Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23B—PRESERVATION OF FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES; CHEMICAL RIPENING OF FRUIT OR VEGETABLES
  • A23B7/00—Preservation of fruit or vegetables; Chemical ripening of fruit or vegetables
  • A23B7/06—Blanching
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L5/00—Preparation or treatment of foods or foodstuffs, in general; Food or foodstuffs obtained thereby; Materials therefor
  • A23L5/40—Colouring or decolouring of foods
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
  • A23L19/03—Products from fruits or vegetables; Preparation or treatment thereof consisting of whole pieces or fragments without mashing the original pieces
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
  • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
  • A23L19/11—Cassava, manioc, tapioca, or fermented products thereof, e.g. gari
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
  • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
  • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
  • A23L19/14—Original non-roasted or non-fried potato pieces
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L5/00—Preparation or treatment of foods or foodstuffs, in general; Food or foodstuffs obtained thereby; Materials therefor
  • A23L5/10—General methods of cooking foods, e.g. by roasting or frying
  • A23L5/17—General methods of cooking foods, e.g. by roasting or frying in a gaseous atmosphere with forced air or gas circulation, in vacuum or under pressure

Definitions

• This invention relates to food processing and, more particularly, to a process for pre-processing foodstuffs containing substances including starches, cellulose, pectin, and/or naturally occurring sugars and enzymes, such as potatoes, corn, peppers, onions, carrots, broccoli, squash and other vegetables, for subsequent further processing and consumption.
• pre-processed vegetables typically are prepared by first cutting (peeling and coring if required) whole vegetables into portions, such as wedges, slices, strips, shreds or rices then blanching those portions in hot water or steam, followed by cooling in air or water (emersion or deluge) and finally freezing.
• the frozen vegetable portions may then be re-thermed/reheated by the end user, typically a restaurant, as an ingredient or by means common to restaurant/commissary kitchens such as boiling, steaming, stir frying, grilling, roasting or sauteing, as by way of example.
• Other re- fherming/reheating methods include oven heating and microwave heating.
• Most prior processes use variations of the foregoing pre-process, including additional steps, to prepare vegetable products for freezing and shipment to the consumer.
• Potato portions typically are prepared by cutting whole potatoes into portions, such as wedges or strips, American “fries” or English “chips,” blanching those portions in hot water or steam, drying the strips in hot air, then par frying the portions in hot oil prior to freezing them.
• the frozen potato portions may then be reconstituted by the consumer, typically a restaurant, by frying them in oil or heating them in either a conventional or microwave type oven.
• Many prior processes use variations of the foregoing process, including some having additional process steps, to prepare potato products to be frozen for shipment to the consumer
• Fresh vegetables may be cleaned, cut and refrigerated in their raw state (without blanching) and then sold to similar businesses.
• This abbreviated process produces what is known as "fresh" product.
• Fresh product has the disadvantage of having a relatively short shelf life and reduced quality due to internal enzymatic action within the product, as well as degradation at the hands of spoiling agents.
• Incoming raw product is then washed and, in some cases such, as potatoes, carrots, onions and sweet, potatoes (yams), peeled. Other products, such as peppers, are cored.
• further processing may include slicing or sectioning. Generally slices range from thin, 1/32 inch slices to thick slices over two inches, whereas sectioned units can range from 2 to over 12 per vegetable unit or even take the form of shreds or rices, for example. Sliced or sectioned pieces then are typically blanched in mediums that include a water bath, a water deluge, heated saturated air environment, microwave energy or live, high temperature steam.
• the product is cooled via water bath, water deluge or chilled using saturated air passing through a bed of the blanched product.
• the product is typically frozen by conventional means.
• Industrial systems pass air, usually in the range of -20 to -40 °F, through a bed of product to achieve freezing of the product.
• the product is then packaged for storage. Generally, freezing increases the shelf life of the product rendering it more marketable and easier to ship and store.
• par frying In the case of preparing of potato portions, the vast majority of traditional processes include at least one par frying step.
• the potato portions typically are immersed in a tank of hot cooking oil or fat.
