# US 8,771,776 B2 · Method to produce, transport, and utilize flour and flour blends > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,771,776 B2 - Document ID: US8771776B2 - Status: Granted - Kind: B2 - Application number: 13/373,027 - Filed: 2011-11-02 - Published: 2012-05-31 - Granted: 2014-07-08 - Earliest claimed: 2010-11-03 - Applicants: Todd W Gocha; Joseph Dileonardo - Inventors: Todd W Gocha; Joseph Dileonardo - Web page: https://patentgrep.com/patent/US8771776B2 ## CPC - A23L 7/178: by pressure release with or without heating - A23L 7/198: {Dry unshaped finely divided cereal products, not provided for in groups A23L7/117 - A23L7/196 and A23L29/00, e.g. meal, flour, powder, dried cereal creams or extracts} - A23P 30/32: by pressure release, e.g. explosion puffing; by vacuum treatment - A23L: FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF (preservation thereof A23B) - A23P: SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS ## Abstract A method to produce a food product comprises the steps of providing a plurality of flint corn kernels; drying the flint corn kernels; popping the flint corn kernels; cooling the porous, airy, elastic foam particles produced during popping; cutting with a moving blade said porous, airy foam particles into pieces having a width greater than 0.005 inches to produce an elastic, air entrained popcorn flour occupying a volume; and, vacuum packaging the elastic popcorn flour to reduce the volume occupied by the popcorn flour. ## Claims ### Claim 1 A method for producing a food product, flour comprising the steps of (a) providing a plurality of flint corn kernels; (b) drying the flint corn kernels to a moisture content in the range of 12% to 16% by weight; (c) popping said flint corn kernels by heating said kernels to (i) produce in said kernels a temperature greater than 275 degrees F. and a pressure greater than 100 psi, (ii) gelatinize and soften the starch in the kernel, (iii) rupture the hulls of said flint corn kernels to produce a sudden drop in pressure inside the kernel to permit a rapid expansion of the steam to expand the starch and proteins of the endosperm into porous, airy, elastic foam particles; (d) cooling said porous, airy, elastic foam particles; (e) cutting with a moving blade said porous, airy foam particles into pieces having a width greater than 0.005 inches to produce an elastic, air entrained popcorn flour occupying a volume; (f) vacuum packaging said elastic popcorn flour to reduce the volume occupied by said popcorn flour. ### Claim 2 (depends on 1) The method of claim 1 wherein (a) said vacuum package of said popcorn flour is transported to a selected location; (b) said vacuum package is opened at said selected location to permit said popcorn flour to expand elastically; and, (c) at least a portion of said popcorn flour is substituted for wheat flour in a recipe to make a food product. ### Claim 3 (depends on 1) The method of claim 1 wherein said vacuum packing reduces the volume occupied by said popcorn flour by at least 10%. ### Claim 4 (depends on 1) The method of claim 1 wherein said vacuum packing reduces the volume occupied by said popcorn flour by at said vacuum packing reduces the volume occupied by said popcorn flour by at least 20%. ### Claim 5 (depends on 1) The method of claim 1 wherein said vacuum packing reduces the volume occupied by said popcorn flour by at least 30%. ### Claim 6 (depends on 1) The method of claim 1 wherein said air entrained popcorn flour has a density at least 10% less than conventional wheat flour found in supermarkets. ### Claim 7 (depends on 1) The method of claim 1 wherein said air entrained popcorn flour has a density at least 20% less than conventional wheat flour. ### Claim 8 (depends on 1) The method of claim 1 wherein said air entrained popcorn flour has a density at least 30% less than conventional wheat flour. ### Claim 9 (depends on 1) The method of claim 1 wherein said air entrained popcorn flour has a density at least 50% less than conventional wheat flour. ### Claim 10 (depends on 1) The method of claim 1 wherein (a) said vacuum packing reduces the volume occupied by said popcorn flour by at least 10%; and, (a) said air entrained popcorn flour has a density at least 10% less than conventional wheat flour. ### Claim 11 (depends on 1) The method of claim 1 wherein (a) said vacuum packing reduces the volume occupied by said popcorn flour by at least 20%; and, (a) said air entrained popcorn flour has a density at least 20% less than conventional wheat flour. ### Claim 12 (depends on 1) The method of claim 1 wherein (a) said vacuum packing reduces the volume occupied by said popcorn flour by at least 30%; and, (a) said air entrained popcorn flour has a density at least 30% less than conventional wheat flour. ### Claim 13 (depends on 1) The method of claim 1 wherein (a) said vacuum packing reduces the volume occupied by said popcorn flour by at least 30%; and, (a) said air entrained popcorn flour has a density at least 50% less than conventional wheat flour. ### Claim 14 (depends on 1) The method of claim 1 wherein opening said vacuum packed flour causes the volume of said flour to increase by at least 5%. ### Claim 15 (depends on 1) The method of claim 1 wherein opening said vacuum packed flour causes the volume of said flour to increase by at least 10%. ### Claim 16 (depends on 1) The method of claim 1 wherein opening said vacuum packed flour causes the volume of said flour to increase by at least 15%. ### Claim 17 (depends on 1) The method of claim 1 wherein (a) said vacuum packing reduces the volume occupied by said popcorn flour by at least 10%; and, (b) opening said vacuum packed flour causes the volume of said flour to increase by at least 5%. ### Claim 18 (depends on 17) The method of claim 17 wherein said air entrained popcorn flour has a density at least 20% less than conventional wheat flour. ### Claim 19 (depends on 1) The method of claim 1 wherein (a) said vacuum packing reduces the volume occupied by said popcorn flour by at least 20%; and, (b) opening said vacuum packed flour causes the volume of said flour to increase by at least 10%. ### Claim 20 (depends on 17) The method of claim 17 wherein said air entrained popcorn flour has a density at least 30% less than conventional wheat flour.