U.S. patent application number 11/146447 was filed with the patent office on 2006-12-21 for in-package hydration, cooking, and pasteurization.
This patent application is currently assigned to Kraft Foods Holdings, Inc.. Invention is credited to James Bell, Laura Gail Hill, Yeong-Ching Albert Hong, Jimbay Loh, John Howard Pasch, Zuoxing Zheng.
Application Number | 20060286226 11/146447 |
Document ID | / |
Family ID | 37545689 |
Filed Date | 2006-12-21 |
United States Patent
Application |
20060286226 |
Kind Code |
A1 |
Hong; Yeong-Ching Albert ;
et al. |
December 21, 2006 |
In-package hydration, cooking, and pasteurization
Abstract
This invention relates to a method for combining the multiple
steps of hydration, cooking, and pasteurization of a food product
into one simplified process. In one embodiment, this invention
relates to a method for in-package hydration, cooking and
pasteurization of a food product in a single step comprising (a)
combining at least one low moisture food component and an aqueous
based component in a heat-stable, sealable container wherein an
effective amount of the aqueous based component is present to allow
proper hydration and cooking; (b) sealing the heat-stable, sealable
container; and (c) treating the sealed container at a temperature
and time effective to hydrate, cook, and pasteurize the low
moisture food product in a single step.
Inventors: |
Hong; Yeong-Ching Albert;
(Kildeer, IL) ; Zheng; Zuoxing; (Palatine, IL)
; Loh; Jimbay; (Green Oaks, IL) ; Hill; Laura
Gail; (Prospect Heights, IL) ; Pasch; John
Howard; (Lake Zurich, IL) ; Bell; James;
(Evanston, IL) |
Correspondence
Address: |
FITCH EVEN TABIN & FLANNERY
120 S. LASALLE STREET
SUITE 1600
CHICAGO
IL
60603-3406
US
|
Assignee: |
Kraft Foods Holdings, Inc.
|
Family ID: |
37545689 |
Appl. No.: |
11/146447 |
Filed: |
June 7, 2005 |
Current U.S.
Class: |
426/326 |
Current CPC
Class: |
A23L 3/10 20130101; A23L
5/10 20160801; A23L 5/55 20160801 |
Class at
Publication: |
426/326 |
International
Class: |
B65B 55/00 20060101
B65B055/00 |
Claims
1. A method for in-package hydration, cooking, and pasteurization
of a food product in a single step, said method comprising: (a)
combining at least one low moisture food component and an aqueous
based component in a heat-stable, sealable container wherein an
effective amount of the aqueous based component is present to allow
proper hydration and cooking; (b) sealing the heat-stable, sealable
container; and (c) treating the sealed container at a temperature
and time effective to hydrate, cook, and pasteurize the low
moisture food product in a single step.
2. The method as defined in claim 1, wherein the sealed container
is agitated during at least a portion of step (c).
3. The method as defined in claim 1, wherein the low moisture food
component is selected from the group consisting of dry pastas, dry
rice, dehydrated potatoes, dried cereals, dried grains, dried
beans, dried legumes, dried vegetables, and mixtures thereof.
4. The method as defined in claim 1, wherein the aqueous based
component is selected from the group consisting of water, aqueous
solutions, aqueous emulsions, aqueous dispersions, sauces, gravies,
milk, whey, cream, syrups, juices, extracts, and mixtures
thereof.
5. The method as defined in claim 1, wherein the effective amount
of the aqueous based component is an amount sufficient to cover at
least the low moisture food component.
6. The method as defined in claim 1, wherein the ratio of the low
moisture food component and the aqueous based component is in the
range of about 10:90 to about 70:30.
7. The method as defined in claim 1, wherein at least one of the
ingredients selected from the group consisting of preservatives,
acidulants, antimicrobials, bactericins, antioxidants, flavorants,
colorants, spices, salt, seasonings, sweeteners, stabilizers, and
mixtures thereof is added to the container prior to sealing.
8. The method as defined in claim 3, wherein an acidulant is added
to the container prior to sealing.