• Alternative frying methods may be used such as "deluge" frying wherein hot frying oil is sprayed downwardly or caused to cascade downwardly onto the potato portions as they are conveyed beneath the cooker.
• the frying oil which typically has a temperature of 350° F to 375° F, partially cooks the potato portions, driving out moisture and thereby increasing the solids percentage of those portions. Removal of moisture from the potato portions is also- desirable in order to reduce hydrolysis of the cooking oil, thus prolonging its useful life.
• the par frying step while effective to quickly remove moisture content from potato portions, is a relatively harsh means for extracting moisture, especially at higher frying temperatures, thus adversely affecting the organoleptic qualities of the ultimate prepared potato product.
• Processing of vegetable products into refrigerated or frozen states traditionally renders a product with characteristics that are not regarded as fresh. Specifically, the product color, texture, turgor and flavor are degraded enough to render the products less desirable than fresh products. Frozen products are also inferior to fresh products because freezing causes the breakdown of the vegetable's inter- and intra-cellular conditions, increased liquid purge and a loss of flavor characteristics.
• vacuum infusion is used for the introduction of flavors and property enhancers for vegetable portions as well as some types of meat. This is done by placing the food portion in a chamber subjecting it to a vacuum and then introducing various flavorings and property enhancers that, due to the vacuum, penetrate into the pores of the treated portion when the vacuum is removed. Vacuum infusion may be employed to treat foodstuffs with various antibacterial and/or anti-fungicidal agents, as well.
• Goldberg et al. in U.S. Patent No. 6,245,291, discusses the application of biocidal treatment to whole muscle meats, processed meats and various fruits as well as porous and nonporous foodstuffs.
• the focus of which is the destruction of bacteria and spore formers that are toxic to humans.
• Of particular interest is the use of vacuum to induce movement of the biocidal or non-biocidal substances.
• the focus of the disclosed process is the minimization of perceptible changes to the subject product by the end user. This is in contrast with the optimization of quality, attributes and storability that is not dependant on agents such as biocides.
• a vacuum environment is specifically claimed in the embodiment by Haamer, in
• Minelli et al. in U.S. Patent No. 6,514,554, claims vacuum application during par frying and blanching in an oil medium under a vacuum. Neither of these processes lends themselves to the preparation of potato and/or vegetable portions that can be packaged, shipped and prepared by the end user as a "fresh", unfrozen, vegetable product. Rather, Minelli focuses on in-vessel processing with water or oil mediums to attain the desired characteristics. It is well understood that this is a very expensive, process system in terms of both operational costs and investment funding and does not produce the most desirable vegetable characteristics.
• the fresh produce industry uses vacuum cooling to cool cleaned or freshly harvested fruits and vegetables, including bean sprouts. See article specifically entitled, "Effects of Vacuum Cooling and Storage Temperature on the Quality of Bean Sprouts," Jennifer R. DeEll et al., ENESAD, France.
• the products are packaged, generally near the point of harvest.
• the packaging temperature is lowered utilizing various refrigeration techniques and vacuum systems.
• Product temperature may be near freezing at the completion of the process. This requires fresh unprocessed product that is packaged for distribution the goal being the removal of field heat in preparation for shipping.
• ICR065 M. Houska et al., describes methodology for subjecting various processed meats to a vacuum system for cooling. This disclosed system approaches only finished, ready- for-distribution meat products. Additionally, infusion of ingredients into the surface of the meat under a vacuum is discussed, which is a common practice in the meat industry.
• the present invention comprises an improved pre-process method for preparing "fresh" vegetables, (including potatoes), vegetable and potato portions and the like.
• fresh shall be used to identify vegetables and vegetable portions that have been processed according to the LintonizingTM process in contrast to the term “raw”, which is the state of vegetables at the beginning of the LintonizingTM process.
• the term “vegetable portions” may include whole vegetables as well.
• LintonizingTM is a service mark for a proprietary process licensed to Viands Concerted, LLC of Columbus, Ohio.
