Abstract:
Disclosed are packaged frozen precooked dough or batter-based food products and methods of heating the food products. The packaged precooked frozen dough or batter-based food products comprises one or more frozen precooked dough or batter-based food products that are encased in a pouch for heating. The pouch is sealed with the exception of the presence of two or more vent holes that function to release air or steam that may otherwise cause the food product to become soggy when they are heated in an oven.

Description:
BACKGROUND 
       [0001]    The packaging industry is in continual need of improved packaging materials having new or advantageous uses, properties, or product performance features. Product packaging is no longer a mere means for containing a product during transport or sale, but can be an important feature of the product itself. The packaging can be useful for marketing and advertising, but also now for adding product use or performance features. Heatable product packaging can be used in the food industry to allow a packaged food product to be heated in the package and optionally consumed from the package. If the package contains a single serving of a food product, is easy to open, and allows for convenient use, the package is more than just a holder for the food but is a means for improving the use and enjoyment of the food product it contains. New and newly useful packaging materials are desirable for food and non-food products, especially if the packaging material provides new or advantageous functionality for a contained product. 
         [0002]    Food packages illustrate how a packaging material or package configuration can improve the value of a packaged product. Precooked frozen food products are very desirable to consumers because precooked frozen products can be stored for long periods of time and then heated quickly in a conventional oven, convection oven, or microwave oven for consumption. The use of a package that allows in-package heating or consumption of the contained food product offers added value. 
         [0003]    As more specific examples, packages that allow in-package heating of a contained food product, followed by a holding period useful with large-scale food processing, can be particularly desirable for certain types of precooked breakfast foods. Precooked frozen dough or batter-based food products (e.g., pancakes, French toast, fruit filled Danish, breadsticks, scones, donuts waffles, muffins, pizza rolls, and cinnamon rolls) are particularly challenging to heat from a frozen state to the optimal temperature state for consumption. The precooked frozen food products may become dry and tough if the heating conditions are too high or too long, or may become moist and soggy if the amount of moisture in the food product is too great. As an added complication, in some instances, after a frozen food product has been heated, the food product must be held in a heated state at a desirable serving temperature until the food is served. For example, when serving large groups, a large amount of food must be prepared for serving to the group at the same time. This may involve heating the frozen food product as individual servings or in batches, and then holding the heated food at a desired serving temperature until served. The holding process may cause food properties to deteriorate such that the food products are undesirable (e.g., too soggy or dry) when served. 
         [0004]    Food products designed to be precooked and then served after heating (with optional holding time) are generally designed to be served as individual servings for consumption by one person, meaning that a package can contain an amount of precooked food product to be eaten by one consumer (e.g., a single or individual serving). The package (as opposed to the food contained in the package) can exhibit features useful for this type of preparation and serving of the food. For example, the package might contain a single serving of precooked food product, and, therefore, should be capable of being individually sold, stored, shipped, heated, held, and eaten by a consumer. The package must, therefore, be cold temperature stable, and heat stable, To be even more useful to a consumer, e.g., “user-friendly,” the package may include information on the contents (e.g., printed product labeling) and can be easily opened. 
         [0005]    In view of the foregoing, what is desired is new packaging materials that add value to a packaged food product. As a specific example, consumers desire precooked frozen dough or batter-based food products that can be heated from a frozen state to a desired temperature (e.g., 150° F. (65.6° C.)), and may be held at the desired temperature for a holding period (e.g., 240 minutes) while maintaining a desired temperature and moisture content, optionally along with other food properties. Even more preferably, the package can be easy to open, to gain access to the precooked and heated food contents. 
       SUMMARY  
       [0006]    The invention relates to packaging materials, packages, methods of making packaging material and packages, packaged food products such as packaged frozen precooked dough or batter-based food products, and methods of heating and holding the food products. 
         [0007]    The packaging material includes a cutline at a surface. The cutline includes partial-cut portions that extend only partially through a thickness of the heatable film, and vent hole portions that extend completely through the thickness of the heatable film. The film may be made of a useful packaging material, such as a polymer, and may be a single layer or multiple layers. Multi-layer films are preferably prepared by lamination. The cutlines may be formed by any method, including mechanical methods, laser scoring or cutting, or combinations of these. The packaging material may be useful for packaging any type of non-food product or food product, including refrigerated, frozen, or shelf-stable cooked or raw foods. 
         [0008]    As indicated, a packaging material as described can include a “cutline” that has “scoring,” meaning a partial cut (partial in that the cut does not extend through the entire thickness of the package material) along a surface of the film. The packaging material also includes venting in the form of holes also located at the cutline that extend through the thickness of the packaging material. The scoring extends between vent holes, e.g., connects vent holes, along a length of the cutline. Alternately stated, the package includes one or more cutline along a surface, the cutline including sections of partial culling the scoring) and sections of full cutting (the vent holes). The sections of partial cutting are sections of scoring or sections of a cut of only a portion of the full thickness of the film. The sections of full cutting penetrate the entire thickness of the film, creating a vent hole or aperture in the film. 
