U.S. patent application number 11/841475 was filed with the patent office on 2008-02-07 for methods and apparatus for maintaining fresh quality and safe food attributes of minimally processed produce.
This patent application is currently assigned to Thomas R. Hankinson. Invention is credited to Thomas R. Hankinson, Lisa A. Herickhoff.
Application Number | 20080032010 11/841475 |
Document ID | / |
Family ID | 29218827 |
Filed Date | 2008-02-07 |
United States Patent
Application |
20080032010 |
Kind Code |
A1 |
Hankinson; Thomas R. ; et
al. |
February 7, 2008 |
Methods and Apparatus for Maintaining Fresh Quality and Safe Food
Attributes of Minimally Processed Produce
Abstract
A system and method of maintaining the integrity of freshly
harvested, or freshly cut fruits and vegetables. Specifically, the
invention focuses on a distinct series of processes which confer a
lower total microbial count, delay browning, improve general
organoleptic properties, and decrease the amount of chemical
contaminants on the exposed surfaces without the use of
preservatives. Examples of such process may be applying a first
produce integrity maintenance process, a second produce integrity
maintenance process, application of an antibrowning agent to the
produce by a produce antibrown agent applicator, exposing the
produce to ultraviolet light by an ultraviolet light system, and
applying an ozone treatment by an ozone treatment system.
Inventors: |
Hankinson; Thomas R.;
(Framingham, MA) ; Herickhoff; Lisa A.; (Fort
Collins, CO) |
Correspondence
Address: |
SANTANGELO LAW OFFICES, P.C.
125 SOUTH HOWES, THIRD FLOOR
FORT COLLINS
CO
80521
US
|
Assignee: |
Hankinson; Thomas R.
Framingham
MA
|
Family ID: |
29218827 |
Appl. No.: |
11/841475 |
Filed: |
August 20, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10383278 |
Mar 7, 2003 |
7258882 |
|
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11841475 |
Aug 20, 2007 |
|
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60362783 |
Mar 7, 2002 |
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Current U.S.
Class: |
426/248 ;
422/105; 426/262; 426/312; 426/416; 426/541 |
Current CPC
Class: |
A23B 7/015 20130101;
A23V 2250/128 20130101; A23V 2200/10 20130101; A23B 7/157 20130101;
A23B 7/144 20130101; A23V 2002/00 20130101; A23V 2002/00
20130101 |
Class at
Publication: |
426/248 ;
422/105; 426/262; 426/312; 426/416; 426/541 |
International
Class: |
A23B 7/00 20060101
A23B007/00; A23B 7/015 20060101 A23B007/015; A23B 7/14 20060101
A23B007/14; A23B 7/158 20060101 A23B007/158 |
Claims
1-79. (canceled)
80. A system for maintaining the integrity of produce comprising
the steps of: providing produce processing equipment configured to
achieve a first overall treatment modality to maintain produce
integrity; altering said produce processing equipment to achieve a
second overall treatment modality to maintain produce integrity;
making an input capability for at least one item of produce
available to said produce processing equipment adapted to said
second overall treatment modality to maintain product integrity;
making a transport capability for said at least one item of produce
available within said produce processing equipment adapted to said
second overall treatment modality to maintain product integrity;
establishing said second overall treatment modality to maintain
product integrity as available within said produce processing
equipment in response to said steps of making said input capability
for said at least one item of produce available to said produce
processing equipment adapted to said second overall treatment
modality to maintain product integrity and making said transport
capability for said at least one item of produce available within
said produce processing equipment adapted to said second overall
treatment modality to maintain product integrity; and making an
output capability for said at least one item of produce available
to said produce processing equipment adapted to said second overall
treatment modality to maintain produce integrity.
81. A system for maintaining the integrity of produce as described
in claim 80 wherein one of said treatment modalities comprises the
step of exposing said at least one item of produce to ultraviolet
light.
82. A system for maintaining the integrity of produce as described
in claim 80 wherein one of said treatment modalities comprises the
step of applying an ozone treatment to said at least one item of
produce.
83. A system for maintaining the integrity of produce as described
in claim 80 wherein one of said treatment modalities comprises the
step of applying an antibrowning agent to said at least one item of
produce.
84. A system for maintaining the integrity of produce as described
in claim 83 and further comprising the step of altering said
produce processing equipment to achieve said step of applying said
antibrowning agent to said at least one item of produce following
said step of exposing to said at least one item of produce to said
ultraviolet light.
85-88. (canceled)
89. A system for maintaining the integrity of produce as described
in claim 80 wherein said step of making said input capability for
at least one item of produce available to said produce processing
equipment adapted to said second overall treatment modality to
maintain product integrity for produce comprises the step of making
input capability for at least one mushroom.
90. (canceled)
91. A system for maintaining the integrity of produce as described
in claim 80 wherein said step of altering said produce processing
equipment to achieve a second overall treatment modality to
maintain produce integrity comprises the step of altering said
produce processing equipment to equally expose the whole surface of
said at least one item of produce during said second overall
treatment modality.
92. A system for maintaining the integrity of produce as described
in claim 80 wherein said step of altering said produce processing
equipment to achieve a second overall treatment modality to
maintain produce integrity comprises the step of altering said
produce processing equipment to preferentially expose at least one
selected surface of said at least one item of produce during said
second overall treatment modality.
93. A system for maintaining the integrity of produce as described
in claim 80 and further comprising the step of covering said at
least one item of produce with an oxygen scavenging film during
said second overall treatment modality.
94. A system for maintaining the integrity of produce as described
in claim 80 wherein said step of establishing said second overall
treatment modality to maintain product integrity as available
within said produce processing equipment in response to said steps
of making said input capability for said at least one item of
produce available to said produce processing equipment adapted to
said second overall treatment modality to maintain product
integrity and making said a transport capability for said at least
one item of produce available within said produce processing
equipment adapted said second overall treatment modality to
maintain product integrity comprises the step of increasing shelf
life of said at least one item of produce.
95. A system for maintaining the integrity of produce as described
in claim 82 and further comprising providing said ozone treatment
having a pH about equal to a pH of tissue of said at least one item
of produce.
96. A system for maintaining the integrity of produce as described
in claim 81 wherein said step of altering said produce processing
equipment comprises the step of altering said produce processing
equipment to apply said step of exposing said at least one item of
produce to ultraviolet light before said step of applying of said
ozone treatment to said at least one item of produce.
97. A system for maintaining the integrity of produce as described
in claim 81 and further comprising the step of exposing said at
least one item of produce to a second ultraviolet light wherein
said step of exposing said at least one item of produce to
ultraviolet light occurs before said step of applying said ozone
treatment to said at least one item of produce and said step of
applying said ozone treatment to said at least one item of produce
occurs before said step of exposing said at least one item of
produce to a second ultraviolet light.
98. A system for maintaining the integrity of produce as described
in claim 81 and further comprising the steps of: applying a first
ozone treatment to said at least one item of produce; applying a
second ozone treatment to said at least one item of produce;
exposing said at least one item of produce to a second ultraviolet
light, wherein said step of exposing said at least one item of
produce to ultraviolet light occurs before said step of applying
said first ozone treatment to said at least one item of produce and
said step of applying said first ozone treatment to said at least
one item of produce occurs before said step of applying said second
ozone treatment to said at least one item of produce and said step
of applying said second ozone treatment to said at least one item
of produce occurs before said step of exposing said at least one
item of produce to said second ultraviolet light.
99-107. (canceled)
108. A system for maintaining the integrity of produce as described
in claim 81 and further comprising the step of repositioning said
at least one item of produce for said at least one process.