• peeled and portioned vegetable portions are blanched, drained of excess surface moisture, cooked at a low-temperature and low pressure and then cooled down prior to packaging.
• the prepared and portioned vegetables are blanched, drained of excess surface moisture, cooked at a low-temperature and low pressure and then cooled down prior to packaging.
• the prepared and portioned vegetables are blanched, drained of excess surface moisture, cooked at a low-temperature and low pressure and then cooled down prior to packaging.
• the vegetable portions may be rinsed after cutting and prior to blanching to remove pieces of any cutting residuals from the vegetable surface.
• portions may be grilled or roasted following the low temperature, low pressure cooking process.
• Another advantage of the present invention is that it enables the enhancement of organoleptic qualities even from lower grade raw product, thus increasing quality while reducing costs. In some cases fully cooked vegetable portions prepared according to the present invention exhibit the color raw vegetables. As should be recognized by those skilled in the art, other processing advantages and improved product features will also be achieved by the present invention.
• Figure 1 is a flow diagram of a process for inter- and intra-cellular stabilization of foodstuffs, and in particular vegetables (including potatoes), according to an embodiment of the present invention.
• raw vegetables including without limitation, potatoes, corn, onions, peppers, carrots, squash, egg plant, sweet potatoes, and sugar snap peas
• raw vegetables including without limitation, potatoes, corn, onions, peppers, carrots, squash, egg plant, sweet potatoes, and sugar snap peas
• Conventional cleaning methods for various products includes husldng/de-silking (corn), peeling (root crops) and washing such as with a water plume, flume or spray.
• the cleaned vegetables may then be cut into portions or pieces suitably sized for the end product as in step 60.
• portions is used in its broadest sense to include strips or segments, and vegetables cut to specific lengths, as well as substantially whole vegetables, in some cases.
• the portions may be rinsed, as at step 70, by spraying or immersing the vegetables in a water bath to remove any process- produced debris.
• the rinsed vegetable portions are then blanched at step 80 by subjecting them to any number of means, including immersion in hot water, generally at about 165° F to boiling from about 15 seconds up to 70 minutes, depending upon the- characteristics of the vegetable being processed. Blanching may be accomplished by a number of conventional means, such as by immersion, steam, deluge or microwave. With the exception of potatoes and sweet potatoes (yams), a rolling boil water bath for 1 to 5 minutes is utilized, for
• the blanching step deactivates enzymes present in the vegetables and prevents the vegetables from discoloring during storage.
• the vegetable portions may be blanched in steam, using microwave energy or in a deluge blancher at 80.
• the time and temperature combination for the blanching process is an important part of the process. If the blanching time is too short, such as less than 15 seconds at 165° F, then the portion will be insufficiently heated resulting in enzymes that are not deactivated and leaving bacteria, yeasts and molds that . are not adequately neutralized. On the other end of the timing spectrum, if blanched too long, such as 45 minutes or more at 185° F, then the portions will be overcooked, become mushy and too soft to handle. Likewise, blanching the portions at too high a temperature, such as 195° F or greater, for as long as 70 minutes or more, will cause most vegetable portions to become mushy, discolored and undesirable to the final consumer.
• the portions are quickly drained of excess surface moisture as at step 80 before further processing.
• a shaking process or a high velocity fan air knife may be used to rapidly blow off excess surface moisture while trying to retain as much heat in the portions as possible.
• Such equipment can also be included in the blanching process.
• Steps 10 through, and including, step 80 are well known processes within the vegetable processing industry and are shown in Fig. 1 called out with arrows and entitled
• the process includes transfer of drained vegetable portions to a sealed vacuum chamber in which they are subjected to a vacuum while they are still in a heated state from the prior blanching process, as shown in step 90.
• the vacuum vessel access door is designed to close and lock. Once the vessel is loaded and locked, a valve opens, allowing the vacuum pressure contained in the system's accumulator to rapidly bring the vessel to a predetermined level of vacuity.
• a vacuum pump can operate in an automatic mode to further aid in achieving the target vacuity in a short period of time, with about 30 seconds being preferred. While the target vacuum ramp time may vary to cut down on the processing time, it is desirable for the target vacuum to be attained as quickly as possible.
