edible film there by restricting the microbial growth and thus increasing its shelf life.

[00029] None of the patents cited herein above disclose thinly metalised water resistant edible film characterized by reduced thickness for both metal as well as substantially thin support edible film which remains tough for a longer duration due to water resistant property resulting into increased shelf life of the food products to be wrapped or packed therein and the said water resistant metalized edible film is further mounted on a carrier thus providing ready to eat health friendly food products to the consumer.

[00030] It has been observed that the metalized edible film when exposed to the environment absorbs the moisture and gets softened on standing resulting in to reduced shelf life. A film made from the prescribed composition is resistant to the moisture. A product intended for a longer shelf life of 3 month -12 months requires resistance to moisture from the ambient condition to keep the product intact. In the absence of above there can be microbial growth, fungal attack, poor appearance, lump formation, etc in the product, thereby deteriorating the overall product quality. Even if the ingress of moisture from atmosphere is protected by using expensive packaging in case of packed products, several food products have a moisture content of its own. In such cases standard edible film absorb moisture from within the product packed or wrapped therein and as a result the non water resistant edible film may get softened or dissolved and lead to microbial growth due to presence of starch in edible film thus defeating the purpose of using edible film for prolonging the shelf life of food products stored therein.

[00031] As a solution to the above mentioned problems, a water resistant edible film is developed, which can help overcome these problems and maintain the shelf life of the product for longer durations. On the other hand, they are so thin films that when they go in mouth as a composition of the product they dissolve immediately thereby making no difference to the end consumer.

[00032] Disclosed herein is a water resistant substantially thin edible film which is ultra thinly coated with a precious edible metal mounted on a carrier base film which is coated that acts as a helping aid to peel it off before final packaging leaving behind the food product left with edible metalized film that can be put directly into the mouth. The process under the subject invention is capable of producing ultra thin metallic edible film possessing water resistance property having metal thickness in the range of about 0.01 micron to about 0.1 micron and edible film in the range of about 0.5 microns to about 8 microns. This implies a better control on the product, since the effective thickness of the metal layer can be defined complying with FDA permitted level and the desired metal thickness is measured within the ongoing manufacturing process over that of conventional method thereby reducing the consumption of the metal to a remarkable extent making the process more economical without any wastage of precious metal.

[00033] Novelty and the inventive feature of the subject invention resides in the fact that the substantially thin edible film to be coated by ultra thin precious edible metal is made water resistant and is further coated with ultrathin metallic coating which is not achievable by the conventional method. The said ultrathin metalized substantially thin edible film comprises substance like sodium carboxy methyl cellulose which prevents the edible film from absorbing the moisture from the packed product or from the environment thus making it stable and sturdy and becomes more supportive for a long duration. Moreover the said edible film is mounted on carrier base film which can be used throughout the manufacturing process as a mere mechanical support for the manufacturing of the said substantially thin base edible film, and during the metallization process, to avoid damages to the product which is too thin and delicate to be self- supporting.

[00034] The special features of the process are characterized by the ultra thin also referred as substantially thin thickness of the water resistant edible film and also ultra thickness of precious metal layer which is not achievable by the conventional methods disclosed therein in the prior art for the preparation of edible metalized films possessing desired mechanical properties. The said ultrathin edible film comprises edible polymeric substrate having good mechanical properties and the ultrathin coating with a precious-metal (which gives the metal-like appearance to the product). One more feature of the process is that the ultrathin metalized water resistant edible film is a composite of i) pullulan or sodium carboxy methyl cellulose or methyl cellulose or tapioca starch or soy protein or zien or amylomize starch or mixture thereof which constitute about 55% to about 60% quantum of the said edible film, ii) glycerol or sodium alginate or sodium oleate or potassium oleate or xylitol or citric acid or agar or pectin or sorbitol or sugar or magnesium hydroxide or aluminum hydroxide on mixture thereof which constitute about 10 to about 20% quantum of edible film and iii) edible metal selected from the group comprising silver or gold or other edible metals which constitute about 10 to about 20% of the said edible film. Another feature of the process of the subject invention is that the product can be shredded just by transferring the edible sheets in to the shredder bypassing the horizontal cutters where long strips of edible Film (Metal coated/ metalized) are crushed into a desired mesh size which is then finally collected in a drum for sale.