         [0009]    According to certain embodiments, the cutline functions as a location along which the package can be opened by pulling on one or more pieces of the package to create a separation (rip, tear, cut, etc.) along the cutline, e.g., controlled tear propagation along the cutline. The package may be openable, or may be an “easy open” package, these terms referring herein to a package that can be manually opened relatively easily along a cutline as described. The physical mode of opening may include pulling one portion (e.g., surface) of the package away from another portion (e.g., surface) of the package, at or along the cutline; i.e., before opening, surfaces of the two portions of the package border each other along a length of the cutline, and upon opening the portions separate along the cutline to produce separate portions, each having an edge that corresponds to the original cutline. Pulling the one portion will cause the portions to separate along the cutline such as by cohesive failure, tearing, or fracturing of the film at the cutline. The cutline provides a location along which a tear can easily propagate, preferably opening the package by creating a tear along the cutline, with the tear not extending beyond the cutline to a different location on a surface of the package that does not include the cutline. 
         [0010]    While the packaging material may be useful for any food product, the described packaging materials may be particularly useful with frozen precooked dough or batter based food products. A packaged precooked frozen dough or batter-based food product as described includes one or more frozen precooked dough or batter-based food product encased in a package (e.g., pouch) for heating. The pouch is sealed with the exception of two or more vent holes that function to release air or steam that may otherwise cause the food product to become soggy when the food product is heated in an oven (e.g., microwave, convection, or conventional oven). The amount of venting in the pouch also controls the headspace atmosphere in the pouch so that the food products do not dry out excessively with extended warm hold time. 
         [0011]    A large market for pre-prepared or pre-baked foods, e.g., breakfast foods, is for school children between Kindergarten and high school. These food products must contain food that is nutritious, tasty, efficiently prepared, and preferably easily accessed and consumed by young children. Accordingly, a packaged food product can optimally include food in a package that is easy to open. 
         [0012]    In one aspect, the invention relates to a packaged frozen precooked dough or batter-based food product. The product includes: one or more frozen precooked dough or batter-based food product; and a heatable pouch that includes a heatable film having a thickness, the heatable pouch encasing the one or more frozen precooked dough or batter-based food products. The heatable film includes a cutline having a length and multiple partial-cut portions, each partial-cut portion having a cut that extends partially through the thickness of the heatable film. The cutline also includes multiple vent hole portions, each vent hole portion having a vent hole that extends completely through the thickness of the heatable film. 
         [0013]    In another aspect the invention relates to a packaging material. The packaging material includes a heatable film having a width, a length, a thickness, a surface, and a surface area. The heatable film includes a cutline at the surface. The cutline includes multiple partial cut portions, each partial-cut portion including a cut that extends partially through the thickness of the heatable film. The cutline also includes multiple vent hole portions, each vent hole portion including a vent hole that extends completely through the thickness of the heatable film. 
         [0014]    In another aspect, the invention relates to a method of preparing a heated dough or batter-based food product from a frozen packaged dough or batter-based food product. The method includes: providing a packaged frozen precooked dough or batter-based food product as described herein, including a heatable pouch encasing one or more frozen precooked dough or batter-based food product; and heating the one or more frozen precooked dough or batter-based food product in the heatable pouch. 
         [0015]    In yet another aspect, the invention relates to a method of preparing a heatable film having vent holes and partial cuts. The method includes providing a heatable film having a width, a length, a thickness, a surface, and a surface area; and producing a cutline in the heatable film. The cutline includes a length, multiple partial-cut portions, each partial-cut portion comprising a cut that extends partially through the thickness of the heatable film. The cutline also includes multiple vent hole portions, each vent hole portion comprising a vent hole that extends completely through the thickness of the heatable film. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the invention and together with the description of the preferred embodiments, serve to explain the principles of the invention. A brief description of the drawings is as follows: 
           [0017]      FIG. 1  is a perspective front view of an embodiment of packaged precooked frozen dough or batter-based food product of the invention. 
           [0018]      FIG. 1A  is perspective back view of an embodiment of packaged precooked frozen dough or batter-based food product of the invention. 
           [0019]      FIG. 1B  is a cross sectional view of the embodiment of  FIG. 1  taken along line  1 B- 1 B. 
           [0020]      FIG. 2  is a graph displaying crust moisture as a function of vent area ratio. 
           [0021]      FIG. 3  is a graph displaying crust moisture as a function of vent area ratio at various hold times. 
           [0022]      FIG. 4  is a graph displaying crust moisture as a function of the number of vent holes at constant vent area ratio. 
           [0023]      FIG. 5  is a graph displaying crust moisture percent as a function of vent area ratio for fruit filled danish for a period of 5 hours of hold time in a warming cabinet at 150° F. (65.6° C.). 
           [0024]      FIG. 6  is a graph displaying crust moisture percent as a function of vent area ratio for French toast for a period of 5 hours of hold time in a warming cabinet at 150° F. (65.6° C.). 
           [0025]      FIG. 7  is a graph displaying crust moisture percent as a function of vent area ratio for breadsticks for a period of 4 hours of hold time in a warming cabinet at 150° F. (65.6° C.). 
           [0026]      FIG. 8  is a graph displaying scone crust moisture percent as a function of vent area ratio for a period of about 4 hours in a warming cabinet at 150° F. (65.6° C.). 
           [0027]      FIG. 9  is a graph displaying pizza roll crust moisture percent as a function of vent area ratio for a period of about 4 hours in a warming cabinet at 150° F. (65.6° C.). 
           [0028]      FIGS. 10A through 10F  show examples of patterns of cutlines on an outer surface of a package. 
           [0029]      FIGS. 11A ,  11 B, and  11 C show detailed views of exemplary cutlines. 
           [0030]      FIGS. 12A and 12B  show embodiments of package materials and webs. 
           [0031]      FIGS. 13A ,  13 B, and  13 C show embodiments of a package material and a package as described. 
       