9. The method as defined in claim 3, wherein an antimicrobial agent
is added to the container prior to sealing and the antimicrobial
agent is selected from the group consisting of nisin,
nisin-containing cultured whey or milk, poly-L lysine, lysozyme,
natamycin, and combinations thereof.
10. The method as defined in claim 3, wherein a preservative is
added to the container prior to sealing and the preservative is
selected from the group consisting of sorbic acid, benzoic acid,
propionic acid, lactic acid, diacetic acid, and salts thereof as
well as combinations thereof.
11. The method as defined in claim 1, wherein an antioxidant is
added to the container prior to sealing.
12. The method as defined in claim 3, wherein an antioxidant is
added to the container prior to sealing.
13. The method as defined in claim 4, wherein an antioxidant is
added to the container prior to sealing.
14. The method as defined in claim 1, wherein the heat-stable,
sealable container is a plastic pouch.
15. The method as defined in claim 3, wherein the heat-stable,
sealable container is a plastic pouch.
16. The method as defined in claim 4, wherein the heat-stable,
sealable container is a plastic pouch.
17. A method for in-package hydration, cooking, and pasteurization
of a food product in a single step, comprising: (a) combining at
least one low moisture food component and an aqueous based
component in a heat-stable, sealable container wherein an effective
amount of the aqueous based component is present to allow proper
hydration and cooking; (b) adding at least one of the ingredients
selected from the group consisting of acidulants, antimicrobials,
antioxidants, flavorants, and mixtures thereof; (c) sealing the
heat-stable, sealable container; (d) treating the sealed container
at a temperature and time effective to hydrate, cook, and
pasteurize the low moisture food product in a single step; (e)
agitating the sealed container simultaneously with at least a
portion of step (d); and (f) cooling the hydrated, cooked, and
pasteurized food product to a proper storage temperature.
18. The method as defined in claim 17, wherein the low moisture
food component is selected from the group consisting of dry pastas,
dry rice, dehydrated potatoes, dried cereals, dried grains, dried
beans, dried legumes, dried vegetables, and mixtures thereof.
19. The method as defined in claim 18, wherein the aqueous based
food component is selected from the group consisting water, aqueous
solutions, aqueous emulsions, aqueous dispersions, sauces, gravies,
milk, whey, cream, syrups, juices, extracts, and mixtures
thereof.
20. The method as defined in claim 18, wherein the effective amount
of the aqueous based component is an amount sufficient to cover at
least the low moisture food component.
21. The method as defined in claim 18, wherein the ratio of the low
moisture food component and the aqueous based component is in the
range of about 20:80 to about 60:40.
22. The method as defined in claim 18, wherein the heat-stable,
sealable container is a plastic pouch.
Description
FIELD OF THE INVENTION
[0001] This invention generally relates to food processing. More
specifically, this invention relates to a method for combining the
multiple steps of hydration, cooking, and pasteurization of a low
moisture food product in a single process step. The food products
which can be treated using the methods of this invention include,
for example, dry pasta, dry rice, dehydrated potato, and the like,
as well as mixtures thereof.
BACKGROUND OF THE INVENTION
[0002] "Ready to eat" and "ready to heat" food products are high in
consumer demand. The manufacture of these high quality processed
foods typically involves multiple time consuming and labor
intensive processes. Specifically, separate processes of hydration,
cooking, and pasteurization are involved in the manufacture of
these high quality processed food products and are performed
separately from each other. As a result, such conventional
processes require the use of multiple containers and process steps
and utilize unnecessary energy. Moreover, excess solid and/or
liquid wastes are produced from the execution of these processes in
separate steps and containers.
[0003] The separate processes of hydration, cooking, and
pasteurization are not new in the art. In fact, in-package
pasteurization is well known. For example, U.S. Pat. No. 6,797,308
(Sep. 28, 2004) relates to the stabilization of cooked pasta
compositions against the development of toxins and other
contaminates. In essence, U.S. Pat. No. 6,797,308 teaches a method
of pasteurizing a food product inside its final package.