[00035] Synergistic and surprising effect of the present invention can be seen in terms of i) reduced consumption of the precious edible metal thereby producing higher output with less input of the precious metal, ii) Water resistant nature of the film prevents the softening thereby making it sturdy to stand unsoftened having longer shelf life iii) Better aesthetic look along with better protection for the food products iv) peelable or removable carrier base film from the metalized edible film leaving it to be ready to eat food product and reusing peeled off carrier base films v) edible metal quantity within drug regulatory permitted limits.

OBJECTS OF THE INVENTION:

[00036] The main objective of the present work is to determine the optimal composition of edible coatings possessing longer shelf life.

[00037] The first aspect of the invention is to provide a novel ultra thin metalized water resistant substantially thin edible film that can be used for the packaging of the food products which not only gives the protection to food stuffs but also enhances the aesthetic look and shelf life of the product.

[00038] Second aspect of the invention is to provide an ultrathin metalized water resistant edible film which will not absorb the moisture from the product packed inside or from the environment thus will remain sturdy and unsoftened thereby avoiding microbial attack and hence will enhance the shelf life of the film and product packed or wrapped therein. [00039] Third aspect of the invention is to reduce the quantity of the precious metal by producing it having the thickness in the range of about O.Olmicron to about 0.1 micron against 0.3 to 5 microns produced by the conventional method, thereby increasing the productivity.

[00040] Fourth aspect of the invention is to provide an economical process for the preparation of ultrathin metalized substantially thin support water resistant edible films having thickness of metalized layer in the range of about 0.01 to about 0.1 micron thick while that of edible layer is about 0.5 micron to about 8 microns.

[00041] Fifth aspect of the invention is to improve the mechanical strength hence avoiding the cracking of the metal film by using water resistant edible film as a support.

[00042] Sixth aspect of the invention is to mount substantially thin substrate water resistant edible film over a carrier film/sheet which facilitates the rolling of the film.

[00043] Seventh aspect of the invention is to furnish the ultrathin metalized water resistant edible film that will supply the precious metal in such an amount that will be as per the regulatory requirement and will not harm the human on its consumption as the thickness of the metal film can be adjusted during the process.

[00044] Eighth aspect of the invention is to provide a novel composition for water resistant edible film of the subject invention comprising sodium carboxy methyl cellulose or methyl cellulose, pullulan, tapioca starch, soy protein, chitosan, zien, amylomize starch, glycerol, sodium alginate, sodium oleate, xylitol, citric acid, agar, pectin sorbitol and sugar or mixture thereof. [00045] Ninth aspect of the invention is to obtain the saleable product either in the form sheets or in the shredded form and several other possible forms.

[00046] Tenth aspect of the invention is to provide a process for the preparation of ultra thin metalized water resistant edible film comprising steps: a) mixing sodium carboxy methyl cellulose or methyl cellulose or mixture thereof with pullulan, tapioca starch, soy protein, chitosan, zien, amylomize starch, glycerol, sodium alginate, sodium oleate, xylitol, citric acid, agar, pectin and sorbitol, sugar; b) making substantially thin water resistant edible film of the substrate by applying novel composition over the carrier base film; c) drying the raw material mixture in a dryer to get roll of substantially thin water resistant edible coated film (ECF): d) feeding edible coated film roll in the metal coating machine where desired quantity of precious metal is deposited on the surface of ECF to get ultrathin metal coated roll done in a vacuum coater; e) subjecting metal coated roll into peeling off machine to separate carrier base film from metalized water resistant edible film; f) subjecting the product for shredding into desired small pieces in shredding machine or cut into desired pieces in a cutting machine to get different sizes; g) packaging of final product.

SUMMARY OF THE INVENTION:

[00047] The present invention disclosed herein relates to an ultra thin water resistant edible film comprising substances like sodium carboxy methyl cellulose or methyl cellulose or mixture thereof and process for the production of the same characterized by vaporization of edible metal over the substantially thin water resistant edible film which can replace the conventional metallic foil thereby reducing the quantity of metal over the traditional methods of making precious metal leaf (e.g. gold or silver) providing an economical and health friendly edible film with enhanced productivity and longer shelf life.