109. A system for maintaining the integrity of produce as described
in claim 80 wherein said step of altering said produce processing
equipment to achieve said second overall treatment modality to
maintain produce integrity comprises the step of adding at least
one spray bar in relation to said transport capability.
110-111. (canceled)
112. A system for maintaining the integrity of produce as described
in claim 80 and further comprising the step of altering said
produce processing equipment to achieve removal of macrodebris from
said at least one item of produce.
113. A system for maintaining the integrity of produce as described
in claim 112 wherein said step of altering said produce processing
equipment to achieve removal of said macrodebris from said at least
one item of produce comprises the step of altering said produce
processing equipment to treat said at least one item of produce in
conjunction with a sieve-type element and removing macrodebris from
produce through apertures in said sieve-type element.
114. (canceled)
115. A system for maintaining the integrity of produce as described
in claim 80 wherein said step of establishing said second overall
treatment modality to maintain product integrity as available
within said produce processing equipment in response to said steps
of making said input capability for said at least one item of
produce available to said produce processing equipment adapted to
said second overall treatment modality to maintain product
integrity and making said a transport capability for said at least
one item of produce available within said produce processing
equipment adapted said second overall treatment modality to
maintain product integrity comprises the step of washing said at
least one produce with a cleaning solution.
116-120. (canceled)
121. A system for maintaining the integrity of produce as described
in claim 80 wherein said step of providing produce processing
equipment comprises the step of providing said produce processing
equipment selected from the group consisting of providing a dip
tank, providing a flume system, providing a overhead spray bar,
providing a conveyor, providing a air knife, providing a overhead
drench system, providing a vat, providing a vessel, providing an
air compressor, providing an attendant electrical motor control
center, providing a variable a frequency drive, providing a
computer controlled electrical apparatus, providing a programmable
logic controller, providing a pump, providing a hopper, providing a
surge tank, and providing a storage tank.
122-372. (canceled)
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/362,783, filed Mar. 7, 2002, herein incorporated
by reference.
I. BACKGROUND
[0002] Generally this invention relates to a system and method of
maintaining the integrity of freshly harvested, or freshly cut
fruits and vegetables. Specifically, the invention focuses on a
distinct series of treatments which confer a lower total microbial
count, delay browning, improve general organoleptic properties, and
decrease the amount of chemical contaminants on the exposed
surfaces without the use of preservatives.
[0003] The desire to retain the freshly harvested attributes of
produce has been known by the produce, food safety, grocery and
canning industries for several decades. Many types of produce,
especially that having white flesh, begin to brown shortly after
the fruit or vegetable is cut. In mushrooms in particular, the
flesh browns as the produce ages, regardless of its having been
cut. There are other distinct signs of aging including tissue
breakdown (which induces more browning), microbial decay and the
like. The desire to maintain freshly picked attributes is important
both in the industries where the produce is consumed fresh (within
weeks of harvest) and within industries where the produce is to be
further processed.
[0004] Mushrooms are grown under conditions such that picked
mushrooms contain much surface dirt. Moreover, growing conditions
and hand-harvesting of mushrooms provides many opportunities for
inoculation with spoilage organisms and human pathogens. Mushroom
processors are prohibited from mechanically handling and processing
mushrooms because of the propensity of mushroom tissue to bruise
and subsequently brown. This attribute lowers the commercial appeal
and nutritional value of the mushrooms.
[0005] Retention of fresh attributes desire has been an acute need
within the mushroom industry where rapid browning, and product
deterioration severely limits commercial potential and affects
production. Browning and product deterioration are biological
phenomena governed by enzymatic processes and cellular degradation.
The rate of degradation is influenced by several factors including
variety, innate levels of browning enzyme, storage temperature,
growing conditions, harvesting conditions, bacterial levels,
handling protocols and water exposure.
[0006] A primary concept for delaying enzymatic browning is the use
of chemical compounds to quell effects of the browning enzyme
either by inhibiting the enzyme, preventing formation of crucial
intermediates, or by excluding or removing substrates of browning
enzyme. In the past, many in the produce industry, and mushroom
industry, used a solution of chemical preservatives including
sodium metabisulfite. Mushrooms were washed with sodium
metabisulfite until such treatment was deemed inappropriate for use
by the FDA on products to be consumed fresh, as described in a book
edited by Lee and Whitaker (1995). A second popular chemical for
delaying or slowing browning of produce include treatment with
various concentrations of sodium erythorbate and its stereoisomer
ascorbic acid Under 21 C.F.R. .sctn..sctn. 170.3 and 182.3041, this
ingredient is approved for use on foods by the FDA as a chemical
preservative and is GRAS (Generally Recognized As Safe). If a
non-detectable amount of chemical remains on the produce after
processing then the chemical preservative is reclassified as a
processing aid, and does not require inclusion on the ingredients
list. The use of sodium erythorbate, alone or in combination with a
few other chemicals, was discussed in a U.S. Pat. No. 4,814,192 by
Sapers, et al., U.S. Pat. No. 5,919,507 by Beelman, U.S. Pat. No.
4,011,348 by Farrier, et al., U.S. Pat. No. 5,925,395 by Chen, U.S.
Pat. No. 5,055,313 by Warren, U.S. Pat. No. 4,818,549 by Steiner,
et al., U.S. Pat. No. 6,139,890 by Simpukas, as well as various
publications including Sapers, et al. (1990) in a book edited by
Wiley (1994), a book edited by Lee and Whitaker (1994) and PMP
Fermentation Products, Inc. brochure entitled "Fruit &
Vegetables". Sodium erythorbate functions to control enzymatic
browning by acting as a free radical scavenger and chelator,
altering the redox potential of the system and/or acting as a
reducing agent. There are many other chemicals, or combination of
chemicals that can function in a similar capacity as found in 21
C.F.R. .sctn..sctn. 182-184.
[0007] In U.S. Pat. No. 5,919,507 by Beelman et al. may employ the
concept of chemical compounds, especially sodium erythorbate, on
mushrooms in combination with a highly basic solution (as an
antimicrobial). Treatment with this combination may be too
expensive for commercial implementation and the use of a highly
basic solution may be quite dangerous if workers are not
sufficiently skilled. If mushroom tissue is not sufficiently
neutralized browning can be induced by this treatment due either to
cellular damage, or subsequent susceptibility to microbial attack.
U.S. Pat. No. 6,287,617 by Bender, et al. may also describe a
method utilizing pH shock (a highly basic treatment) followed by a
known bactericidal treatment. U.S. Pat. No. 6,262,038 by Pierce et
al. may use surfactant and biocompatible fruit acids (acidic pH).
These technologies may suffer from the same faults as Beelman et
al. coupled with the possible issues surrounding use of non-GRAS,
non-process-aid bactericides.
[0008] A second method, similar to U.S. Pat. No. 5,919,507 by
Beelman is described in U.S. Pat. No. 6,500,476 by Martin, et al.
The Martin technology may employ a neutralizing step (acidic pH
solution) after treating with basic pH, and prior to sodium
erythorbate treatment. This technology requires storage and
handling of dangerous chemicals, and may be fraught with disposal
and environmental issues associated with acidic and basic solutions
including as death of beneficial bacterial in leech field and/or
settling ponds. In addition, there is potential for microorganisms
on mushrooms to become tolerant to such chemical technology.
[0009] Another method which employs sodium erythorbate in
combination with hydrogen peroxide as an antimicrobial for
treatment on mushrooms is outlined in "Enzymatic Browning Control
in Minimally Processed Mushrooms", Sapers, et al. 1994, Journal of
Food Science, V. 59, No. 5, 1994 p. 1042-1047 and "Shelf-Life
Extension of Fresh Mushrooms (Agaricus bisporous) By Application of
Hydrogen Peroxide and Browning Inhibitors", Sapers, et al. 2001,
JFS: Sesory and Nutritive Qualities of Food, Vol. 66, No. 2, p.