[0004] U.S. Pat. No. 5,695,801 (Dec. 9, 1997) provides a method for
producing shelf-stable, uncooked or partially cooked moist pasta by
treating the pasta with steam, immersing the pasta in an aqueous
solution containing acidulants and/or humectants, allowing the
pasta to dry, sealing the pasta into a container, and pasteurizing
the pasta within the container using conventional thermal
processes.
[0005] U.S. Pat. No. 6,136,355 (Oct. 24, 2000) provides a process
for the manufacture of instant cooking pasta or noodles by heating
dry pasta with either wet or dry heat, drying the surfaces of the
pasta if the heating is effected with wet heat, and packaging the
pasta into a sealable container. The food product is then later
reheated within the package.
[0006] U.S. Patent Application, publication no. 20040156960, filed
Feb. 10, 2003, entitled "Food Product Preservation Method" teaches
a method for preservation of a food product which comprises
combining a food product with an amount of an edible acid to obtain
an acidified food product, placing the acidified food product in a
heat-stable, sealable container, sealing the container,
pasteurizing the food product and then rapidly reducing the
temperature to below about 55.degree. F. The food product is then
stored under refrigerated conditions and then later reheated.
[0007] Although previous methods have produced acceptable "ready to
eat" and "ready to heat" food products, there remains a need for
even further improvements. These previous methods only teach
in-package pasteurization. They neither teach nor suggest
in-package hydration, cooking and pasteurization in a single step.
The present invention addresses these needed improvements. Indeed,
the present method allows the various manufacturing processes of
hydration, cooking, and pasteurization to be completed in a single
step to obtain high quality finished products with consistent, and
organoleptic pleasing, textural properties.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method which allows the
combination of the multiple steps of hydration, cooking, and
pasteurization in a single step that occurs within a food product's
sealed and final container. The present invention reduces the
number of containers and/or process steps, which can be translated
into consumer friendly and lower cost products. In contrast to
separate process steps using conventional processes, the present
invention, by combining heating steps (e.g. cooking and
pasteurization), also minimizes the total heat treatment received
by the finished food products, thus improve the organoleptic and
nutritional quality. Further advantages of the present method are
the reduction of liquid and solid waste, the utilization of less
energy in the manufacture of these high quality processed food
products, and reduced risk of contamination since transfer of the
food product from one process to the next is eliminated.
[0009] More specifically, this invention relates to a method for
in-package hydration, cooking, and pasteurization of a low moisture
food product in a single step, said method comprising (a) combining
at least one low moisture food component and an aqueous based
component in a heat-stable, sealable container wherein an effective
amount of the aqueous based component is present to allow proper
hydration and cooking; (b) sealing the heat-stable, sealable
container; and (c) treating the sealed container at a temperature
and time effective to hydrate, cook, and pasteurize the low
moisture food product in a single step. The food product within the
sealed container preferably is agitated for at least a portion of
the time when it is treated at a temperature and time effective to
hydrate, cook, and pasteurize the food product in a single step.
The low moisture food components which can be used in the methods
of this invention include, but are not limited to, dry pastas, dry
rice, dehydrated potatoes, dried cereals or grains, dried beans or
legumes, dried vegetables, dried meats, dried seafood, dried spices
or herbs, and the like, as well as mixtures thereof. Generally, the
preferred low moisture food components for use in the present
invention are dry pastas, dry rice, and dehydrated potatoes. The
aqueous based components which can be used in the methods of this
invention include, for example, water, aqueous solutions, aqueous
emulsions, aqueous dispersions, sauces, gravies, milk, whey, cream,
syrups, juices, extracts, and the like, as well as mixtures
thereof.