• the applied vacuum is permitted to ramp up from ambient atmospheric pressure to around 15" Hg to 30" Hg where it is maintained in the range of about 15" Hg to 30" Hg, preferably about 27.5" Hg, for a period that can range up to 70 minutes. Depending upon the vacuum source and methodology used, it may take as much as 10 minutes or more to reach the desired level of vacuity.
• moisture is extracted, from the surface and . .
• the vacuum vessel at step 90 may additionally comprise a cooling means where the exterior of the vessel is deluge cooled during or following the vacuum cycle. It is believed that the introduction of additional cooling media will further aid the cooling and stabilization of vegetable portions.
• the drastic cooling rate provided by the liquid nitrogen produced a deleterious effect on, not only the surface of the vegetable portion, but also in the micro fibril cellulose structure of the processed vegetable portions.
• micro fibril cellulose structure of the vegetable portions is purged of excess water during the low temperature, low pressure cooking process. This results in the toughening of the cell walls and cellulose fibers. This optimizes texture and turgor in the vegetable portions particularly desirable for extended refrigerated storage. It will be appreciated that the actual vacuum parameters are influenced by a number of factors including the physical characteristics of the product portion being processed and target specifications of the final product.
• the fresh vegetable portions may be passed through a machine that adds grill or roasting marks, as at 102, to the surface of the vegetable portions. This may be accomplished prior to cooling at 100, including immersion in a water bath, air or mist, having ozone or chlorine dioxide or other bacterial,
• 16 mold and yeast treating agents may be supplied via a pump at step 101.
• the vegetable portions are sprayed with the sanitizing agent just prior to a dewatering process as illustrated at step 110.
• Pump 101 supplies the sanitizer agent to either process 100 or 110.
• the vegetable portions are then transferred to a dewatering device 110 where surface water is removed via high velocity air provided by an air stripper or other suitable dewatering device.
• Vegetable portions may then packaged at step 120 where excess air may be evacuated the package via a vacuum pump following the introduction of inert gases such as CO 2 , N and/or other inert gases appropriate to the particular vegetable portions.
• Packaged products may then be transported to a warehouse for storage 130 or shipped directly to the consumer, as shown at step 140.
• flavor and texture components of vegetable portions may be significantly degraded during each process phase of the traditional process. This is due primarily to the evaporation of essences and other components in the vegetable that are volatile and the adverse effect on the micro fibril cellulose structure and cellulose treatment.
• the present low temperature, low pressure cooking process preserves these delicate flavors, color, and texture components for several different product applications because it maximizes water removal within cell structure and strengthens cellular and cellulose fibers even at very low temperatures.
• Example 1 This first example illustrates one application of the present invention.
• the portions prepared in accordance with the process of the present invention were then removed from the packaging and prepared by boiling in water and by microwave heating.
• the resulting portions were very tender, juicy, and tasted sweet with excellent color and minimal wrinkling or puckering of corn kernels, as is typically encountered when reheating cob corn prepared in a traditional manner.
• Example 2 This second example illustrates another application of the present invention.
• the general parameters in this example apply to a medley of vegetable portions.
• a medley of recently harvested whole peppers, onions and zucchini squash were received, cleaned, cored (peppers), peeled (onions), inspected, cut into predetermined portions and then rinsed to remove surface residual debris from coring, peeling and cutting.
• the medley of vegetable portions was then immersion blanched in boiling (rolling boil) for about 90 seconds until interior product temperature reached around 154° F. The portions were removed from the blanch water, shaken to remove excess surface moisture and then directly placed into a vacuum vessel at step 90.
• LintonizingTM process were then removed from their package and reheated, then observed and sampled. The portions were tender, but slightly crunc y, juicy and flavorful with bright color and pleasing appearance. These products were ready for immediate consumption, furthering grilling or as a meal side dish, right out of the package.
• Example 3 This third example illustrates another application of the present invention.
• the general parameters in this example apply to sliced sweet potato (yam) portions.