362-366, 2001. This technique may also be expensive in commercial
implementation and extremely dangerous for unskilled workers. In
addition, hydrogen peroxide at concentrations sufficient to
suppress spoilage can induce browning. Hydrogen peroxide is not
currently approved by the FDA for use on produce.
[0010] An additional method which employs the use of kojic acid is
described in "Effect of Kojic Acid on the Oxidation of
N-Acetyldopamine by Mushroom Tyrosinase", Kahn, et al. 1999. Kojic
acid is an inhibitor of browning not approved for use by FDA. There
are a host of other such chemicals which may inhibit browning but
are not approved for use on foods according to sections in 21
CFR.
[0011] Another method, described in U.S. Pat. No. 6,224,926 issued
to Wrolstad et al. may use antibrowning/antioxidant compounds,
specifically an L-cysteine and glutathione derivative, as isolated
from pineapple juice, and pineapple processing plants. L-cysteine
is commonly used in the produce industry as an antibrowning
compound. This treatment alone could not wash mushrooms, or dirty
produce.
[0012] Another concept for delaying enzymatic browning may be heat
inactivation of the browning enzymes. It may not be desirable to
heat produce that is to be consumed fresh as heat induces
organoleptic changes making it less valuable commercially.
[0013] Food safety is an important consideration in all food
industries including the produce industry where various spoilage
pathogens are detrimental not only to the commercial appeal
(organoleptic properties) of the product, but also to the health of
the consumer. One example of a pathogen that negatively affects
human consumers and is found on mushrooms and other produce is
Clostridium botulinum. It is important to reduce the indigenous
populations of bacteria and other pathogens to both decrease the
risk of illness to the consumer and to increase the useful shelf
life of the product.
[0014] Mushrooms are subject to visible degradation by various
plant pathogens and spoilage organisms. At times, degradation by
this cause does not manifest itself until after said mushroom has
been harvested and packaged. In addition to affecting the solitary
mushroom initially infected, all surrounding mushrooms can be
affected and may render the entire package commercially useless.
Moreover, excessive moisture on the surface or interstitial spaces
of the mushroom can create a micro-environment that increases the
susceptibility of the mushroom to microbial or pathogen
decomposition.
[0015] One concept for reducing the microbial load of produce may
be to treat with a highly basic or highly acidic solution. A highly
basic treatment is discussed in U.S. Pat. No. 5,919,507 by Beelman
and U.S. Pat. No. 6,500,476 by Martin. These treatments do reduce
the level of bacteria, and perhaps other pathogens, but may not
treat as well as some known antimicrobial treatments that do not
work well on mushrooms. Further without proper neutralization,
residual acidity can result in damaged tissue that is more
susceptible to pathogenic degradation. Moreover, it is possible,
and probable that microbes will become resistant to such
treatment.
[0016] An additional concept for reducing the pathogens on
mushrooms may be to treat with ultraviolet light. Ultraviolet light
has been utilized for sterilization for over 60 years (see U.S.
Pat. No. 2,248,618 by Fisher) and continues to provide a reliable
source of surface sterilization. Ultraviolet light causes death to
cells and microorganisms via photochemical changes in DNA and
cellular proteins, as discussed in the 1998 Jay reference. UV light
is commonly used to treat fruitcakes and related products prior to
packaging. With limited exposure the ultraviolet light could not
penetrate the surface of the produce and could not negatively
affect its organoleptic properties, nor induce browning, but it
would help to surface sterilize. Ultraviolet radiation may be used
in the food industry to create aseptic packaging as described by
U.S. Pat. No. 4,121,107 by Bachmann. U.S. Pat. No. 6,171,458 by
Rose, et al. may describe use of UV plus ultrasound to sterilize
food products, and inorganic products. U.S. Pat. No. 6,165,526 by
Newman may describe the use to UV irradiation to decontaminate food
in combination with heat and microwaves. This may not appropriate
for fresh-cut foods. Ultraviolet radiation use on foodstuffs is
also described in U.S. Pat. No. 5,364,645 by Lagunas-Solar, et
al.
[0017] A further concept for decreasing the microbal load of
produce may be to subject produce to ozone. Ozone, triatomic oxygen
dissociates into a highly reactive monatomic oxygen. Monatomic
oxygen readily oxidizes cellular components. Ozone disinfects
through direct oxidation as well as through formation of
hydroperoxide intermediates, also bactericidal. Ozone is the fourth
most powerful oxidizing agent known with an oxidation potential of
2.07 millivolts (chlorine is 1.35 millivolts) and disinfects
approximately 3,000 times faster than chlorine. Ozone delivered in
an aqueous solution is 5000 times more toxic than in gas phase.
[0018] In addition to disinfections, ozone may be used to
deodorize, and remove color. In addition to affecting biota, ozone
is also reported to breakdown pesticides, herbicides, and other
chemicals as used in the food industry as discussed in U.S. Pat.
No. 6,200,618 by Smith et al. There are no known toxic residues or
byproducts of ozone therefore disposal may be a mute issue.
Moreover, because ozone may be generated on-site and at the time of
use, there may be no storage of chemicals, or other potentially
dangerous issues.
[0019] Ozone is approved as a food additive as found in 21 C.F.R.
.sctn. 173 and is starting to be used as a technology in the fruit
and vegetable industry. Art specific to food may be described in
U.S. Pat. No. 6,485,769 by Audy, et al. where utilizing ozone in
water may be coupled with mechanical tumbling. This may not
appropriate to mushrooms and bruise-prone produce due to the
mechanical damage that would be induced. U.S. Pat. No. 6,120,822 by
Denvir, et al. may describe the use of an ozone gas in a humid,
pressurized environment. Similarly, in PCT Pub. No. WO 90/02572 to
Cammiss may describe a technology to disinfect storage rooms and
packed produce using ozone gas. U.S. Pat. No. 5,783,242 to Teague
may describe a technique for treating food with UV gaseous ozone,
or ozone in liquid. Ozone gas alone could not remove the large
particulates from the mushroom surface and does not address other
organoleptic issues associated with aging mushrooms. U.S. Pat. No.
6,200,616 to Smith et al. and U.S. Pat. No. 5,403,602 to Endico may
describe contacting food with an ozone containing wash liquor
followed by addition of a surfactant. These technologies may not
address physiological browning, nor is the period of immersion
(minimum 2 minutes) suitable for mushrooms. Moreover, because this
process may occur in one tank, all ozone could be reduced by gross
contaminants present in the water after the first batch of
mushrooms was washed, and may render ozone treatment ineffective.
Similarly, U.S. Pat. No. 5,405,631 to Rosenthal and U.S. Pat. No.
6,132,784 to Brandt et al. utilize UV irradiation and ozone
generation (by UV light) to treat fruit. U.S. Pat. No. 6,514,459 to
Crisinel, et al. may have introduced a technology to utilize ozone
in combination with dirt-removal via tank agitation. Mushrooms
generally float however too much agitation can cause them to sink,
and could result in water-logged mushrooms. Mushrooms with too much
water may lose fresh-cut, organoleptic properties more quickly than
unwashed mushrooms.
[0020] In addition to delaying browning, and microbial load
reduction, there is a desire to rid the mushrooms of growing media
for both aesthetic and cleanliness reasons. Mechanical means for
reducing macro surface contaminants include, but are not limited to
the use of an air knife or similar forced air treatment. As the
surface of the mushroom appears to be slightly sticky, this method
may not work well.