[0010] In a preferred embodiment, this invention relates to a
method for in-package hydration, cooking, and pasteurization of a
low moisture food product in a single step, said method comprising
(a) combining at least one low moisture food component and an
aqueous based component in a heat-stable, sealable container
wherein an effective amount of the aqueous based component is
present to allow proper hydration and cooking; (b) adding at least
one ingredient selected from the group consisting of preservatives,
antioxidants, acidulants, stabilizers, salt, sweeteners, flavors,
colorants, and combinations thereof; (c) sealing the heat-stable,
sealable container; (d) treating the sealed container at a
temperature and time effective to hydrate, cook, and pasteurize the
low moisture food product in a single step; (e) agitating the
sealed container during at least a portion of step (d); and (e)
cooling the hydrated, cooked, and pasteurized food product to a
proper storage temperature. The at least one ingredient in step (b)
may be added or introduced into the container as a separate
ingredient and/or with the low moisture food component or aqueous
based component in step (a).
DETAILED DESCRIPTION
[0011] This invention relates to a method for combining the
multiple steps of hydration, cooking, and pasteurization of a food
product into a simplified, one-step process. This invention relates
to a method for in-package hydration, cooking, and pasteurization
of a low moisture food product in a single step, said method
comprising (a) combining at least one low moisture food component
and an aqueous based component in a heat-stable, sealable container
wherein an effective amount of the aqueous based component is
present to allow proper hydration and cooking; (b) sealing the
heat-stable, sealable container; and (c) treating the sealed
container at a temperature and time effective to hydrate, cook, and
pasteurize the low moisture food product in a single step. The
sealed container is preferably agitated during at least a portion
of step (c). The low moisture food components which can be treated
using the methods of this invention include, but are not limited
to, dry pastas, dry rice, dehydrated potatoes, dried cereals, dried
grains, dried beans, dried legumes, dried vegetables, dried meats,
dried seafood, dried spices or herbs, and the like, as well as
mixtures thereof. Generally, the preferred low moisture food
components for use in the present invention are dry pastas, dry
rice, and dehydrated potatoes. The aqueous based components which
can be used in the methods of this invention include, for example,
water, aqueous solutions, emulsions, or dispersions (e.g.,
acidulants, nisin-containing ingredients, broths, and the like),
sauces, gravies, milk, whey, cream, syrups, juices, extracts, and
the like, as well as mixtures thereof.
[0012] The relative amounts of the low moisture food component and
the aqueous based component should be maintained at levels to
provide an acceptable finished food product. In one embodiment, the
amount of aqueous based component should be sufficient to cover the
low moisture food component. In another embodiment, the relative
amounts should be adjusted so that, for the finished food product,
most (e.g., greater than about 50 percent), and in some cases
essentially all of the water is absorbed. In another embodiment,
the amount of the aqueous based component in the form of a sauce
should be sufficient to maintain a sauce in the finished food
product. In another embodiment, the relative amounts of low
moisture food component and aqueous based component should be
adjusted so that, the food component reaches optimum degree of
hydration and texture after the process. In yet another embodiment,
the ratio of low moisture food component and aqueous based
component is in the range of about 10:90 to about 70:30, and
preferably about 20:80 to about 60:40. For a given low moisture
food component, a given aqueous based component, and a given
desired finished product, one of ordinary skill in the art can
readily determine appropriate relative amount. By controlling the
amount of aqueous based component added to each sealed container
common textural defects due to under- or over-hydration that can
occur with traditional hydration processes can be avoided.
[0013] The present invention represents a significant
simplification in the manufacturing of high quality prepared foods
(e.g., "ready to eat" or "ready to heat" foods). This simplified
manufacturing process is made possible by combining hydration,
cooking, and pasteurization in a single processing step and a
single container. Secondary microbiological barriers (e.g.,
acidulants, salt, chemical preservatives, biological preservatives,
and the like, as well as mixtures thereof) may also be combined
with this simplified manufacturing process.
[0014] Preferably, the food products of this invention are
contained in a heat-stable, sealable plastic pouch such that the
food products can be hydrated, cooked, and pasteurized directly in
the pouch. Similar heat-stable, sealable containers that may be
used in the method of this invention include cans, glass bottles,
tubs, trays, and the like. Indeed, one of the advantages of the
present invention is that the multiple processes of hydration,
cooking, and pasteurization, which would conventionally occur in
separate steps, can now occur in a simplified process in a single
step thereby eliminating multiple processes and multiple
containers.