[00048] The subject invention provides an ultra thin water resistant edible film which is metalized over substantially thin edible film supported on a carrier base film that is peeled off before final packaging leaving behind the food product left with edible metalized film that can be put directly into the mouth and the process thereof.

[00049] Said process allows manufacturing of small to large product formats, with selectable surface finishing selected from matt, semi-gloss, gloss, mixed matt and gloss, embossing and the like. The same product can be easily treated to manufacture edible flakes/shreds with silver/gold appearance.

[00050] The process of the subject invention comprises: a) i) mixing sodium carboxy methyl cellulose or methyl cellulose or mixture thereof with pullulan, tapioca starch, soy protein, chitosan, zien, amylomize starch forming about 55 to about 60% quantam of the film; ii) glycerol or sodium alginate or sodium oleate or potassium oleate or xylitol or citric acid or agar or pectin or sorbitol or sugar or magnesium hydroxide or aluminum hydroxide - one or more of the mentioned ingredients forms about 10 to about 20% quantum of edible film; iii) silver or gold or other edible metals forms about 10 to about 20% quantum of film; b) making substantially thin water resistant edible film of the substrate by applying novel composition of step a) over the carrier base in the edible film coater; c) drying the carrier film supported substrate obtained in step b) to get roll of edible coated film (ECF); d) feeding edible coated film roll in metal coating machine where desired quantity of precious metal is deposited on the surface of ECF to get metal coated roll; the said precious metal coating is done in vacuum coater; e) subjecting metal coated roll obtained in step e) into peeling off machine to separate carrier base film from metalized edible film; f) subjecting the product for shredding into desired small pieces in shredding machine or cut into desired pieces in cutting machine to get different sizes; g) packaging of final product.

DETAILED DESCREPTION OF THE INVENTION:

[00051] The present invention provides an ultrathin metalized water resistant edible film and method of making the same and utilizing the said edible film for packaging of various food products. The products and processes of the present invention rely on the interaction among various steps of the production of the films in order to provide film that not only substantially reduce the quantity of the precious metal that is used for providing an ultrathin metal film coating over a substantially thin edible film but also is water resistant. Desirably, the edible film is water resistant comprising use of sodium carboxy methyl cellulose or methyl cellulose or mixture thereof which keeps the film sturdy and unsoftened and there is also a high level of uniformity in the thickness of the metallic films over the substantially thin substrate edible films prepared by the present invention. Monitoring and control of the thickness of the precious metallic film also contributes to the economics of the production process. [00052] Other film-forming methods used in conjunction with the methods of the present invention comprises making of an edible film supported on a carrier base film as a mere mechanical support for the manufacturing of the substantially thin edible film, and during the metallization process. After these process steps, the product (edible film+metal coating) is separated from the carrier base film in peel-off equipment.

[00053] Although the films of the present invention preferably are described herein according to certain parameters, it will be understood that these may be altered in various ways without substantially affecting the resulting end product.

[00054] In a general embodiment there is provided a process for making an ultra thin metalized water resistant edible film having a substantially uniform distribution of components, comprising the steps:

a) i) The film products of the present invention is produced by a novel combination of properly selected components and mixing the said set of components selected from the group comprising sodium carboxy methyl cellulose or methyl cellulose or mixture thereof, pullulan, tapioca starch, soy protein, chitosan, Zien, amylomize starch forms about 55 to about 60% quantam of the film. ii) sugar, citric acid, glycerol, sodium alginate, sodium oleate, potassium oleate, xylitol, citric acid, agar, pectin, sorbitol, magnesium hydroxide, aluminum hydroxide and mixture thereof forms about 10 to about 20% quantum of edible film. iii) silver or gold or other edible metals forms about 10 to about 20% quantum of film; b) making of substantially thin water resistant edible film of the substrate by applying novel composition of step a) over the carrier base film in the edible film coater; c) drying the carrier film supported substrate obtained in step b) to get roll of edible coated film (ECF); d) feeding edible coated film roll in metal coating machine where desired quantity of precious metal is deposited on the surface of ECF to get metal coated roll; the said precious metal coating is done in a vacuum coater; e) subjecting metal coated roll obtained in step e) into peeling off machine to separate carrier base film from metalized water resistant edible film; f) subjecting the product for shredding into desired small pieces in shredding machine or cut into desired pieces in cutting machine to get different sizes; g) packaging of final product.