[0021] Mushrooms, and other fruits and vegetables may be treated
with various chemicals (herbicides, pesticides, fertilizers, and
the like) during growth. The popularity of organic produce
underscores the public's perception of residual chemicals on food
products. Removal of such could be beneficial to the sale of fruits
and vegetables. Ozone may be the only food safe technology which
has addressed this issue in an economic manner, as discussed in
U.S. Pat. No. 6,200,616 to Smith.
[0022] Produce may be washed in either chlorinated water, also a
widely used bactericide, or non-chlorinated (organic produce) water
flume to remove external contaminants such as dirt. Generally such
treatment may not serve to reduce the indigenous population of
microbes, rather it may increase said population; however it can
remove loose surface impurities. Extended treatment of this type
may not be appropriate for mushrooms as excessive water is taken up
by the mushroom and causes a surface imperfection called "window
paneing". Window paneing may be commercially detrimental. At
chlorine levels sufficient to reduce spoilage organism on mushroom
surfaces, browning is induced due to non-enzymatic oxidation of
indigenous substrates to form chemicals that serve as browning
intermediates. This is noted in the book edited by Lee and Whitaker
(1995).
[0023] Another concept for sanitizing the surface of fruits, and
vegetables as well as other food products may be through the
combined used of two or more of the aforementioned technologies.
For example, UV and ozone are reported to work synergistically to
sanitize exposed surface, and to whiten a product. U.S. Pat. No.
4,156,652 to Wiest may utilize the synergy of ozone and ultraviolet
light to sterilize fluids. U.S. Pat. No. 5,213,759 to Castberg may
describe the use of UV radiation in an atmosphere of ozone followed
by hydrogen peroxide for sterilization of food packaging.
Similarly, U.S. Pat. No. 6,162,477 to Crisinel, et al. may describe
a process utilizing an aqueous chemical treatment followed by
pressurized ozone injection into a tank of aqueous liquid. This
process may be designed to be used primarily on fish and therefore
may not address cleaning of macro debris, and residual sugars, that
will decrease, or nullify the effectiveness of the first solution
and/or ozone. This could be overcome by frequent refreshing of the
tank; however, this would create inordinate expenses to the
processor. The patent may not address removal of excess liquid on
the surface of the food product which will affect the quality of
the end product. Further, this technology may not exploit the
synergy of other antimicrobial technologies with ozone
treatment.
[0024] U.S. Pat. Pub. No. 20020094363 to Traeder, et al. may
describe spraying a food product with ozone plus a surfactant
followed by a preserving agent. Because the ozone may be used
directly on a dirty, or freshly cut product, the ozone could not
oxidize microbial products, but could instead be used to oxidize
cellular materials and gross contaminants, thus minimizing, or
eliminating its antimicrobial action. Further, a spray system alone
likely could be insufficient to remove macro debris, especially on
mushroom surface. Sufficient force to remove the dirt could likely
result in surface bruising and subsequent browning. Moreover,
because this art may suggest collecting, filtering and re-ozonating
the wash solution, it is unlikely that ozone levels could be
maintained at a sufficiently high levels. Filtration of liquid
could not remove all contaminates such as cellular sugars, and
organic load could build up in the water, and the ozone could be
used to oxidize organic contaminants rather than microbes on the
surface of produce.
[0025] As in the produce industry and the mushroom industry, the
general public clamor for produce that maintains its integrity, its
"freshly-picked" organoleptic properties over its shelf life, is
treated in a manner safe for workers and consumers alike, and is
economically feasible. The present invention discloses a system
which overcomes virtually everyone of the aforementioned problems
in a practical fashion. It provides a method to rid the produce and
mushrooms of growing media, decrease the indigenous level of
pathogens, decreases the amount of residual chemical on the
surface, and inhibit or slow browning of the surface without
inducing negative attributes, nor requiring disclosing of wash
ingredients on the finished package.
II. SUMMARY OF THE INVENTION
[0026] Accordingly, the present invention includes a variety of
aspects or embodiments which may be selected in different
combinations to suit the needs of the user. First it can function
as a treatment for whole mushrooms, or whole produce which is to
remain whole and sold as fresh. Further, it can function as a
treatment for whole mushrooms, or produce which are to be sliced
and sold as fresh, sliced mushrooms or sectioned (fresh-cut)
produce. Also, it can function as a treatment for previously sliced
produce. In addition, it can function as a treatment for mushroom,
or produce which is to ultimately be used for canning, or further
processing, either whole or sliced, such that processing can wait
until such time as it is practical to process a batch without
having to address issues such as browning during holding time.
Perhaps also, it can function as an aid to consolidate and
coordinate picking, processing and packaging such that mushrooms,
can be treated in large, economical batches rather than singular
type treatment as is the current practice. It does so by increasing
the practical shelf life thereby extending the time in which the
mushrooms must reach the marketplace. Further, it can aid
mechanization of the treatment and packaging of mushrooms which are
currently packaged in a manual line. By inhibiting the browning
enzyme from functioning, treatments which may normally cause
bruising and subsequent browning now may only cause a surface
deformation. Also, the present invention serves as a `worker-safe`
method such that inordinate training is not required for
implementation of the various treatment steps, nor are dangerous
chemicals stored in the vicinity of the worker. The invention may
utilize GRAS ingredients that are not extremely caustic either in
concentrated, or diluted form and methodologies for which
`easy-to-implement` safeguards already exist, and/or may utilize
treatments for which the functioning element is generated on-site
and on-demand. Also, the process helps to create a safer consumable
by reducing the amount of residual chemical (pesticide, herbicide,
fertilizer) on the surface of the produce. The invention may be
also environmentally safe, as the amount of water utilized in the
process is reduced in comparison to traditional wash processes due
to the recycling step and the water is free from contaminants which
will harm downstream biota.
[0027] This invention may relate to processing of fresh-cut
produce, including but not limited to fruits and vegetables.
Further the invention may relate to, but not limiting to, non-leafy
produce, fungal items of produce, edible fungal items of produce,
mushrooms or white button mushrooms. Non-leafy produce may include,
but is not limited to root vegetable, tuber vegetable, bulb
vegetables, flower vegetables, immature fruit vegetable, seed
vegetable, simple fresh berry fruits, simple fresh hesperidium
fruits, simple drupe fruits, simple pome fruits, multiple fleshy
berry fruits, potato, artichoke, broccoli, pea pods, shelled peas,
banana, citrus, peach, apple, and strawberry It is described in the
context of the preparation of mushrooms but is believed to be
useful on other fruits and vegetables, especially those that are
subject to browning. The technology could be used on whole produce,
whole produce to be sliced, or otherwise sectioned, or sections of
produce.
[0028] One of broad objectives of the invention is to allow
mushroom farms to retrofit current equipment such that capital
expenditures for implementation are minimal. One goal of the
present invention may include having flexibility in the process
such that treatments can be applied in a variety of manners
including dip tanks and spray methods (drenching, spraying or
misting). Another goal may include defining the requirements for
treatment such that parameters are well understood and can be
achieve through retrofitting of common mushroom treatment
equipment.
[0029] Another broad objective could be treatment in such a manner
that mushrooms are not broken, or otherwise damaged during
processing. A goal could be to ensure maximum care will be taken to
design equipment requirements such that physical handling and
manipulation of the mushrooms is minimized. A further goal is to
minimize the number of different treatment steps utilizing
different pieces of equipment.
[0030] Additionally, one broad objective of the invention may be to
minimize the time mushrooms are exposed to solution to minimize
water and chemical uptake by mushrooms. One goal may include
maximum utilization of treatments that are not of an aqueous
nature. Another goal may be to minimize residence time in solution
and maximize effectiveness of the treatment solution.