    
    
     DETAILED DESCRIPTION 
       [0032]    Embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to the particular embodiments disclosed in the following detailed description. Rather, the embodiments are described so that others skilled in the relevant arts can understand the principles and practices of the present invention. 
         [0033]    The invention involves a film packaging material that is formed to include a cutline, the cutline including and extending along a length, at a surface of the film. The invention also relates to packages made from the packaging material, methods of preparing the packaging material, packaged food products (e.g., precooked frozen food products) that include the packaging material, and methods of preparing or using the packaged food products. 
         [0034]    The cutline includes two types of cuts. One cut that is part of the cutline is a full cut, or an aperture, that penetrates entirely through the thickness of the film to form an opening between the interior of the package and an exterior. The full cut functions to vent the package, as is described herein. The second type of cut is a partial cut, or a “score,” that extends between and connects full cuts, and that functions as a physical location for opening a package made of the film. 
         [0035]    Referring now to  FIG. 1 , a front perspective view of an embodiment of a packaged food product according to the invention is shown. Packaged precooked frozen dough or hatter-based food product  10  includes heatable pouch  12  that encases one or more precooked frozen dough or batter based food products  14 . Pouch  12  is formed from film  16  that is sealed to form longitudinal seam  18  and end seams  20  and  22  as shown in  FIG. 1A . Pouch  12  also optionally includes transparent window  24  that allows the food product  14  to be viewed from the exterior of the pouch. Certain features of pouch  12 , such as seams  18 ,  20 , and  22 , are similar to a pouch type package described in U.S. patent application Ser. No. 12/636,133 (“Packaged Frozen Precooked Dough or Batter-Based Food Products and Methods”), filed Dec. 11, 2009, the entirety of which is incorporated herein by reference. 
         [0036]    Pouch  12  includes a length (L) and a width (W). In some embodiments, the length can be considered to correspond to a “web” direction or a “machine” direction, which in the terminology of film processing is a direction in which the packaging film used to prepare package  10  travels along a machine used in the preparation or processing of the packaging film. The width can be considered to correspond to a “cross-web” direction, which in the terminology of film processing is a direction perpendicular to the direction in which the packaging film used to prepare pouch  12  travels along a machine used in the preparation or processing of the packaging film. Cutline  30  includes partial-cut portions  32  and full-cut portions (vent holes)  28  (see, e.g.,  FIGS. 11A ,  11 B, and  11 C). 
         [0037]    In the embodiment shown at  FIG. 1 , cutline  30  includes two segments  34  that extend along a length of package  12  in the “machine” direction, on generally opposite sides of package  12 ; another segment,  36 , extends along a width of package  12  to connect length-wise segments  34 . In alternate embodiments, a cutline may be located to extend across a surface of a pouch in other patters, e.g., diagonally, meaning that the cutline has directional components in both the width direction and the length direction. Specific examples are shown at  FIGS. 10A ,  10 B,  10 C,  10 D,  10 E, and  10 F. 
         [0038]      FIG. 10A  shows package  12 , which includes cutline  30  (shown as a dashed line). Package  12  has a length and width as illustrated at  FIG. 1 . Cutline  30  includes partial-cut portions  32  and full-cut portions (vent holes)  28  (see figures  11 A,  11 B, and  11 C). Cutline  30  includes five segments: segments  40 ,  42 ,  44 ,  46 , and  48 . Segments  40  and  42  extend in the length direction, along sides of pouch  12 . Diagonal segments  44  and  46  extend diagonally (in a direction that extends along both the length and the width of pouch  12 ) from the sides toward a center location of end seam  20 . Tab  48  is at an intersection of diagonal segments  44 . To open pouch  12  along cutline  30 , tab  48  can be lifted and pulled in the direction of arrow P, away from endseam  20  and toward endseam  22 . 
         [0039]    Referring to  FIG. 10B , cutline  30  includes four segments. Segments  40  and  42  extend in the length direction along sides of pouch  12 . Diagonal segment  46  extends diagonally from one side to the opposite side, and toward a side location of end seam  20 . Tab  48  is at an intersection of side segment  40  and diagonal segments  46 . To open pouch  12  along cutline  30 , tab  48  can be lifted and pulled in the direction of arrow P. away from endseam  20  and toward endseam  22 . 
         [0040]    Referring to  FIG. 10C , cutlines  30 A and  305  of pouch  12  includes multiple segments that define two openable segments. Cutline  30 A includes segment  40 A extending along a length of one side of package  12 , segment  42 A extending along a length of the opposing side of package  12  (in a crooked line that includes a straight segment and a diagonal segment), and shared diagonal segment  45  extending diagonally between central ends of segments  40 A and  42 A. Tab  48 A is at an intersection of side segment  42 A and shared diagonal segment  45 . To open pouch  12  along cutline  30 A, tab  48 A can be lifted and pulled in the direction of arrow PA, away from endseam  22  and toward endseam  20 . Cutline  30 B is complementary to cutline  30 A, and shares a common segment, shared diagonal segment  45 . Cutline  30 B includes segment  40 B extending along a length of one side of package  12  (in a crooked line that includes a straight segment and a diagonal segment), segment  42 B extending along a length of the opposing side of package  12 , and shared diagonal segment  45  extending diagonally between central ends of segments  40 B and  42 B. Tab  48 B is at an intersection of side segment  42 B and shared diagonal segment  45 . To open pouch  12  along cutline  30 B, tab  48 B can be pulled in the direction of arrow P, away from endseam  20  and toward endseam  22 . 
         [0041]    Package  12  of  FIG. 10D  is similar to package  12  of  FIG. 10B  except that segments  40  and  42  have reduced lengths. 
         [0042]      FIGS. 10E and 10F  show a topview and a side-perspective view of another embodiment of a package  12  having a cutline  30 . In this embodiment, the cutline extends across both a top surface and a bottom side of the package, allowing the package to be opened at a side of the package. Referring to the top view of  FIG. 10E , cutlines  30 T includes segment  40 T extending lengthwise along a length of package  12 , and diagonal segment  46 T extending from a central end the end away from endseam  22 ) of segment  40 T to a side of package  12  and near endseam  20 . A similar but opposite cutline  30 B can be located on the opposite (bottom) surface of package  12 , as shown at  FIG. 10F . Tabs  48 T and  48 B are located at side  50  of package  12  at an intersection of segments  46 T and  46 B. Package  12  can be opened by pulling tabs  48 T and  48 B in a direction away from package  12 , as shown by arrow P, to open package  12  at side  50 . 