[00055] The components used for the preparation of composition of water resistant edible film as described in the step a)hereinabove may be varied as per the requirements and therefore, change in the composition by changing the ingredients remains under the scope of the invention. Mixing of the various ingredients can be done by any of the technique known in the art. Various types of mixing systems are contemplated herein, including, but not limited to static mixers, dynamic mixers, and small and large volume inline mixers and the like. The compositions may optionally be combined and mixed continuously in any desired mixer. Mixers may allow for continuous flow of components or the components may be intermittent, or there may be a combination, wherein particular components are continuously fed into the mixer, while others may be fed intermittently.

[00056] In general the ultrathin metalized water resistant edible film comprises a highly soluble/edible polymer, which in turn can be (for example, but not exhaustively):sodium carboxy methyl cellulose or methyl cellulose or mixture thereof, pullulan, cellulose derivatives, corn starch, tapioca starch, arabic gum, pectine, potatoes starch and the like. More generally, any naturally derived polysaccharide is a good candidate to manufacture said edible films: the choice depends on the desired mechanical properties of the film itself, from its solubility, taste, etc., which have varies case by case. In some cases, proper food additives can be added to the film composition to improve its strength, flexibility, solubility, stability, etc. [00057] The carrier base film or sheet is selected from the group comprising thermo plastic polymer, paper and non toxic substances those can be peeled off from the edible film. The thermo plastic polymer is selected from the group comprising polyethylene terephthalate abbreviated as PET, PP, polystyrene, EVA and the like.

[00058] Drying of raw material mixture is done in a dryer to get a roll of substantially thin water resistant edible coated film (ECF). A controlled drying process is used to dry the film, and may additionally reduce the variability of the composition in the film. Controlled drying methods are useful in eliminating the formation of bubbles in the film during drying, thereby reducing the likelihood of variability of content in the film.

[00059] Product formats is selected from the group comprising rolls, sheets starting from 50 mm x50 mm to 600 mm xlOOO mm (which is not possible with traditional methods), shreds.

[00060] Product finishing is selected from the group comprising gloss, matt, semi-gloss, watermarked, punched, laser engraved and shapes and the like.

[00061] The precious metal used for the metal coating is selected from the group comprising silver and gold.

[00062] In a specific embodiment of the invention there is provided a process for making an ultra thin water resistant edible film having a substantially uniform distribution of components, comprising the steps of: a) The edible film of the present invention is produced by a novel combination comprising sodium carboxy methyl cellulose or methyl cellulose or mixture thereof, pullulan, tapioca starch , soy protein, chitosan, zien, amylomize starch forming about 55 to about 60% quantam of the edible film, glycerol, sodium alginate, sodium oleate, potassium oleate, xylitol, citric acid, agar, pectin, sorbitol, sugar magnesium hydroxide, aluminum hydroxide, forming about 10 to about 20% quantam of the edible film and gold or silver metal forming about 10 to about 20% quantam of edible film; b) making of substantially thin film of the substrate by applying said novel composition over the thermoplastic polymer film(PET) to act as carrier done over the edible film coater; c) drying the raw material mixture in dryer to get roll of edible coated film (ECF); d) feeding edible coated film roll in metal coating machine where desired quantity of silver is deposited on the surface of ECF to get silver coated roll done in vacuum coater; e) subjecting silver coated roll into peeling off machine to separate carrier base film of PET from silver film; f) subjecting silver coated product for shredding into desired small pieces in shredding machine or cut into desired pieces in cutting machine to get different sizes; g) packaging of final product.