[0015] In addition to the low moisture food component and the
aqueous based component, additional ingredients may be added before
the heat-stable container is sealed. Such ingredients may include
preservatives, acidulants, antimicrobials, bactericins,
antioxidants, flavorants, colorants, spices, salt, seasonings,
sweeteners, stabilizers, and the like, as well as mixtures thereof.
The addition of preservatives (e.g., sorbic acid, benzoic acid,
propionic acid, lactic acid, diacetic acid, and salts thereof as
well as combinations thereof, acidulants (e.g., food grade acids
such as hydrochloric acid, sulfuric acid, metal acid sulfates,
phosphoric acids, tartaric acid, fumaric acids, citric acid, lactic
acid, gluconic acid, and the like), antimicrobials (e.g., nisin,
nisin-containing cultured whey or milk, poly-L lysine, lysozyme,
natamycin, and the like as well as combinations thereof),
bactericins, and antioxidants will not only extend the shelf life
of the finished products, but it will also provide additional
safety and/or preservation. Such additives may be added as separate
ingredients or may be added with the aqueous based component (e.g.,
solution, slurry, emulsion, dispersion, or the like) and/or the low
moisture food component. One especially preferred antimicrobial,
nisin-containing whey, which may be used in this invention is fully
described in U.S. Pat. No. 6,110,509 (Aug. 9, 2000), U.S. Pat. No.
6,113,954 (Sep. 5, 2000), U.S. Pat. No. 6,136,351 (Oct. 24, 2000),
U.S. Pat. No. 6,242,017 (Jun. 5, 2001), U.S. Pat. No. 6,613,364
(Sep. 2, 2003), and U.S. Pat. No. 6,797,308 (Sep. 28, 2004).
[0016] Prior to sealing the containing, the headspace above the
food product and other ingredients may optionally be flushed with
an inert gas (e.g., nitrogen, carbon dioxide, steam, and the like)
or may be reduced using a partial vacuum.
[0017] The sealed container containing the food product and other
ingredients is treated at a temperature and time effective to
hydrate, cook, and pasteurize the food product in a single step. In
other words, the heating profile should be effective in hydrating,
cooking, and pasteurizing in a single step. Conventional heating
equipment that may be used includes, but is not limited to, water
baths, submersion cookers, steamers, electrical ovens, gas ovens,
infrared cookers, microwave cookers, and the like, as well as
combinations thereof. Preferably, the sealed container is placed in
a boiling water bath for a temperature and time effective to
hydrate, cook, and pasteurize the food product. Generally, the time
necessary using a boiling water bath is about 1 to about 60 minutes
for a conventional sized pouch (i.e., one holding about 20 to about
1000 g of food product) depending on the specific low moisture food
component used.
[0018] In the preferred embodiment, this invention also relates to
a method for in-package hydration, cooking, and pasteurization of a
food product in a single step, said method comprising (a) combining
at least one low moisture food component and an aqueous based
component in a heat-stable, sealable container wherein an effective
amount of the aqueous based component is present to allow proper
hydration and cooking; (b) adding at least one ingredient selected
from the group consisting of preservatives, antioxidants,
acidulants, and any combinations thereof; (c) sealing the
heat-stable, sealable container; (d) treating the sealed container
at a temperature and time effective to hydrate, cook, and
pasteurize the low moisture food product in a single step; (e)
agitating the sealed container for at least a portion of step d);
and (f) cooling the hydrated, cooked, and pasteurized food product
to a proper storage temperature.
[0019] The following examples are intended to illustrate the
invention and not o limit it. Unless otherwise indicated, all
percentages used in the present specification are by weight. All
patents and publications referred to in the present specification
are hereby incorporated by reference.