         [0043]      FIG. 12A  shows an unfolded package material  13 , which can be folded to produce a package  12  of  FIG. 10E and 10F . Material  13  is a heat stable film  16  as described, optionally including printed graphics (not shown), and including cutline  30  ( 30 T and  30 B) as described herein. Material  13  can be folded along lines  150  and  152  to produce sides  50  and  52  (see  FIG. 10E ), so that opposing edges  110  are brought into contact to produce a (lengthwise) seam at a bottom (not shown) of package  12  of  FIGS. 10E and 10F . Edge  120  folds onto itself to produce endseam  20 , and edge  122  folds onto itself to produce endseam  22 . 
         [0044]      FIG. 12B , discussed in more detail below, shows a series of multiple materials  13  connected to form a web  15 . Upon cutting web  15  at each of two separation lines  17 , three separate materials  13  are formed, each of which can be used to produce a package  12  as shown at  FIGS. 10E and 10F . 
         [0045]    As shown in  FIG. 1B , which is a cross-sectional view of pouch  12  taken along line B-B, film  16  defines cavity  26 , which holds one or more precooked frozen dough or batter-based food products  14 . In  FIG. 1B , the dough or batter-based food products  14  depicted are pancakes, although fruit filled Danish, waffles, French toast, scones, breadsticks, donut, muffins, cinnamon rolls, pizza rolls, and the like may also be contained within the cavity. Other examples of useful food products that may be incorporated into a packaged food product, using a package as described, can include pre-cooked food products that have a topping or a filling, such as a Quesadilla, Pizza, Flatbread, Monkey bread, Bagel pulls, Grilled cheese sandwich, Breakfast sandwich, and the like. 
         [0046]    As shown in  FIG. 1 , film  16  includes cutline,  30 , which including an alternating series of full cuts (also referred to herein as vent holes) and partial cuts (also referred to herein as scoring)  32 . The full cuts function as vent holes  28  that allow venting from the interior of the package, through the vent holes, to an exterior of the package, e.g., to allow steam and air to escape from the cavity  26  of pouch  12  when the pouch is exposed to heat. In the embodiment of  FIG. 1 , the vent holes  28  can be in any form, such as elongate or circular apertures arranged regularly, intermittently, or along intermittent patterns, over a length of cutline  30  (see  FIGS. 11A ,  11 B, and  11 C). Alternate vent hole configurations include, for example, laser perforations (circular apertures) resulting in a non-linear vent. Partial cuts (scoring)  32  of cutline  30  provide a line of weakness that allows film  16  to be fractured, torn, ripped, or otherwise separated along the length of cutline  30 , into two pieces of film  16 . 
         [0047]      FIG. 11A  illustrates an example of a cutline in detail, including partial-cut portions and full cut portions. As illustrated, film  16  (a heat stable, ovenable film as described) includes a top (e.g., exterior) surface  60 , a lower (e.g., interior) surface  62 , thickness (t). and may include a single layer or multiple layers (e.g., laminated layers), optionally including printing or graphics and a tie-layer located between the two layers. Cutline  30  extends along surface  60 . Portions  28  of cutline  30  are full-cuts or apertures that penetrate the entire thickness (t) of film  16 . Portions  32  of cutline  30  are partial cuts (which do not constitute apertures) that penetrate only a portion of the thickness (t) of film  16 , e.g., a depth from surface  60  that extends to 25 percent of thickness t, e.g., 50 percent of thickness t, or even 75 percent of thickness t. 
         [0048]      FIGS. 11B and 11C  show details of additional embodiments of cutline  30 . Cutline  30  is continuous over a surface of film  16 , and is illustrated to be straight, but could be curved, cornered, or straight, or any combination curved, linear, and straight.  FIG. 11B  shows cutline  30 , having partial-cut portions  32  connecting linear full-cut portions  28 . Cutline  30  includes longer lengths of partial-cut portions  32  extending partially through the thickness of film  16 , that allow opening along cutline  30 , interrupted by shorter lengths of elongate or linear full-cut portions (apertures)  28 , for venting, extending through the full thickness of film  16 .  FIG. 11C  shows cutline  30 , having partial-cut portions  32  connecting circular full-cut portions  28 . Cutline  30  includes longer lengths of partial-cut portions  32  extending partially through the thickness of film  16 , that allow opening along cutline  30 , interrupted by shorter lengths of a series of closely-spaced round full-cut portions (apertures)  28 , for venting, extending through the full thickness of film  16 . 
         [0049]    Any heat stable film capable of being formed into at least a portion of a package may be used in the present method and many such films, also known as “heatable” or “cook-in” films, are known. Typically, such films are comprised of one or multiple layers of polymeric materials, including, for example, polyesters such as polyethylene terephthalate, nylon, and the like. A useful film may include a single layer of polymeric material, or multiple layers of the same or different polymeric materials, optionally different polymeric materials that provide multiple functions. Examples of layers and functions that be part of a film or a film layer (e.g., co-extruded or laminated layers) include, e.g.: a barrier material layer such as an oxygen barrier layer, a carbon dioxide barrier layer, a moisture barrier layer, or one or more layers that perform a combination of these barrier properties; a layer that contains coated or embedded graphics; a layer that contains a chemical scavenger such as a carbon dioxide or an oxygen scavenger; an adhesive layer such as a thermoplastic adhesive layer; or combinations of these and other layers of materials that may be useful. Commercially available examples of such films include those sold under the trade designation Mylar (E.I. du Pont de Nemours, Wilmington Del.), Nylon 6 and Nylon 66 (E.I. du Pont de Nemours, Wilmington Del.), and Milprint Ovenable Film (Milprint, Oshkosh Wis.), 
         [0050]    According to certain embodiments of films and methods, a cutline can he produced by laser-cutting methods, in these laser-cutting methods, a laser will produce partial-cut portions of a cutline. Certain heatable films can be particularly useful for forming a partial-cut portions of a cutline, including laminated multi-layer heatable films. In specific, a laminated multi-layer heatable film will have a boundary between the layers that is relatively clearly defined, as compared to a boundary between layers of a multi-layer film formed by another method, such as coextruding. A more clearly defined boundary between layers of a multi-layer beatable film will allow for improved formation of partial-cut portions using a laser. A typical laminated multi-layer heatable film will have a film layer, an adjacent layer of print (if this is a printed retail package), a tie layer adjacent to the layer of print (that holds the two layers together), and a second film layer (placing the layer of print and the tie layer between the two film layers. The two film layers may be made from any polymer material, such as PET (Polyethylene terephthalate), which can withstand sustained temperatures above 425 Fahrenheit without degradation, A PET/PET structure can be a preferred multi-layer laminated heatable film for methods and products described herein. Other useful multi-layer laminated heatable film structures include PET/Metalized multi-layer films, PET/Foil multi-layer films, and PET/Foil laminated multi-layer films. Layer thickness can depend upon on the application of the film and the power of a laser used to produce portions of the cutline. 