[00063] The invention can be best understood from the example given herein below:

Step 1): In the first process sodium corboxy methyl cellulose, methyl cellulose pullulan, Tapioca starch, zein, agar, soy protein, amylomize starch are mixed with other raw materials viz sugar, citric acid, glycerol, sodium alginate, sodium oleate, potassium oleate, xylitol, citric acid, agar, pectin, sorbitol, magnesium hydroxide, aluminum hydroxide to form a homogenous powder using a mixer. Water is added to the mixture in the same mixer in a defined ratio to form a thick starch paste which is uniform, consistent and homogenous in nature with no lumps at all. Once the paste is made, it is left for maturation after which it is transferred to the edible film coating equipment to coat this mix/paste on a carrier substrate. The paste is spread on the substrate uniformly with the help of a roll to roll coater. In this machine carrier coated roll passes through a series of rollers to apply the paste and evenly spread it out at a desired thickness. Once the application part is done, the coated roll passes through a drying tunnel where the coated mix is dried and thus a completely uniform and consistent water resistant edible film is formed.

Step 2): Once the coated rolls are received from the step 1, they are mounted on vacuum coater with help of hoist. Once mounted, the substrate is guided through the set of rollers to provide the direction of movement. Thereafter, the machine is turned on, the vacuum pump activates and starts achieving the vacuum required to do the metal coating. Simultaneously the SILVER METAL pieces are fed into the designated places on the machine which ultimately are taken to a vaporization phase. Once the vacuum is achieved, silver starts flowing in the vacuum chamber in form of a mist but in a guided fashion so that it mainly goes to the area which needs to be coated. Once the silver is coated it goes through drying chamber to achieve a completely DRY silver coated water resistant edible film with a base substrate.

Step 3): Once the metalized rolls are received from step 2, material is put onto a slitting and splicing machine where the substrate base is peeled off using a gripper and simultaneously the roll is being slit into the desired width. The substrate which is being peeled off keeps on winding on a roll to form a roll that can be used later. The peeled off edible film (silver coated) is then cut using horizontal cutters to form sheets of desired sizes which come of the machine in stacks of specified numbers which are further packed using other packaging machines. However, if shreds are required instead of sheets, the material bypasses the horizontal cutters and gets transferred to a shredder where long strips of edible film (silver coated) are crushed to a desired mesh size which is then finally collected in a drum for sale.

ADVANTAGES OF THE PRESENT INVENTION:

[00064] Present invention provides an ultra thin precious metal film over substantially thin water resistant edible film comprising substances like sodium carboxy methyl cellulose or methyl cellulose or mixture thereof; wherein the thickness of the metal film is in the range of about 0.01 micron to about 0.1 micron; the said ultrathin metalized substantially thin water resistant edible film has good mechanical properties. The said ultrathin film comprises edible/highly soluble polymeric substrate possessing good mechanical properties along with substances like sodium c carboxy methyl cellulose or methyl cellulose or mixture thereof that impart water resistance to the substantially thin edible film making it water resistant and further coated with a precious-metal ultra thin film which gives the metallic appearance to the product and also protect the food product wrapped or stored therein from micro organism attack prolonging the shelf life of the food product stored or wrapped therein.

[00065] Present process for the preparation of metal films reduces the quantity of the precious metal over the conventional method as it comprises metal deposition by vaporization rather than obtaining it by hammering as done in the conventional methods.

[00066] The thickness of the metal film can be achieved in such a way so that the precious metal will not exceed the medically permissible limit of the metal when consumed.

[00067] Use of a carrier film or sheet as a mounter for the water resistant edible film facilitates the production of substantially thin edible film as it not only provides a solid support to retain its mechanical property but also help in rolling of the edible films.

[00068] Metalized technique helps in providing ultra thin coating of the metal with enhanced adhesion onto the surface of substrate film. Metalized technique disclosed herein comprises making of the film by directing a stream of metal vapor onto the surface of substrate film by vacuum deposition technique that gives the uniform thickness and also uses less metal over the conventional method.

[00069] Hygienic advantage of present manufacturing process is that it doesn't require any contact between operators and product, so that any possible contamination can be strongly reduced to negligible or none. Moreover, the whole manufacturing plant can be installed in a clean room with full control over possible contamination deriving from environment. The plant has been designed and manufactured complying with food-safety regulatory requirements.

[00070] The said metalized water resistant edible film of the invention having the ease of handling can be used for the packaging of the food products or non food items that will not only protect the food stuff from germs attack fOr a longer duration but also enhances the aesthetic look of the product. [00071] The said metalized water resistant edible film of the invention can also be converted into shredded product by passing the horizontal cutters and transferring the metalized edible sheet into the shredder.