Classifications

• • 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
  • A23L19/18—Roasted or fried products, e.g. snacks or chips
• • 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
  • A23B7/04—Freezing; Subsequent thawing; Cooling
• • 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
  • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
  • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
  • A23P20/10—Coating with edible coatings, e.g. with oils or fats

Definitions

• the present invention relates to a method for producing a (finish)-fried potato product, in particular French fries.
• Finish-frying of potato products requires processing time, and product quality is sensitive to the actual frying conditions, including time and temperature. In practice, this may result in potato products that are too hard or too soft. In addition, poor frying conditions may result in an undesired uptake of oil and/or undesired evaporation of water from the product. This may reduce quality perception by a consumer such as taste.
• the present invention has for its object to provide a method for producing a finish-fried potato product, in particularly French fries, that can be relatively easily transformed from a frozen product to a ready-to-eat product by a consumer or operator in a fast-food restaurant, for example.
• a finish-fried potato product in particularly French fries
• at least an acceptable product quality is achieved, with product quality related to the quality as it is ultimately perceived by the consumer in respect of crunchiness, bite, mouthfeel, colour, flavour, and the like.
• finish-frying the frozen finish-fried potato product in a time interval of 50 to 110 seconds to achieve the fried potato product.
• the method according to the present invention produces a finished-fried potato product, in particular French fries. It will be understood that other potato products may also be subject to the method according to the invention. This may relate to other potato starch or granulate products.
• a (suitable) batch of potatoes is selected and in a next step washed, peeled and cut into the desired shape of the basic potato product. Thereafter, the basic potato product is treated in respective blanching, drying and coating steps.
• the coating may provide protection of the potato product and reduce absorption of oil and retain moisture in the product. Examples of such coating are described in WO 2016/153350 Al. Experiments showed that this coating provided a fried potato product as an end-product that is easy to process and provides a crispy product.
• the coated potato product is pre-fried and frozen into a frozen pre-fried potato product and is kept frozen for at least 48 hours.
• the frozen pre-fried potato product hardens. This provides additional strength and stability to the finish-fried potato product.
• this step contributes to keeping the water in the product by preventing undesired evaporation from the product.
• weight reduction in the processing between the basic potato product and the finish-fried potato product after the second finish-frying step is reduced. For example, experiments with a conventional process shows a weight reduction of more than 25%, while the method according to the invention shows a weight reduction of less than 10%, and even less than 5%. This provides a higher (end)-product output that is achieved with the method of the present invention.
• the first finish-frying process is performed under controlled conditions, preferably in the factory directly after coating and pre-frying, and including a cooling/freezing step. It will be understood that finish-frying the potato product under controlled conditions significantly contributes to maintaining the product quality as perceived by the consumer. Product quality may involve different aspects, such as crunchiness, bite, mouthfeel, colour, flavour, and the like. By finish-frying under controlled conditions in a factory, the product quality problems caused by finish-frying by a consumer (or fast-food restaurant) are obviated.
• performing the first finish-frying step in a factory has as a further advantage that process conditions can be controlled and monitored. This reduces undesired oil uptake or overfrying the product. This significantly contributes to the product quality perception of the consumer in relation to one or more of crunchiness, bite, mouthfeel, colour, flavour and the like. In addition, oil uptake in the finish-frying operation can be reduced significantly. This contributes in preventing all types of health issues and reduces the calorie intake by a consumer.
• This finish-frying can be performed in a continuous process or, alternatively, in a batch operation.
• the potato products are typically transported using conveyor belts through a hot air tunnel wherein the potato product is exposed to the desired temperature for a certain residence time.
• the potato products are put in a batch-wise operated hot air chamber and exposed in the chamber for a desired time period to the desired temperature. It will be understood that other processes can also be envisaged in accordance to the present invention.
• the consumer or operator is provided with a product that is relatively easy to handle.