[0031] Yet another broad objective of the invention may be to
minimize the cost to the processor such that the invention is
commercially practical. One goal may incorporate the preservation
of expensive solutions such that they can be used for multiple
treatments. Another goal may include the minimization of
contamination of the expensive solution. A further goal may
encompass the use of minimal amounts of the most expensive
solutions. Also, a goal may espouse the recycling of natural
resource such as water, to minimize disposal. Yet another goal may
address the use of environmentally safe products, such that
disposal of treated water may be accomplished without requiring
special steps, or modification of current disposal systems, or
additional disposal expenses.
[0032] Another broad objective of the invention may be the creation
of a treatment which does not modify the chemical constituents of
the mushroom, nor may there be any detectible level of chemical
remaining after treatment therefore rendering the treatment as a
processing aid, not requiring labeling on the final package. One
goal may include the use of GRAS ingredients at the lowest possible
concentration which still achieves a positive benefit.
[0033] Another broad objective of the invention may be to create a
treatment which is applicable to a all commercially important
mushroom species and varieties. As such, one goal may encompass the
ability to treat mushrooms that do have open veils.
[0034] A further broad objective of the invention may be to render
a final product which is a value-added product, having improved
organoleptic properties and decreased risk of food-borne illness.
One goal may encompass the use of technologies which effectively
decrease human pathogens and decay related microbes on the surface
of the produce. A further goal may be to efficiently minimize the
impact of the enzymes and processes which induce browning.
III. BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a block diagram illustrating the principal
components of a wash-line which may be used to carry out the method
of the present invention.
[0036] FIG. 2 is a block diagram illustrating the ozone/ultraviolet
light treatment tank, side view.
[0037] FIG. 3 is another block diagram illustrating some of the
elements through one design of an embodiment.
IV. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The basic concepts of the present invention may be embodied
in a variety of ways. It involves both treatment techniques,
combinations of food grade chemicals, as well as equipment to
accomplish the appropriate treatment. In this application, the
treatment techniques and equipment are disclosed as part of the
results shown to be achieved by the various devices described and
as steps which are inherent to utilization. In addition, while some
devices are disclosed, it would be understood that these not only
accomplish certain methods but also can be varied in a number of
ways. Importantly, as to all of the foregoing, all of these facts
should be understood to be encompassed by this disclosure.
[0039] FIG. 1 shows a block diagram illustrating the principal
components of a wash-line which may be used to carry out the method
of the present invention and FIG. 2 details the
ozonation/ultraviolet treatment area. For both figures (1)
indicates a slotted vibratory table or conveyor; (2) indicates a
cleaning solution treatment; (3) a surface water removal system;
(4) and (5) are antibrowning treatment tanks; (6) is an ultraviolet
light process; (7) indicates an ozone treatment system and ozonated
water collection tank; (8) indicates a conveyor; (9) indicates a
slicer; (10) indicates a vacuum cooler; (11) indicates a packaging
system; (12) indicates ozone treatment system.
[0040] In some embodiments of the present invention, a series of
treatments and baths which may include a macro-cleansing step, an
anti-browning step, and an antimicrobial step which will clean a
mushroom such that it goes from freshly picked to having superior
organoleptic properties and lower microbial load including human
pathogens and mushroom decay organisms.
[0041] In the one embodiment, present invention may provide a
method for accepting input of at least one item of produce, making
an input capability for produce, or a non-damaging produce input
(13). The macrodebris including, but not limited to physical
particulates and gross contaminants such as large pieces of soil,
or broken or fractured mushroom parts may be sorted from whole
mushrooms by a macrodebris removal system (21) or by collecting
them on an oscillating, or vibratory table (1) which may have slots
or apertures through which gross contaminants can pass but over
which whole mushrooms may be transported. A method to remove these
macrodebris may be treating a produce in conjunction with a
sieve-type element. To those skilled in the art, there are any
variety of alternatives to accomplish this task. At the end of the
table, or immediately following physical vibrating, the mushrooms
may be conveyed or pass into or under, at least one process. The
present invention may provide for a transport capability where at
least one produce may be carried or moved through at least one
process. Examples of such process may be applying a first produce
integrity maintenance process, a second produce integrity
maintenance process, application of an antibrowning agent to the
produce by a produce antibrown agent applicator (4,5) exposing the
produce to ultraviolet light by an ultraviolet light system, and
applying an ozone treatment (7) by an ozone treatment system. In
one embodiment, the present invention may provide for a
non-damaging produce output (15) so that the produce may not be
bruised or damaged. A produce conveyor (8) may be positioned at
least partly in a processing path between the non-damaging produce
input and the non-damaging output.
[0042] In one embodiment, the cleaning solution (2) may be a pH
neutral, for example about pH 6.5 to 7.5, aqueous solution that may
or may not include a surfactant to aid in the removal of visible
and invisible contaminants. The surfactant used may be any
surfactant used in the industry. The cleaning solution may also
contain an anti-foaming agent to suppress dirt and excess proteins
coupled with agitation, from creating an excessive mess, and to
ensure adequate treatment of the mushrooms with the solution.
Anti-foam could be a food grade agent and may be at a concentration
at, or around, 5 ppm. The cleaning solution (2) may be applied for
a period of time not to exceed 15 seconds, for example, less than
four seconds and can be applied as either a spray, mist, drench or
as an immersion bath treatment. In the preferred embodiment, the
cleaning solution may be applied as a spray using about two to
three spray bars positioned about 3 to about 7 inches above the
conveyor surface.
[0043] In embodiments, the cleaning solution (2) may be
re-circulated such as through a recirculator (19) and may be
filtered to remove large contaminants as well as passed through a
fine filter to remove microscopic contaminants before being
re-utilized for further rinsing or disposed of down a drain.
[0044] In embodiments, the cleaning solution (2) may be applied
such that all surfaces of the mushroom are exposed equally and for
an equal period of time or the treatment may also be applied
preferentially to certain surfaces which are less sensitive to
water-uptake. Produce may have a plurality of surfaces and each may
have a different predominant directional orientation. The produce
or mushroom may be repositioned during the cleaning solution
process to facilitate equal application. The treatment may be
followed by removal of excess water on the surface of the mushroom
by a commercially available air knife or other such forced air
treatment. The removal of excess water, after any process step, not
only the cleaning solution, may include affirmatively drying the
produce wherein a process or drying element is used to expedite the
drying. After affirmatively drying the produce, the produce may be
then in a relatively dry state where the produce may have a small
amount of water remaining on it. For example, removing at least
about 80% of surface water from a produce or perhaps even removing
at least about 90% to 95% of surface water from a produce.
[0045] In one embodiment, the aqueous portion of the cleaning
solution step may be recovered and transported via standard food
industry art, to a holding reservoir. The cleaning solution step
may be, but is not limited to be, the first step in the wash
process, which may increase the efficacy of each of the following,
more expensive steps by avoiding contamination of those wash or
spray tanks.
[0046] In some embodiments, the cleaning step may or may not be
followed by surface water removal system (3). The length of time,
and/or the length of conveyor, to the next treatment may impact the
need for a drying step post the cleaning step. If the length of
time is greater than 5 seconds, such a drying step may be
desirable.
[0047] In embodiments, the antibrowning agent (4,5) may be a
solution which is maintained at a pH at or near that of the pH of
produce or mushroom tissue. For example, the pH of the antibrowning
agent solution may be in the range of about pH 5.5 to about 7.5.
Further, the pH of the antibrowning agent solution may be at the
physiological pH of mushrooms, which may be about pH 6.5, or at the
physiological pH of the tissue of the produce being treated.