EXAMPLE 1
[0020] In-package cooked/acidified shelf stable plain pasta. Dry
shell pasta (about 60 g) was placed in a heat stable polyester
pouch (about 5 by about 6.5 inches; SealPAK from KAPAK Corp.,
Minneapolis, Minn.). A sodium acid sulfate aqueous solution (0.7%;
about 86 g) was added to the pasta in the pouch. Most of the air
was evacuated from the pouch and the pouch was sealed. The pouch
was mixed slightly and then placed in a boiling water bath. The
pouch was agitated frequently in the water bath until the liquid
was absorbed by the pasta (about 20 minutes). The pouch was removed
from the boiling water and immediately cooled in cold water until
the product reached room temperature. This process yielded fully
cooked acidified shelf stable pasta at a pH of about 3.8; the
product had excellent properties and was microbiologically stable
for at least six months under ambient conditions.
EXAMPLE 2
[0021] In-package cooked/acidified shelf stable macaroni and
cheese. An acidified sauce mixture of 45% of 0.7% aqueous sodium
acid sulfate, and 55% of acidified cheese flavor sauce was
prepared. The acidified cheese flavor sauce consisted of about 1.5%
cheese powder, about 4.5% starch and gums, about 11% bulking agents
(i.e., corn syrup solid and maltodextrin), about 9% butterfat,
about 1.6% salt, about 0.18% TiO.sub.2, about 0.45% emulsifiers,
about 0.15% colors, about 0.3% flavors. The pH of the sauce mixture
was about 3.85. Dry shell pasta (about 46 g) and acidified sauce
mixture (150 g) was placed in a heat stable plastic pouch, as used
in Example 1. Most of the air in the package was evacuated and the
pouch was sealed. The pouch was mixed slightly and then placed in a
boiling water bath. The pouch was agitated frequently in the water
bath in the first phase of the cooking process. The pouch
containing the pasta was removed from the boiling water bath after
about 22 minutes and immediately cooled in cold water until the
product reached temperature. This process yielded fully cooked,
acidified, and pasteurized shelf stable macaroni and cheese at a pH
of about 3.8; the product was microbiologically stable for at least
six months under ambient conditions.
EXAMPLE 3
[0022] Refrigeration stable in-package cooked plain pasta. A
nisin-containing cultured sugar solution was prepared to contain
about 500 lU/ml of nisin equivalent activity (e.g., 1.0% Danisco
Guardian CS1-50 in water). Dried shelf stable pasta (about 56 g)
and the nisin-containing solution (about 81 g) were placed in a
heat-stable, sealable plastic pouch. Most of the air in the pouch
was evacuated and the pouch was sealed. The pouch was mixed
slightly and then placed in the boiling water bath. The pouch was
agitated frequently in the water bath. The pouch containing the
pasta was removed from the boiling water bath after about 20
minutes, when all the liquid was absorbed by the pasta. The heat
treated pouch was cooled in cold water until it reached a
refrigerated temperature of about 40.degree. F. This process
yielded fully cooked refrigeration stable pasta that contains about
450 lU/g of nisin equivalent activity and has a pH of about 5.2;
the product had excellent sensory properties and nisin activity was
maintained for at least six weeks under refrigeration storage.
EXAMPLE 4
[0023] Refrigeration stable in-package cooked pasta and sauce.
Nisin-containing cultured milk was added to dairy based cheese
sauce to yield a nisin equivalent activity of about 400 lU/g (e.g.,
0.8% Danisco Guardian CS1-50). Dried shelf stable pasta (48 g) was
placed in a heat-stable, sealable plastic pouch. The
nisin-containing dairy based cheese sauce was added to the pouch
and most of the air was evacuated from the pouch. Evacuating the
air inside the pouch could be achieved with, among other methods, a
vacuum or with nitrogen flushing. The pouch was then placed in a
boiling water bath and agitated for approximately 22 minutes or
until the pasta was fully cooked. The pouch was then removed from
the water bath and cooled quickly in a cold water bath. The process
yielded fully cooked pasta in sauce that contained about 300 lU/g
of nisin equivalent activity and had a pH of about 5.22. This pasta
in sauce product, which had excellent organoleptic properties, was
stable under refrigerated conditions for at least about three
months; nisin activity was essentially unchanged after this storage
period.
[0024] Other pasta and sauce (e.g., Alfredo) combinations can be
prepared and used in a similar manner.
* * * * *