• such consumer or operator only needs to perform a second finish-frying step for the potato product which involves heating the product. This can be performed by a consumer and/or a fast-food restaurant, for example. Therefore, the method provides a user-friendly processing for providing a potato product that allows for relatively fast preparation of the potato product.
• This second finish-frying step of the frozen finish-fried product provides the fried potato (end)-product. It was shown that the finish-fried product can be processed to a ready-to-eat product in a limited amount of time, such as within a time range of 50 seconds to 110 seconds and at good quality.
• the potato product is processed in a first finishfrying step. After finish-frying the potato product in this first finish-frying step the product is frozen to a frozen finish-fried potato product.
• This frozen finish-fried potato product can be stored and/or transported to a restaurant, shop, and consumer.
• the (end)-product is suitable for being used at flight-conditions. This enables serving fries during a flight, preferably by performing the second finish-frying step in hot air.
• the method of the present invention provides a high-quality fried potato product capable of being served at high altitude, while consumers have a high-quality perception.
• the second finish frying step is performed in a time interval of 60 to 90 seconds.
• the second finish-frying step is performed at a temperature in the range of 160 °C to 190 °C, preferably in the range of 170 °C to 180 °C, in oil.
• the second finish-frying step is performed at a temperature in the range of 190 °C to 235 °C, preferably in the range of 200 °C to 225 °C, in hot air.
• the second finish-frying step is performed at a modulating temperature.
• the temperature and time ranges of the aforementioned embodiments are combined. It was shown that such process conditions for the second finish-frying step provide a good quality ready-to-eat product having good taste, and that is preferably also of a relatively low caloric/calorific value, as compared to a potato product that is finish-fried in a conventional manner under sub-optimal conditions, for example. Tests have shown that the second finish-frying step can be performed in about 1 minute in heated oil in a temperature range of 170-180 °C, and in about 1 minute in a so-called hot-air oven in a temperature range of 220-250 °C, for example enabling in-flight serving of the potato product. These tests were done with 125 gram portions, and 200 gram portions. Depending on the in-flight capacity and power of the devices, such as an oven, the second finish-frying step can be performed in a time period in the range of 18 minutes to 20 minutes, preferably in about 19 minutes.
• the method further comprises the step of providing the finish-fried potato product or the pre-fried coated potato product in a hot air packaging unit.
• the hot air packaging unit is configured for receiving an amount of potato product that amounts to a portion-pack. This provides a specific and known amount of potato product to the packaging unit, preferably in an automated manner with a packer.
• the second finish-frying step to provide the fried potato product comprises regenerating the frozen finish-fried potato product in a hot air regenerating system. More specifically, in the regenerating process an amount of heat is provided to the potato product, optionally in a hot air packaging unit and preferably the potato product that is provided to it. In combination with the hot air packaging unit, preferably with a portion-pack amount of potato product, the regeneration process can be performed in a controlled manner, i.e. the amount of heat that is required for the regeneration process can be provided by a hot air regenerating system effectively. This guarantees a correct and consistent regenerating process. Experiments showed a substantially constant product quality of the potato product after regeneration and ready for consumption.
• the finish-fried product can be regenerated to a ready-to-eat product in a limited amount of time and at good quality.
• Regeneration typically includes heating the product, optionally in a moist environment.
• the regenerating system comprises a hot air oven or air fryer.
• the step of applying a coating comprises applying a coating with a potato to coating weight ratio in the range of 100: 10 to 100: 12.
• Providing a coating, preferably the coating that is disclosed in WO 2016/153350 Al, in the indicated range provides a good protection for the potato product. It was especially shown that a reducing effect on evaporation and associated weight loss was achieved.
• the step of pre-frying is performed at a temperature in a range of 170 °C to 190 °C, preferably about 180 °C, in a time interval in the range of 90 seconds to 150 seconds, preferably in the range of 105 seconds to 135 seconds, and most preferably in the range of 115 seconds to 125 seconds.
