METHOD AND SYSTEM FOR MAKING PARTIALLY POPPED POPCORN
The present invention is directed to methods and systems for making partially popped popcorn. The invention comprises the steps of providing a plurality of corn kernels of the zea mays everta variety; soaking the plurality of corn kernels with water at substantially room temperature for a period of time sufficient to increase the pre-existing moisture content of less than about 15% water to a modified moisture content of greater than about 18% water; dewatering the soaking water away from the plurality of corn kernels; and forcing heated air upwardly through the perforated screen while the perforated screen is being vibrated such that the plurality of corn kernels having a modified moisture content of greater than about 18% water is suspended and heated above the perforated screen by the heated air thereby causing heating and expansion of the plurality of corn kernels to thereby yield the partially popped popcorn.
1 . A method for making partially popped popcorn comprising the steps of:
providing a plurality of corn kernels of the zea mays everta variety, with each corn kernel having a pericarp structure and an interior volume comprising an endosperm material having a pre-existing moisture content of less than about 15% water on a weight percentage basis;
conveying the plurality of corn kernels into a soaking tank for soaking with water;
soaking the plurality of corn kernels with water at substantially room temperature for a period of time sufficient to increase the pre-existing moisture content of less than about 15% water to a modified moisture content of greater than about 18% water on a weight percentage basis;
dewatering the soaking water away from the plurality of corn kernels having a modified moisture content of greater than 18% water on a weight percentage basis;
conveying the plurality of dewatered corn kernels having a modified moisture content of greater than 18% into a processor by way of a top positioned processor inlet, wherein the processor comprises a housing about a processing chamber, a perforated screen positioned substantially horizontally within the housing and below the processing chamber with the perforated screen including a plurality of holes smaller in size than each of the plurality of corn kernels, a bottom positioned heated air inlet configured to force heated air upwardly through the perforated screen and into the processing chamber, a vibration unit for controllably vibrating the perforated screen, and a circumferentially positioned processor outlet for expelling partially popped popcorn out of the processing chamber;
forcing heated air upwardly through the perforated screen while the perforated screen is being vibrated by the vibration unit for a selected period of time and at a selected temperature such that the plurality of corn kernels having a modified moisture content of greater than about 18% water is suspended and heated above the perforated screen by the heated air thereby causing heating and expansion of the plurality of corn kernels to thereby yield the partially popped popcorn; and
expelling the partially popped popcorn out of the processing chamber by way of the circumferentially positioned processor outlet.
2 . The method for making partially popped popcorn according to claim 1 wherein the period of time for soaking with water is about 48 hours.
3 . The method for making partially popped popcorn according to claim 1 wherein the perforated screen is substantially circular.
4 . The method for making partially popped popcorn according to claim 1 , further comprising a housing stand, wherein the housing of the processor is mounted onto the housing stand by way of a plurality of springs.
5 . The method for making partially popped popcorn according to claim 4 wherein each of the plurality of springs has a spring tension that is controllably adjustable.
6 . The method for making partially popped popcorn according to claim 1 wherein the heated air has a temperature ranging from about 400° F. to about 450° F.
7 . The method for making partially popped popcorn according to claim 6 wherein the heated air has a temperature of about 435° F. and the selected period of time is about 4 minutes.
8 . The method for making partially popped popcorn according to claim 1 wherein the plurality of dewatered corn kernels having a modified moisture content of greater than 18% moves in an outwardly spiralling pathway while within the processor chamber.
9 . A method for making partially popped popcorn comprising the steps of:
providing corn kernels of the zea mays everta variety, with each corn kernel having a pericarp structure and an interior volume comprising an endosperm material having a pre-existing moisture content of less than about 15% water on a weight percentage basis;
soaking the corn kernels with water at substantially room temperature for a period of time sufficient to increase the pre-existing moisture content of less than about 15% water to a modified moisture content of greater than about 18% water on a weight percentage basis;
dewatering the water away from the corn kernels having a modified moisture content of greater than 18% water;
conveying the corn kernels having a modified moisture content into a processor, wherein the processor comprises an internal perforated screen;
forcing heated air upwardly through the perforated screen while the perforated screen is being vibrated for a selected period of time and at a selected temperature such that the corn kernels having a modified moisture content of greater than about 18% water are suspended and heated above the perforated screen by the heated air thereby causing heating and expansion of the corn kernels to thereby yield the partially popped popcorn.
10 . The method for making partially popped popcorn according to claim 9 wherein the corn kernels having a modified moisture content of greater than about 18% water are conveyed through the processor in a generally horizontal and an outwardly spiralling pathway.
11 . Partially popped popcorn made in accordance with the process of claim 1 or 9 .