Additionally, an antibrowning agent solution may comprise about
2.0% to 4.5% (w/v) of sodium erythorbate. Also, an antibrowning
agent solution may comprises about 3.0% to about 3.5% (w/v) of
sodium erythorbate at a temperature of about 34 to about 50 degrees
F. The antibrowning solution may contain a chelator to remove
divalent cations from the solution which may render the sodium
erythorbate more effective. This chelator may be disodium EDTA at
about 0.1 to about 0.4% (w/v) in solution. The solution may also
contain calcium chloride, or any other chemical known to those
skilled in the art, to stabilize plant cell walls, at a
concentration of about 0.1 to about 0.4% (w/v). Further, the
solution may comprise ascorbic acid and/or sodium chloride in
various concentrations. The solution may contain, in addition, or
as substitution, any other GRAS substance which is known, to those
skilled in the art, to inhibit browning, including, but not limited
to citric acid, and cysteine-HCL. Any of these may be involve the
use of an additional substance applicator (18) that may be
specified as to the particular substance involved.
[0048] In some embodiments, the antibrowning solution may be
applied for less than about 1.5 minutes, for example less than
about 30 seconds, but more than about 2 seconds. The antibrowning
agent solution may be applied as either a spray, mist, drench or as
a total immersion treatment. The application may occur in single
step, or in multiple, sequential steps and using a variety of
application techniques.
[0049] In one embodiment, the antibrowning agent treatment (4,5)
may be followed by a water rinse such as through a water rinse
system (22) to ensure abatement of chemical residual on the produce
surface. Such water rinse may be immediately preceded by surface
liquid removal. Such water removal treatment may also immediately
follow a fresh water rinse step.
[0050] In embodiments, the antibrowning solution may be applied
such that all surfaces of the mushroom are exposed equally and for
an equal period of time or the treatment may also be applied
preferentially to certain surfaces which contain a greater
concentration of browning enzyme. The produce or mushroom may be
repositioned during the antibrowning solution process to facilitate
equal application.
[0051] In some embodiments, the antibrowning agent step may or may
not be followed by surface water removal system (3). The length of
time, and/or the length of conveyor, to the next treatment may
impact the need for a drying step post the cleaning step. If the
length of time is greater than 5 seconds, such a drying step may be
desirable.
[0052] The present invention may provide for an
antimicrobial/anti-pathogen treatment. The
antimicrobial/anti-pathogen treatment may consist of either
treatment with simultaneous or sequential application of ozonated
water by an ozone treatment system (7) and ultraviolet light by an
ultraviolet light system (6) as may be effected by a simultaneous
produce treatment control system (23). Both of these treatments may
be generated using commercially available apparatuses that can be
adapted to a conveyor, shaker table or aqueous application
equipment. For example, the ozone generation machine will be a
corona discharge ozone generator, such as the Ozonice by Boley and
Associate, covered by Boley U.S. Pat. No. 6,132,629, utilized in
the disclosed experiments.
[0053] The present invention may provide for substantially
simultaneously subjecting a produce to at least a portion of a
first produce integrity maintenance processes and at least a
portion of a second produce integrity maintenance process. In one
embodiment, the substantially subjecting may include a first
process overlapping at least part of a second process. In one
embodiment, the substantially subjecting may include a first
process overlapping a majority of a second process. In one
embodiment, the substantially subjecting may include a first
process overlapping nearly all of a second process. In one
embodiment, the substantially subjecting may include a first
process completely overlapping a second process.
[0054] If a process or treatment is sequential, the order of
treatment may be reflected in many permutations, including, but not
limited to: (U.V., ozone), (U.V., ozone, U.V.), (U.V. ozone, ozone
U.V.), (ozone, U.V.). Statement of these permutations is not
intended to be limiting. Alternatively, treatment may be
simultaneous, and followed by a second exposure to ultraviolet
light, or multiple treatments of any of the process described
herein. Further, the process may include a first ozone treatment, a
second ozone treatment, multiple ultraviolet light systems, or a
second ultraviolet light.
[0055] This treatment may maintain integrity of the produce to at
least some degree by exerting sufficient ultraviolet light and
ozone to reduce the indigenous population of human pathogens or
microbial decay organisms on the mushroom surfaces while refraining
from damaging the mushroom tissue. Such application rate may be
about 0.5 to about 5 ppm ozone (in water) at a temperature not to
exceed about 60 degrees F. but preferably at or below about 40
degrees F., and a pH between about 6 and about 8, for example at,
or around pH 6.5, or the physiological pH of the produce being
treated. Ozone treatment application rates shall be limited by
current FDA/USDA regulations for ozone treatment application on
food products, as well as efficacy. Ozone may be in aqueous
solution and may be applied as a dip, spray or drench solution,
most preferably as a spray solution.
[0056] The total exposure time for the antimicrobial/anti-pathogen
treatment may be between about 5 and 60 seconds, for example about
20 seconds. In the preferred embodiment this solution may be
applied such that all surfaces of the mushroom are exposed equally
and for an equal period of time or the treatment may also be
applied preferentially to certain surfaces which are less sensitive
to water-uptake. The produce or mushroom may be repositioned during
the ozone treatment (7) process to facilitate equal
application.
[0057] The ultraviolet light (6) may be comprised of at least three
wavelengths, for example, 185 nm, 189 nm, and 253.7 nm from a
standard ultraviolet source. The ultraviolet light may be
positioned at a distance of about 1 to about 24 inches from the
exposed surface of produce. In one embodiment, a dose of 0.1
joules/cm.sup.2 may be considered effective, as is known to those
skilled in the art. The dose of ultraviolet light may be achieved
by using either individually or in combination of different wattage
bulbs with varied distance to the product, and varied time of
exposure, or the like in any combination therein. In one
embodiment, a dose of ultraviolet light may be used to determine
the optimal distance from the surface of the mushroom to the U.V.
light source, and will be effected by the height of the mushroom
relative to the conveyor, et cetera. Low-pressure, commonly
available ultraviolet bulbs emitting a broad germicidal spectrum
may be used and may be used with at least three wavelengths. In
some embodiments, bulbs having single, or short spectra can be used
such that the appropriate wavelength is utilized at the appropriate
place. For example, wavelength of 180-200 nm may be used
simultaneous with ozone treatment, while a bulb having 253.7 nm
wavelength may be used immediately following ozone treatment. This
application may treat all surfaces of the mushroom and the mushroom
may be gently rotated during the exposure to ozone or ultraviolet
light by technologies common in the food industry, or particular
surfaces will be treated preferentially. Moreover, one surface may
be treated by ozone, and ultraviolet light while another surface
might be treated only by ultraviolet light. Both ultraviolet light
and ozone treatments are commonly used to treat various, organic
and inorganic materials in order to decrease the bacterial
contamination on the exposed surfaces of said material.
[0058] In some embodiments, the antimicrobial/anti-pathogen
treatment may be placed immediately following the initial water
wash treatment, or immediately following treatment with the
antibrowning solution. It may also occur at multiple steps during
the treatment.
[0059] In one embodiment, the antimicrobial/anti-pathogen treatment
would occur such that the mushrooms are free from macro
contaminants such as casing materials. This enables the full
functionality of the ozone/ultraviolet treatment.
[0060] In the preferred embodiment the aqueous solution from the
antimicrobial/anti-pathogen treatment could be collected
immediately following treatment, and transferred to a reservoir to
be used in the cleansing step.
[0061] In one embodiment, the antimicrobial/antipathogen treatment
might occur in more than one place in the production line thus
ensuring microbial cleanliness. The last step in the production
wash line may be an antimicrobial/antipathogen treatment.
[0062] In some embodiments, the antimicrobial/antipathogen
treatment may or may not be followed by surface water removal
system (3). The length of time, and/or the length of conveyor, to
the next treatment may impact the need for a drying step post the
cleaning step. If the length of time is greater than about 5
seconds, such a drying step may be desirable.