• the freezing step(s) bring the potato product to a temperature of about -20 °C or lower. This achieves a hardening of the potato product resulting in an even more crispy endproduct.
• weight-loss is even further reduced.
• the potato product is maintained for at least 10 days, preferably at least 12 days, and more preferably at least 14 days, at a temperature of about -20 °C or lower. This further enhances the effects on the end-product.
• the second finish-frying step is performed in-flight.
• Performing the second finish-frying step in-flight enables serving French fries in-flight.
• the method of the invention provides a high-quality end-product at these inflight conditions.
• the second finish-frying step is prolonged and is performed in a total time period in the range of 18 minutes to 20 minutes, preferably in about 19 minutes.
• the method further comprises the step of selecting a batch of potatoes and associated processing conditions.
• the selection process enables processing a good batch of potatoes.
• the selection process also enables an optimization in the processing conditions such that the quality and quantity of the end-product is improved.
• the processing conditions preferably comprise blanching and drying times, and the coating ratio.
• different potato varieties have been used, including Innovator and Agria. It will be understood that other potato varieties can also be used.
• the selecting of a batch of potatoes further comprises selecting potatoes of a potato variety with an underwater weight equal to or lower than 300 g/5 kg. With such selection the method according to the invention can be advantageously applied to so-called low-carb potatoes having a relatively low dry matter content.
• the invention also relates to a hot air packaging unit for a potato product, the packaging unit comprising a bottom part and one or more side walls defining a compartment configured for holding a finish-fried potato product or a pre-fried coated potato product, and wherein the side walls are provided with openings configured to enable hot air to directly contact the potato product.
• This hot air packaging unit provides the same or similar effects and advantages as described in relation to the method for producing a finish-fried potato product. After finish-frying the frozen product is typically stored and transported to shops, (fast food) restaurants, and/or consumers, preferably in the hot air packaging units. At this other location the product will be regenerated in the hot air packaging units and being served to the consumer as a ready-to-eat product.
• the hot air packaging unit comprises a lid.
• a lid provides protection to the product, for example during storage and transport. Furthermore, it improves the control of the heat transfer from hot air to the potato product in the regenerating process.
• the lid is hingedly connected to a side wall. Providing a hingedly connection between the lid and the sidewall provides a robust connection.
• a carrier floor is provided at a distance from the bottom part. Providing a carrier floor further improves the control of the heat transfer from hot air to the potato product in the regenerating process.
• the regenerated potato product has a calorific value lower than 200 kCal/100 g. This reduces intake of calories by a consumer, as is described earlier.
• the invention further also relates to a processing line that is configured to perform the method for producing a frozen finish-fried potato product as described above and comprises a hotair finish-frying system for potato products, the system comprising:
• blowers or nozzles configured for providing hot air to the potato products
• the processing line according to the invention can be used in a continuous and preferably also in a batch operation to produce a finish-fried potato product.
• Transport means may comprise conveyor belts to be used in a continuous operation and/or transport cars to be used in a batch operation, for example.
• the processing line further comprises a packer configured for providing the finish-fried potato product or the pre-fried coated potato product in a hot air packaging unit a hot-air finish-frying system as mentioned above
• the hot air finish-frying system further comprises a sensing system configured for sensing the potato product and a control system that is operatively coupled to the sensing system and is configured for controlling the system.
• sensing and control systems enable an automatically controlled finish-frying process.
• the residence time and/or hot air temperature can be amended by the control system.
• the sensing system may make use of different types of sensors, including temperature sensors, moisture sensors, and/or vision systems.
• the invention further also relates to a (finish-fried) potato product obtainable by the method according to an embodiment of the invention and/or the use of such potato product under in-flight conditions.
• the finish-fried potato product can be processed in a second finishfrying step according to the present invention, also under in-flight conditions. Tests at such conditions, typically involving humidity and pressure conditions, showed the possibility to serve in-flight high-quality French fries.