• the yam portions then were subjected to a vacuum ramping up to around 27" Hg and held for 10 minutes. Following the vacuum process the yam portions were submerged in ozone enriched water for 3 minutes, then removed, and excess water shaken off. The portions were then transferred to a deep fat fryer where they were fried for approximately 3 minutes at 350° F.
• the yam portions subjected to the LintonizingTM process were then removed and compared to unprocessed yam portions that had previously been deep-fried.
• the portions processed according to the present invention exhibited a significant improvement in appearance, texture and mouth feel as compared to the unprocessed portions, which were very dark in color, mottled and had a heavy burnt sugar taste.
• Example 4 This fourth example illustrates another application of the present invention.
• the general parameters in this example apply to onion portions specifically . sectioned into 4 quarter sections.
• the onion portions then were subjected to a vacuum ramping up to around 27" Hg and held for 10 minutes. Following the vacuum process, the onion portions were transferred to an open-flame grilling apparatus and then grilled to a pleasing appearance. For comparison purposes, unprocessed onion sections were grilled as well.
• Example 5 This fifth example illustrates yet another application of the present invention.
• the general parameters in this example apply to vegetable portions, specifically sugar snap peas.
• pea portions processed according to the present invention exhibited marked improvements in appearance (bright and colorful), texture and mouth feel, especially crispness, in side-by-side comparison with pea portions processed in the traditional fashion.
• Example 6 This sixth example illustrates another application of the present invention.
• the general parameters in this example apply to potato portions.
• Raw potatoes of the Russet variety were cleaned and then cut into thin slices, appropriately sized for American potato chips. Following their being slices, the portions were rinsed in a cold water bath to remove any debris. The rinsed potato portions where then blanched by immersion into hot water at around 175° F to 180° F for a period of about 10 minutes. Following the blanching process, the potato slices are quickly drained and then transferred to a pressure vessel wherein they are subject to a vacuum ramping up from ambient to around 27.5" Hg. Once the desired vacuity is achieved, the vacuum is removed, bringing the potato portions back to atmospheric pressure. Following the vacuum cooking step, the potato slices were examined and were shown to exhibit a number of desirable characteristics. First, the slices were resilient and were easily handled without breakage.
• the LintonizedTM potato slices exhibited much less stickiness as compared to those processed by traditional means. Further, from a taste standpoint, the processed slices exhibited a pleasing, elevated cooked potato flavor. The potato slices were then transferred to a plastic pouch, evacuated of air and then sealed using an inert gas mixture of nitrogen and carbon dioxide, then refrigerated.
• the present invention may be used to prepare refrigerated/frozen vegetable products for later re-therming by common restaurant or commissary means, it also may be used to produce products intended to be re-thermed by other methods such as oven heating, roasting, frying, steaming, boiling, grilling, etc.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Life Sciences & Earth Sciences (AREA)
• Polymers & Plastics (AREA)
• Food Science & Technology (AREA)
• Nutrition Science (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Wood Science & Technology (AREA)
• Zoology (AREA)
• Preparation Of Fruits And Vegetables (AREA)
• Coloring Foods And Improving Nutritive Qualities (AREA)
• Storage Of Fruits Or Vegetables (AREA)

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• 2004
  • 2004-05-21 CN CNA2004800137899A patent/CN1917771A/zh active Pending
  • 2004-05-21 MX MXPA05012579A patent/MXPA05012579A/es unknown
  • 2004-05-21 KR KR1020057021974A patent/KR20060021849A/ko not_active Withdrawn
  • 2004-05-21 AU AU2004240677A patent/AU2004240677A1/en not_active Abandoned
  • 2004-05-21 WO PCT/US2004/016209 patent/WO2004103131A2/en not_active Ceased
  • 2004-05-21 CA CA002525716A patent/CA2525716A1/en not_active Abandoned
  • 2004-05-21 JP JP2006533334A patent/JP2006528887A/ja active Pending
  • 2004-05-21 EP EP04753096A patent/EP1643885A4/de not_active Withdrawn

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