[0063] In embodiments, the present invention may provide for
rapidly treating a produce by an overall treatment modality. In one
embodiment, the total treatment or overall treatment modality, may
include the cleansing step, the antibrowning step, the
antimicrobial/antipathogen step, and transfer between processing
tank likely may not exceed about 3 minutes in duration. For
example, the total treatment may be less than about 2 minutes in
duration. The total treatment time may exclude the slicing and/or
vacuum cooling and/or packaging steps. Total time of exposure of
produce to a liquid may be between about 8 and about 165
seconds.
[0064] In one embodiment, the processing room may be temperature
controlled such that it ranges between about 34 degrees F. and
about 65 degrees F. Moreover, all solutions can be applied at a
temperature of about 34 to about 50 degrees F. For example the
solutions temperature may be about 35 to about 40 degrees F. The
temperature of a produce, for example mushroom pulp, may remain at,
or around about 38 degrees F., but not more than about 50 degrees
F. Such temperature control may perhaps help ensure that all
mushroom metabolic activity is slowed and microbial activity
minimized.
[0065] In some embodiments, the steps of treatment may be applied
in a number of different orders depending on the variety of the
produce, such as a mushroom, the issues associated with the type of
mushroom, the processors needs, or any other possible variation.
FIGS. 1 and 2 may describe a few such varieties, and outline some
options for application at each step. The figures are not intended
to be fully inclusive of all options for application, or
application order.
[0066] In order to effectively treat specific surfaces, produce,
for example, mushrooms might be oriented using a orientation
element (16) or using technology such as described by U.S. Pat. No.
6,415,902 to Vis et al., U.S. Pat. No. 4,730,719 to Brown et al.,
U.S. Pat. No. 4,198,903 to Turatti and U.S. Pat. No. 5,855,270 to
Throop et al. A produce may have a plurality of surfaces and each
may have a different predominant directional orientation. The
present invention may provide for differential treatment of the
plurality of surfaces of a produce. The invention may provide
orienting a produce in a substantially preferred manner and
directionally subjecting at least part of the plurality of surfaces
to at least one process. These technologies, among others, may
enable each process step to be applied preferentially to a produce,
for example, a single surface of the mushroom, for example, the
cap, without wetting other surfaces. In one embodiment, orientating
a produce may enable treatment of a single surface with more, or
less solution than other surfaces. For example at least part of a
produce may be treated for about 1 second while at least another
part of a produce surface may be treated for 4 seconds using the
same solution. This multi-surface, multi-treatment may occur
simultaneously, or may occur sequentially. Contact with the
specified surface might be via spray of a said surface, via
blocking-off of specified surfaces and subsequent treatment of
whole mushrooms, contacting of desired surface with a piece of
material or other such device capable of absorbing liquid. In one
embodiment, it might be appropriate to avoid the solution "running"
onto untreated surfaces and the surface to be treated may be
subject to `up-side-down`, or cap-side-down, stipe-up
orientation.
[0067] Because excessive water uptake may be detrimental to quality
of the finished product, steps should be taken to limit exposure to
solutions during the wash process. Such steps may include, but not
limit to, the use of an air knife, a vacuum or other means that are
available to those skilled in the art. In the preferred embodiment,
the drying process may not involve extra handling steps and may
avoid technologies such as centrifugal drying. In the one
embodiment, the drying process may remove at least about 80% of the
surface liquid from the treated surface. For example, the drying
process may remove between about 90% and about 95% of the surface
liquid. In addition, although treatment might be limited to a
single surface, exposure to an air knife, or similar method of
liquid removal, might include the entire surface area. This may
help to ensure that liquid sensitive surfaces, are not inordinately
exposed to liquids. Further, treatment with a drying apparatus
might be of different velocities, or air pressures (in the case of
an air knife) on different surfaces to avoid damage to delicate
tissues. The drying steps may be in between each treatment, or
intermittent between treatments, and may preferentially occur after
a last aqueous treatment, and before packaging, making available
for distribution, or further processing. Drying between treatments
may occur by any variety of known technologies, but should not
inordinately slow the processing or washing line. In the preferred
embodiment, it should be understood that a drying process or drying
step can occur at ambient temperature, but may not rely on
increased temperature for effectiveness. In the preferred
embodiment, the liquid removed from the surface of the treated
product may, or may not be collected in order to be re-used in the
processing line.
[0068] In one embodiment, the technology utilized may be commonly
available pieces of produce processing equipment used to achieve
the same results. The produce processing equipment may have
achieved a first overall treatment modality. The present invention
may provide for the altering of produce processing equipment to
achieve a second overall treatment modality. The present invention
may provide altering the produce processing equipment to
preferentially expose at least part of a produce. In this way,
processors can utilize `moth-balled` or otherwise used equipment to
implement the technology without having to fabricate an entire
processing line. For example, the ability to treat produce via
spray, dip, drench or immersion, or any variety of combinations,
may enable a processor to utilize a dip tank, and a spray conveyor,
or a series of small dip tanks, and the like, to achieve the
required processing time. Moreover, small modifications in
equipment, e.g. adding a series of spray bars over a conveyor, may
also allow processors to utilize current equipment without
significant capital expenditures. The retrofitting of equipment may
make this technology superior over technologies in which large
capital expenditures for new, specialized equipment may be required
because it is cost effective in an industry having very small
margins.
[0069] In the preferred embodiment, in order to continue the
effectiveness of this technology while the produce is transported
to the end user, such washed product might be over-wrapped or
covered by `oxygen-scavenging film` that can absorb latent oxygen
in the package, or that is metabolized by the fresh-cut product.
This may include the use of an oxygen scavenging film applicator
(17).
[0070] Having generally described this invention, a further
understanding can be obtained by reference to certain specific
examples which are provided herein for purposes of illustration
only and are not intended to be limiting unless otherwise
specified.
Example 1
[0071] Mushrooms were either 1) untreated (unwashed), that is, left
as picked; 2) sodium metabisulfite (sulfite treated) washed.
Mushrooms were water rinsed with tap water for 2 seconds then
processed through 2 consecutive dip tanks containing 500 ppm sodium
metabisulfite in solution; or 3) Washed using the herein disclosed
process (new wash) specifically as follows: Mushrooms were conveyed
on a slotted conveyor belt and sprayed with tap water for 2
seconds. They dropped into a series of two dip tanks containing 3%
(w/v) sodium erythorbate, 0.15% (w/v) disodium EDTA, 0.15% (w/v)
calcium chloride. Total residence time was 30 seconds. The whole
mushrooms were then treated by dipping in water containing 2 ppm
ozone (15 second exposure) followed immediately by 10 second
exposure to ultraviolet lamp. Half of the mushroom were sliced and
again exposed to 10 seconds of ultraviolet lamp. The mushrooms were
packaged and stored at either 35, 45 or 55 degrees Fahrenheit and
analyzed microbiologically at day 0, 3, 6, and 9 for total aerobic
plate count with a sensitivity of 1,000 cfu/gram, and day 3,6 and 9
for organoleptic properties including degree of whiteness, amount
of veil opening, and overall salability/quality. Storage at 45 and
55 degrees Fahrenheit represent physiologically stressful
conditions and will illustrate benefits of treatments to a greater
extent than 35 degree F. storage.