• the second finish-frying step can be performed in a time period in the range of 18 minutes to 20 minutes, preferably in about 19 minutes.
• FIG. 1 shows a schematic overview of the process for producing a fried potato (end)-product
• FIG. 2 and 3 shows a continuous hot-air tunnel for a continuous finish-frying operation
• FIG. 4 A-C shows a hot-air chamber for a batch finish-frying operation
• FIG. 5A show an embodiment of a hot air packaging unit according to the invention
• FIG. 5 B-E shows another embodiment of a hot air packaging unit according to the invention.
• Process 2 for providing a finish-fried potato product starts with providing in step 4 the (raw) potatoes to a factory, including harvesting and transporting.
• This illustrated process 2 further comprises the step of selecting a good batch of potatoes, optionally of a low dry matter, in selection phase 6.
• the selected products are provided to the factory and subjected to washing 8, peeling 10 and cutting 12 resulting in a basic potato product.
• This basic potato product is subjected to a blanching 14, coating 16 and pre-frying 18 process.
• the blanching time lies in the range of 8 to 12 minutes, preferably in the range of 9 to 11 minutes, and most preferably amounts to about 10 minutes.
• the blanching temperature lies in the range of 74 °C to 84 °C, preferably lies in the range of 76 °C to 83 °C and is most preferably in the range of 78 °C to 82 °C. It has been found that with said temperatures and time periods, preferably in combination, a suitable potato product is obtained.
• the most suitable drying conditions are a combination of a drying time in the range of 8-12 minutes, preferably a drying time of 10 minutes, and a drying temperature in the range of 70-90 °C, preferably a drying temperature of 80 °C.
• the drying operation is optionally performed in a so- called Rational.
• the combination of 10 minutes and 80 °C is found to be particularly suitable, particularly in combination with the above discussed blanching conditions.
• the coating step 16 is performed at a temperature of about 160 °C and the coating is applied together with or just before pre-frying process 18, in one of the embodiments in a time interval in the range of 1.5 to 2.5 minutes. It is found that with said temperatures and time intervals, preferably in combination, the suitable potato product is obtained.
• Pre-frying 18 can be performed in combination with the aforementioned steps or can be used as a separate (sub)-operation at an appropriate temperature, preferably in the range of 170 °C to 190 °C, and more preferably at a temperature of about 180 °C, during a time interval in the range of 1.5 to 2.5 minutes, preferably about 2 minutes.
• the pre-fried potato product is then cooled and frozen in cooling-freezing step 20 for at least 48 hours, and optionally kept in storage step 21 at such temperature for longer time periods, after which the product is finish-fried in first finish-frying step 22.
• the first finish-frying time further preferably lies in the range of preferably 3 to 5 minutes, preferably in the range of 3.5 to 4.5 minutes, and most preferably about 4 minutes. It is found that the suitable potato product is obtained with said temperatures and time periods, preferably in combination.
• the first finish-frying conditions are preferably applied in combination with said blanching conditions. Although finish-frying and preparatory steps, including blanching and pre-frying, are separate (sub-)processes, these steps do have an influence on the product and on the most suitable conditions. It is found that applying such conditions results in a desired product.
• the first finish-frying operation is typically performed at a temperature of about 180 °C.
• the product is frozen in freezing step 24 for at least 48 hours, and ready for transport and/or storage as frozen finish-fried potato product 26, and optionally kept in storage step 25 at such temperature for longer time periods.
• Frozen finish-fried potato product 26 can be packed in different packaging units, including so-called big bags.
• frozen finish-fried product 26 is provided to hot air packaging units in packing step 26a.
• the frozen products 26 can be processed in second finish-frying step 28 to which is also referred to as a regeneration step.