         [0051]    A heatable film (and heatable pouch) includes two or more vent holes in the film, located along the cutline. During heating of the food product, the vent holes allow heat or steam to escape from the cavity of the pouch. The number, size, shape, and arrangement of the vent holes in the pouch are selected to provide desired food product properties including, for example, moisture content, food temperature, relative humidity, and amount of condensation in the pouch. In some embodiments, the pouch contains about 20 or fewer vent holes, for example, about 15 or fewer vent holes, or about 6 to 12 vent holes. Other vent hole amounts may also be useful. In some embodiments, the number, size, and arrangement of vent holes can be chosen to provide a product moisture content that ranges from about 10% to about 60% moisture, for example, when the food product is heated at about 325° F. (163° C.) to about 375° F. (191° C.) for a time period of about 7 to about 15 minutes. 
         [0052]    In many embodiments, vent holes in a pouch (or as part of a film, heatable film, or other package or package material) provide a vent area ratio that ranges from about 0.00005 to about 0.1 (vent area/pouch (or film) area), or from about 0.00005 to about 0.01 (vent area/pouch (or film) area), or from about 0.00005 to about 0.001 (vent area/pouch (or film or package) area). Vent area ratio refers to a ratio of vent area to pouch (or film) area. Vent area refers to the combined open area of all vent holes in pouch (or package or film), e.g., measured in square meters. Pouch area refers to the surface area of a pouch (or package), e.g., measured in square meters. Film area refers to the surface area of a film (or other package material), e.g., measured in square meters. 
         [0053]    Any desired shape may be used for a vent hole. For example, a vent hole may be circular or linear, rectangular, oval, square, diamond-shaped, etc. Multiple vent holes may be distributed on a pouch or film in any desired arrangement or pattern along a cutline. In some embodiments, vent holes can be positioned along an edge of a pouch or film in a linear arrangement. In other embodiments vent holes may be located at a more central surface of a pouch, package, or film, optionally in a linear or a curved arrangement. 
         [0054]    A cutline, including partial-cut portions (scoring) and full-cut portions (vent holes) may be formed by any useful process for creating cuts, scoring, vent holes, etc., with controlled sizes in a heatable film, package, or package material. Examples include mechanical cutting devices such as a blade or rotary dies, laser cutting and perforation devices, and combinations of mechanical and laser devices. A cutline can be formed manually or by automated, high speed processing. All feature of a cutline can be formed by a single device, or, alternately, different features of a the same cutline can be formed using different devices. For example, a partial-cut portion of a cutline may be formed using one laser, and a full-cut portion of the same cutline may be formed using a second laser. Alternately a partial-cut portion may be formed using a laser, and a full-cut portion may be formed in the same cutline using a mechanical blade or die. A cutline may be formed on a package material either before or after the package material is formed into a pouch or other package. 
         [0055]    One exemplary methods of forming a cutline in a packaging material can be, by use of high speed processing equipment, forming cutlines on a large web of packaging material film that can then be converted (e.g., cut, folded, etc.) to individual packages. These methods can involve high speed movement of a web along a device that can produce a cutline as described herein, using high speed cutting and registration techniques. These techniques can allow for cutting full-cut portions and partial-cut portions, at high speed, in the direction of movement of the web (the web direction), in the direction perpendicular to the movement of the web (the cross-web direction), or diagonally along a length that has directional components in both the web direction and the cross-web direction. A web of packaging material can moved at high speed along this processing equipment, and one or more cutting device can produce partial-cut portions and full-cut portions in the moving film to produce a cutline as described and illustrated herein. Exemplary equipment and methods for this type of processing, including high speed movement of a film, cutting, and registration, are shown, e.g., in U.S. Pat. No. 7,640,836 (Ser. No. 09/615,812); United States Patent Application Publication 2011/0073576 (Ser. No. 12/892,335); and International Application Number PCT/US02/15938 (International Publication Number WO 02/092274), the entireties of each of these being incorporated herein by reference. 
         [0056]      FIG. 12B , shows a web  15  that can be prepared or processed in the form of a moving web, using laser or die cutting equipment to produce a cutline (e.g., cutlines  30 T and  30 B). Web  15  moves in web direction (W), which may correspond to a length of a package  12  (see  FIG. 1 ). Cutlines or a segment of a cutline (e.g.,  30 ) can be formed along the web direction, only. Alternately, a cutline or a segment of a cutline may be formed in a perpendicular (crossweb, CW) direction, or diagonally. These methods of producing multiple cutlines  30  along a moving piece of packaging material will produce a web that includes a series of multiple materials  13 . Upon cutting web  15  at each of two separation lines  17 , three separate materials  13  (see  FIG. 12A ) are formed, each of which can be used to produce a package  12  as shown at  FIGS. 10E and 10F . 
         [0057]      FIGS. 12A and 12B  illustrate packaging materials and webs that include cutline  30  shown at  FIGS. 10E and 10F ; alternately, a package material  13  or web  15  could include a cutline of any other configuration that is described or illustrated herein, such as a cutline as illustrated at any of  FIGS. 10A ,  10 B,  10 C, and  10 G. 
         [0058]      FIGS. 13A and 13B  illustrate alternate configurations of package material  16  and package  12 , each of which includes cutline  30  shown at  FIGS. 10E and 10F ; alternately, a package material  16  could include a cutline of any other configuration that is described or illustrated herein, such as a cutline as illustrated at any of  FIGS. 10A ,  10 B,  10 C, and  10 D.  FIG. 13A  shows unfolded package material  16 , which can be folded to produce a package  12  of  FIG. 13B . Material  16  is a heat stable film as described, optionally including printed graphics (not shown), and including cutline  30  as described herein. Material  16  can be folded along lines  150  and  152  to produce sides  150  and  152  (see  FIG. 10E ), so that opposing edges  110  are brought into contact to produce lengthwise seam  18  at a bottom (not shown) of package  12 . Edge  120  folds onto itself to produce endseam  20 , and edge  122  folds onto itself to produce endseam  22 . 
         [0059]      FIGS. 13B  (top view) and  13 C (end view) show pouch  12  prepared from material  16 , with cutline  30  extending along a curved path across package  12  in a cross web (width) direction. Tab  48  (which as illustrated is a piece of material secured to but not part of material  16 ) is located at an apex of the curve of cutline  30 , and can be pulled away from package  12  to open pouch  12  along cutline  30 . After being opened along the length of cutline  30 , the flap of package material  16  that is thereby produced can be pulled toward end  20 , still using tab  48 , and can cause package material  16  to easily and predictably tear in the machine or web direction of material  16  along dashed lines  15  (which are not cutlines). 
         [0060]    According to embodiments of the invention, the ratio of the total area of vents in a package, to the total area of the package, can be selected to produce desired venting of a package upon heating, and holding. A vent area ratio can relate to an area of vents compared to an area of a package, such as package  12 ; alternately to an area of vents compared to an area of a package material, such as package material  13  shown at  FIG. 12A ; and also, alternately, an area of vents compared to an area of a web, such as web  15  shown at  FIG. 12A . That is, a package material  13  can have a vent area ratio in a range from about 0.00005 to about 0.1 (vent area/area of package material  13 ) or as otherwise functionally or specifically described herein, and a web  15 , made up of multiple package materials  13 , can have an identical or similar vent area ratio a range From about 0.00005 to about 0.1 (vent area/area of web  15 ) or as otherwise functionally or specifically described herein. 
         [0061]    Preferred vent area ratios may be selected to provide a desired crust moisture content in the heated food product. For example, a vent area ratio may be selected to provide a crust moisture content in a range from about 15% to about 45% in a heated food product. A desired moisture content depends on the type of frozen precooked dough or batter-based food product that is being heated. For example, a vent area ratio may be selected to provide a crust moisture of about 10% to about 20% for donuts, or about 35% to about 45% for pancakes. 
         [0062]    Precooked dough or batter-based food products suitable for use in the present invention include, for example, pancakes, fruit filled Danish, scones, donuts, pizza rolls, breadsticks, muffins, waffles, French toast, and cinnamon rolls. In many embodiments the precooked dough or batter-based food products are miniature in size. and the pouch contains 1 or more, typically about 4 to about 10 of the dough or batter-based food products in each pouch. For example, in some embodiments, the pancakes or waffles range in diameter from about 1 inch to about 3.5 inches (2.54 cm to 8.89 cm). The French toast may be in the form of slices (i.e., approximately square) or sticks (i.e., rectangular). In some embodiments, the French toast is in the form of sticks have a size of about 0.5 inch by about 3 inches (1.27 cm to 7.62 cm). In some embodiments the food product is a fruit filled Danish, for example having a volume ranging from about 8 in 3  to about 15 in 3  (131 cm 3  to 245 cm 3 ). In some embodiments, the food product is a miniature muffin, for example, having a volume ranging from about 2 in 3  to about 4 in 3  (32.8 cm 3  to 65.5 cm 3 ). The recipe used to prepare the dough or batter-based food product includes any recipe that can be used to prepare a food product suitable for being cooked and frozen in a cooked state for later reheating. 
         [0063]    After being initially cooked (i.e., precooked), one or more of the dough or batter-based food products can be inserted into a pouch and sealed for storage. The pouch is typically hot-sealed, for example, by using metal sealing jaws at a temperature of about 245° F. (118° C.) for a dwell time of about 2.5 seconds. The sealed pouch containing the dough or batter-based food products is then frozen, for example, at a temperature ranging from about −10° F. (−23.3° C.) to about 0° F. (−17.7° C.). The frozen dough or batter-based food product can then be stored for an extended period (e.g., about 12 to about 36 weeks) prior to being heated for consumption. 
         [0064]    Heating of the frozen precooked dough or batter-based food product is typically conducted in a convection oven although a microwave or conventional oven may also be used. Heating temperatures typically range from about 325° F. (163° C.) to about 375° F. (191° C.) for times ranging from about 7 to about 15 minutes. The reheating temperature and time may vary for example, depending upon the type of oven, number of food products being reheated, whether the product is frozen or thawed, and the like. Heating is conducted in order to achieve a temperature suitable for serving the food product to a consumer. For example, the heated product may be at a temperature ranging from about 120° F. (48.9° C.) to about 180° F. (82.2° C.), although other temperatures may be suitable. After heating, the food product may be held at desired temperature in the pouch for a desired period of time, for example, to accommodate cafeteria-style serving or food service holding of the food product. For example, the heated dough or batter-based food product may be held for a time period ranging from about 10 minutes to about 240 minutes at a temperature ranging from about 130° F. (544° C.) to about 155° F. (65.6° C.). For a user to consume the heated, packaged food product, a package as described herein, comprising a cutline, can be opened by pulling on the package to create an opening along the cutline. 
         [0065]    The invention will now be described with reference to the following non-limiting examples. 
       EXAMPLES 
       [0066]    The following Examples show packages that include vent holes as described herein, but that are not described to not include partial cutting or scoring to connect the vent holes, to produce a cutline as described herein. 
         [0067]    This example was conducted in order to determine if a relationship existed between the pancake crust moisture content and the vent area in the pouch. Samples having a range of vent area ratios were tested. Vent area ratios ranging from 0 to 0.125 m 2  were tested and crust moisture was measured for each vent structure. For the testing, crust moisture content was measured using a CEM brand microwave moisture analyzer. The CEM analyzer uses a balance and microwave energy to heat the sample, without burning, until all the moisture has evaporated. The frozen dough based food product was heated to the desired temperature in vented packaging in a convection oven. The food product was then removed from the pouch and a 1 to 3 gram sample of the crust was taken from the heated food product. The sample was deposited onto the sample balance of the CEM moisture analyzer and the crust moisture was measured. The CEM settings used were as follows. 
       CEM Settings 
       [0068]      
         [0000]    
       