• the second finish-frying step is performed at a temperature of 200 °C to 250 °C in oil 28a or at a temperature of 200 °C to 250 °C , more preferably in a temperature range of 200 °C to 225 °C, optionally with a modulating temperature, in a hot-air oven or air fryer, more specifically in a hot-air oven.
• the time interval of second finishfrying step 28 is most preferably in the range of 6 to 90 seconds.
• Second finish-frying step 28 can be advantageously performed in an airplane even under in-flight conditions.
• second finish-frying step is performed in a time interval in the range of 18 minutes to 20 minutes, preferably in about 19 minutes.
• the final ready-to-eat end product 30 is provided.
• the (defrosted) French fries of similar portions take about 1 minute in hot air and/or oil. Tests are particularly done with portions of about 125 g and/or 200 g.
• Finish-frying 22 is presently preferably performed in hot air tunnel 42 (figures 2-3).
• Tunnel 42 is positioned between loading unit 44 and transport/cooling unit 46.
• Finish frying system 42 comprises frame 48 having first conveyor (belt) 50 and second conveyor (belt) 52 that move products P in direction A. It will be understood that another amount of belts can also be envisaged in accordance to the present invention.
• Hot air is provided using fan 54 and heater element 56. Heated air is provided by nozzle 58 to the products P that are transported by belts 50, 52. Distance between nozzles 58 and products P above belt 50 is di and above belt 52 d2. When products P are transferred from belt 50 to subsequent belt 52, products P transfer over distance ds.
• Distance d3 is preferably chosen such that products P re-orientate on belt 52 as compared to their previous orientation on belt 50.
• distance di is below 10 cm
• distance ds is below 10 cm
• distance ds is about 10 cm, for example.
• the (free) distance below belts 50, 52 is below 5 cm to enable circulating the hot air in the tunnel.
• Length L of device 42 is adapted to the desired throughput capacity and can be about 40 meters, for example. The same reasoning applies to the width of device 42 that in the illustrated embodiment typically is about 300 cm.
• finish-frying 22 is performed in a batch operation with hot air chamber 72 (figure 4A-C).
• Chamber 72 comprises housing 74 with entry doors 76.
• transport cars 78 have a number of carriers 80 on which products P can be positioned.
• transport means 78 are transported over rails 82.
• transport car 78 has a length of about 500 cm and carries two shelves or carriers 80. Width of car 78 is about 120 cm.
• Frame 74 of chamber 72 comprises one or more fans 84 and heaters 86 to provide hot air into chamber 72. It will be understood that the size and number of carriers 80 of car 78 and chamber 72 can be designed in accordance with the actual needs.
• transport cars 78 are moved to packer 60 to put the French fries in a hot air packaging unit.
• Hot air packaging unit 102 (figure 5 A) has bottom part 104, sidewalls 106, lid 108 that is hingedly connected to sidewall 106 with hinged connection 110.
• packaging unit 102 is provided with two handles 112.
• Sidewalls 106 are provided with a number of openings 114.
• Lid 108 is also provided with top openings 116.
• hot air enters packaging unit 102 through openings 114, 116 and heat is transferred from the air to the product.
• Alternative hot air packaging unit 202 (figure 5 B-E) has bottom part 204 and sidewalls 206. Lid 208 that is hingedly connected to sidewall 206 with hinged connection 210. Carrier floor 212 is provided in packaging unit 202 at a distance df from bottom part 204. Sidewalls 206 are provided with a number of openings 214. Lid 208 is also provided with top openings 216. In the illustrated embodiment carrier floor 212 is provided with floor openings 218. In the regeneration process hot air enters packaging unit 202 through openings 214, 216, 218 and heat is transferred from the air to the product.

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

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• 2021
  • 2021-11-02 NL NL2029585A patent/NL2029585B1/en active
• 2022
  • 2022-11-02 WO PCT/NL2022/050620 patent/WO2023080783A1/en not_active Ceased
  • 2022-11-02 EP EP22801243.1A patent/EP4426132A1/de active Pending

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