         
               
               
               
             
               
               
               
               
             
               
               
               
             
               
               
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 Description 
                 Setting 
               
               
                   
                   
               
             
             
               
                   
                 Power 
                 50% 
               
             
          
           
               
                   
                 Change Wt. 
                 0.4 
                 mg 
               
               
                   
                 Time max 
                 15 
                 minutes 
               
             
          
           
               
                   
                 Temp max 
                 80° C. (176° F.) 
               
             
          
           
               
                   
                 Wt minimum 
                 1 
                 gram 
               
               
                   
                 Wt maximum 
                 3 
                 grams 
               
             
          
           
               
                   
                 Comp 
                 On 
               
               
                   
                   
               
             
          
         
       
     
         [0069]    The settings cause the CEM machine to use 50% of the microwave power, and to measure the sample weight until it has stabilized to within 0.0004 grams over a time period of 10 seconds. The maximum time of the test was limited to 15 minutes, and the maximum allowed temperature of the food product was 80° ((176″ F.). In some instances, the maximum temperature Setting On the CEM moisture analyzer was adjusted for a particular food product. For example, pancakes required a maximum temperature setting of 90° C. (194° F.), and breadsticks required a maximum temperature setting of 70° C. (158° C.) to prevent burning. 
         [0070]    Initially, when crust moisture was plotted as a function of vent area the graph indicated an exponential relationship. The natural log (i.e., Ln) of the vent ratio was calculated and is plotted in  FIG. 2 .  FIG. 2  shows the relationship between crust moisture content and vent area for various food products.  FIG. 2  demonstrates that increasing the vent area allows more moisture to escape and thus results in a lower crust moisture. The data graphed in  FIG. 2  is also provided in TABLES 1-6. 
         [0000]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Mini Maple Pancakes 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
               
               
                   
               
             
          
           
               
                 0 
                 49.86 
                   
               
               
                 0.000004854 
                 49.68 
                 −12.2357 
               
               
                 0.000012816 
                 44.34 
                 −11.2648 
               
               
                 0.000116329 
                 43.49 
                 −9.05909 
               
               
                 0.000231288 
                 41.54 
                 −8.37185 
               
               
                 0.000794702 
                 34.4 
                 −7.13754 
               
               
                 0.098455598 
                 24.19 
                 −2.31815 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Fruit Filled Danish 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
               
               
                   
               
             
          
           
               
                 0 
                 32.16 
                   
               
               
                 0.000035389 
                 27.17 
                 −10.249085 
               
               
                 0.000081192 
                 24.45 
                 −9.4186951 
               
               
                 0.000330042 
                 20.49 
                 −8.0162919 
               
               
                 0.000342570 
                 19.96 
                 −7.9790355 
               
               
                 0.000367477 
                 20.42 
                 −7.9088502 
               
               
                 0.224803978 
                 14.54 
                 −1.4925265 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 French Toast 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
               
               
                   
               
             
          
           
               
                 3.04599E−05 
                 42.88 
                 −10.399098 
               
               
                 0.000117062 
                 36.49 
                 −9.052809 
               
               
                 0.000189289 
                 37.61 
                 −8.572238 
               
               
                 0.000374466 
                 38.15 
                 −7.8900107 
               
               
                 0.000381000 
                 37.03 
                 −7.8727112 
               
               
                 0.127350967 
                 31.61 
                 −2.0608085 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 4 
               
             
             
               
                   
               
               
                 Breadsticks 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
               
               
                   
               
             
          
           
               
                 3.0426E−05 
                 25.39 
                 −10.400214 
               
               
                 0.000118262 
                 23.07 
                 −9.0426118 
               
               
                 0.000250864 
                 24.55 
                 −8.2905988 
               
               
                 0.000327252 
                 21.86 
                 −8.0247797 
               
               
                 0.000369258 
                 26.06 
                 −7.904016 
               
               
                 0.123685838 
                 14.25 
                 −2.0900105 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 5 
               
             
             
               
                   
               
               
                 Scones 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
               
               
                   
               
             
          
           
               
                 4.09528E−05 
                 16.14 
                 −10.103089 
               
               
                 0.000136258 
                 17.43 
                 −8.9009579 
               
               
                 0.000322478 
                 13.84 
                 −8.0394748 
               
               
                 0.000648787 
                 13.81 
                 −7.3404065 
               
               
                 0.158851351 
                 9.55 
                 −1.8397864 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 6 
               
             
             
               
                   
               
               
                 Donuts 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
               
               
                   
               
             
          
           
               
                 3.367E−05 
                 15.86 
                 −10.298902 
               
               
                 0.000079745 
                 14.26 
                 −9.4366788 
               
               
                 0.000232006 
                 15.79 
                 −8.368748 
               
               
                 0.000515788 
                 13.96 
                 −7.5698139 
               
               
                 0.235939508 
                 9.86 
                 −1.4441798 
               
               
                   
               
             
          
         
       
     
         [0071]    It was also shown that the crust moisture content was maintained over time when product was stored in a warmer.  FIG. 3  shows that the crust moisture content given a vent ratio is maintained over the holding time. Frozen dough-based products (i.e., donuts) were heated in a convection oven and were then held in a warming cabinet for 4 hours at 150 F (65.5° C.). The graph shows that the crust moisture content in relation to the specific vent ratio is maintained for four hours of holding time in a warming cabinet. 
         [0072]    It was also shown that at a constant vent area ratio, the change in crust moisture percent as a function of the number of vent holes is negligible. Packages were tested at a constant vent area ratio while varying the number of vents used to attain the vent area ratio. The results show that crust moisture is affected by the vent area ratio, not the number of vents in the pouch. The results are presented in TABLE 8 and in  FIG. 4 . 
         [0000]    
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 8 
               
             
             
               
                   
               
               
                 Data from pancakes at constant vent area 
               
             
          
           
               
                   
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
                 # holes 
               
               
                   
                   
               
             
          
           
               
                   
                 0.000849773 
                 51.86 
                 −7.07054 
                 1 
               
               
                   
                 0.000849773 
                 51.08 
                 −7.07054 
                 1 
               
               
                   
                 0.000849773 
                 49 
                 −7.07054 
                 1 
               
               
                   
                 0.000864500 
                 44.38 
                 −7.05336 
                 2 
               
               
                   
                 0.000864500 
                 44.79 
                 −7.05336 
                 2 
               
               
                   
                 0.000864500 
                 43.14 
                 −7.05336 
                 2 
               
               
                   
                 0.000800320 
                 49.66 
                 −7.1305 
                 12 
               
               
                   
                 0.000800320 
                 48.51 
                 −7.1305 
                 12 
               
               
                   
                 0.000800320 
                 48.2 
                 −7.1305 
                 12 
               
               
                   
                   
               
             
          
         
       
     
         [0073]    TABLES 9-11 and  FIGS. 5-8  provide additional data on various embodiments of the invention that were tested. 
         [0000]    
       
         
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 9 
               
             
             
               
                   
               
               
                 Mini Muffins Crust Moisture 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
                 Product Type 
               
               
                   
               
             
          
           
               
                 0.087837838 
                 6.93 
                 −2.43226 
                 Blueberry muffin 
               
               
                 0.000533547 
                 13.56 
                 −7.53596 
                 Blueberry muffin 
               
               
                 0.000018773 
                 25.45 
                 −10.8831 
                 Blueberry muffin 
               
               
                 0.029166000 
                 14.05 
                 −3.53496 
                 Apple cinnamon 
               
               
                 0.000823121 
                 17.25 
                 −7.10241 
                 Apple cinnamon 
               
               
                 0.000811688 
                 20.95 
                 −7.11639 
                 Apple cinnamon 
               
               
                 0.000235895 
                 21.98 
                 −8.35212 
                 Apple cinnamon 
               
               
                 0.000117148 
                 25.81 
                 −9.05207 
                 Apple cinnamon 
               
               
                 0.000013246 
                 25.9 
                 −11.2318 
                 Apple cinnamon 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 10 
               
             
             
               
                   
               
               
                 Mini Waffles Crust Moisture 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
                 Type 
               
               
                   
               
             
          
           
               
                 0.124551724 
                 30.61 
                 −2.08303 
                 waffle 
               
               
                 0.120599366 
                 21.42 
                 −2.11528 
                 waffle 
               
               
                 0.000225788 
                 42.5 
                 −8.39591 
                 waffle 
               
               
                 0.000225788 
                 40.92 
                 −8.39591 
                 waffle 
               
               
                 0.000111477 
                 46.42 
                 −9.10169 
                 waffle 
               
               
                 0.000115182 
                 43.67 
                 −9.06899 
                 waffle 
               
               
                 0.000042953 
                 37.84 
                 −10.0554 
                 waffle 
               
               
                 0.000022063 
                 39.19 
                 −10.7216 
                 waffle 
               
               
                 0.000006573 
                 43.53 
                 −11.9326 
                 waffle 
               
               
                 0.000020294 
                 41.06 
                 −10.8052 
                 waffle 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 11 
               
             
             
               
                   
               
               
                 French Toast Mini Sticks crust moisture 
               
             
          
           
               
                 Vent ratio 
                 % moist 
                 Ln (vent ratio) 
                 Type 
               
               
                   
               
             
          
           
               
                 0.102857143 
                 32.91 
                 −2.27441 
                 French toast 
               
               
                 0.000222836 
                 41.36 
                 −8.40907 
                 French toast 
               
               
                 0.000218551 
                 37.43 
                 −8.42849 
                 French toast 
               
               
                 0.000121764 
                 33.35 
                 −9.01342 
                 French toast 
               
               
                  7.3076E−05 
                 42.63 
                 −9.52401 
                 French toast 
               
               
                 7.16161E−06 
                 39.05 
                 −11.8468 
                 French toast 
               
               
                   
               
             
          
         
       
     
         [0074]    In some embodiments, the precooked frozen dough or batter-based food products have a very high water activity filling (e.g. pizza rolls) which causes a change in crust moisture content over hold time. Frozen Pizza rolls are an example where the water activity is greater than 0.95. The data in  FIG. 9  demonstrate that, for pizza rolls, the crust moisture increases as warmer hold time increases. 
         [0075]    Other embodiments of this invention will be apparent to those skilled in the art upon consideration of this specification or from practice of the invention disclosed herein. Various omissions, modifications, and changes to the principles and embodiments described herein may be made by one skilled in the art without departing from the true scope and spirit of the invention which is indicated by the following claims.