[0072] For all examples, data was analyzed statistically using
single factor ANOVA and Student's T-test preparing two groups and
assuming equal variances. All data was analyzed at 95% level
confidence levels. TABLE-US-00001 TABLE 1 Experiment 1
Microbiological Data (total plate count) Day Treatment Temp 0 3 6 9
Unwashed 35 whole 1,504,804 6,372,267 5793268 3406778 sliced
156,446 4682156 3733859 12796706 45 whole 6,479,968 sliced 8628519
55 whole 26,238,308 sliced 53,091,451 sulfite 35 whole 299,999
3,849,234 20709887 31562526 treated sliced 178,805 12,344,021
31345339 383205051 45 whole 216,318,555 sliced 69,673,049 55 whole
145,637,959 sliced 381,362,639 new wash 35 whole 45,605 556,511
7029283 12035695 sliced 131,664 646,497 4064637 37247742 45 whole
14,644,553 sliced 58,160,110 55 whole 44828967 sliced 534,919,543
Total plate count = Average population (cfu/g) of 3 replicates
Temperature = degrees Fahrenheit
For the following organoleptic data this key applies: 1=perfect
condition, paper white, <10% opening on veils 2=few flaws in
cap, slight yellowing, 10-30% veil opening 3=average condition,
some yellow/brown spots, 30-50% veil opening 4=below average, last
day on shelf, brown spots, 60-75% veil opening
[0073] 5=not salable, multiple brown spots or decay, >75% veil
opening TABLE-US-00002 TABLE 2 Experiment 1: Organoleptic Data
Overall appearance visual whiteness % veil opening Treatment Temp
Day 3 6 9 3 6 9 3 6 9 Unwashed 35 whole 3 5 5 4 5 5 3 3 4 sliced 3
5 5 4 4 5 2 5 5 45 whole 4 4 5 4 4 5 3 4 5 sliced 5 5 5 5 5 5 5 5 5
55 whole 3 5 3 5 3 5 sliced 4 5 4 5 4 5 sulfite 35 whole 3 4 5 3 4
5 1 4 5 treated sliced 3 4 5 3 4 5 2 4 5 45 whole 3 5 5 3 5 5 3 5
sliced 3 5 5 3 5 5 3 5 55 whole 4 5 3 5 4 5 sliced 4 5 4 5 4 5 new
wash 35 whole 2 4 4 2 4 4+ 1 3 5 sliced 2 4 4 2 4 4+ 1 3 4 45 whole
2 3 5 2 3 5 1 3 5 sliced 2 4 5 3 4 5 2 4 5 55 whole 2 5 2 5 2 5
sliced 4 5 4 5 3 5
[0074] The effectiveness of the new wash process (the preferred
embodiment) is highly evident in the whole product. Sliced product
can be cross-contaminated when contacting slicing blades previously
contaminated by other product. Both microbiological and
organoleptic data indicates the advantage of the new was process,
especially under stressful conditions of higher temperature; note,
lower percentage veils open indicating slowed maturity, a whiter
product indicating the effectiveness of the antibrowning step, and
a decrease in the microbiological load (whole product, especially)
manifesting the effectiveness of antimicrobial treatment.
[0075] Statistically, there is a significant difference between
microbiological populations on day 0 unwashed, sulfite treated and
new washed whole mushrooms. This indicates the positive
antimicrobial effect of the disclosed treatment. There is not a
statistically significant difference between and within groups of
sliced mushrooms on day 0. As with the organoleptic data, this
likely indicates cross contamination on slicing equipment, and does
not impact the efficacy of the disclosed invention. On day 3, 35
degree storage, the difference between whole mushroom treatments
again showed that the new wash resulted in a significant decline in
microbial population as compared to unwashed, and sulfite washed.
Again, populations on sliced mushrooms at 35 degrees were not
significantly different. On day 6, the difference between
treatments at 35 degrees (both whole and sliced) was not
statistically significant.
Example 2
[0076] Mushrooms were either 1) Mushrooms were washed with water
(2-3 second drench with tap water) then processed through 2
consecutive dip tanks containing an aqueous solution of 500 ppm
sodium metabisulfite (sulfite treated); or 2) Washed using the
herein disclosed process (new wash) specifically as follows:
Mushrooms were conveyed on a slotted conveyor belt and sprayed with
tap water for seconds. They dropped into a series of two dip tanks
containing 3% (w/v) sodium erythorbate, 0.15% (w/v) disodium EDTA,
0.15% (w/v) calcium chloride. Total residence time was 30 seconds.
The whole mushrooms were then treated with 2 ppm ozone spray
followed by 10 second exposure to ultraviolet lamp. Half of the
mushroom were sliced and again exposed to 10 seconds of ultraviolet
lamp. The mushrooms were packaged and stored at either 35, 45 or 55
degrees Fahrenheit. 35 degree F. stored samples were analyzed at
day 0, 2, 6, and 9 and 14 for total aerobic plate count. Both 35
and 45 degree F. stored samples were analyzed on day 2, 6, 9 and 14
for organoleptic properties including degree of whiteness, amount
of veil opening, and overall salability/quality. Storage at 45
degrees Fahrenheit represent physiologically stressful conditions
and will illustrate benefits of treatments to a greater extent than
35 degree F. storage.
[0077] Those categories for which a rating is not given, indicates
a degradation of the product beyond the rating scale.
TABLE-US-00003 TABLE 3 Experiment 2 Microbiological Data (total
plate count) Day Treatment Temp 0 2 6 9 14 sulfite 35 whole 24,188
59,492 428,579 734,285 253,940,711 treated sliced 168,922 736,188
6,101,012 7,976,377 702,413,006 new wash 35 whole 4,864 20,433
35,969 275,377 19,143,778 sliced 121,663 136,975 472,770 432,999
46,576,133 Total plate count = Average population (cfu/g) of 3
replicates Temperature = degrees Fahrenheit
[0078] TABLE-US-00004 TABLE 4 Experiment 2: Organoleptic Data
Overall appearance Visual whiteness Veil opening Treatment Temp Day
2 6 9 14 2 6 9 14 2 6 9 14 sulfite 35 whole 3 3 4 5 3 3 4+ 5 1 1 2
5 treated sliced 3 3 4 5+ 3 3 4+ 5+ 1 2 2 5+ 45 whole 3 5 5+ 3 5 5+
2 4 5 sliced 3 5 3 5 2 5 new 35 whole 2 3 4 4.5 2 3 4 4.5 0 1 2 3
wash sliced 2 3 4 4.5 2 3 4 4.5 1 2 2 3 45 whole 3 4 5 3 4 5 2 4 5
4 sliced 3 4+ 3 4 2 4+ 4
[0079] Statistically, the microbial population on whole mushrooms
treated with the new wash was significantly lower on day 0, 2 and 9
than the other two treatments. Sliced mushrooms treated with the
new wash had significantly lower populations on day 0 and day 6.
These results, when combined with the organoleptic results, again
demonstrate the efficacy of the wash treatment
Example 3
[0080] Mushrooms were either 1) untreated (unwashed), that is, left
as picked; 2) sodium metabisulfite (sulfite treated) washed.
Mushrooms were water rinsed with tap water for 5 seconds then
processed through 2 consecutive dip tanks containing 500 ppm sodium
metabisulfite; or 3) Washed using the herein disclosed process (new
wash) specifically as follows: Mushrooms were conveyed on a slotted
conveyor belt and sprayed with tap water for 2 seconds. They
dropped into a series of two dip tanks containing 3% (w/v) sodium
erythorbate, 0.3% (w/v) sodium chloride, 0.3% (w/v) calcium
chloride. Total residence time was 30 seconds. In the third
treatment (new wash 1) the whole mushrooms were then treated with 2
ppm ozone spray followed immediately by 10 second exposure to
ultraviolet lamp. New wash 2 mushrooms were treated as described
above but was treated only with ozone, no ultraviolet light. New
wash 3 mushrooms were treated with 7 seconds of ultraviolet light,
no ozone. New wash 4 mushrooms were treated with ozone and
ultraviolet light simultaneously.
[0081] Mushrooms were analyzed for microbial load within 18 hours
of processing. Total aerobic population was analyzed with a
sensitivity of 1000 cfu/gram. TABLE-US-00005 TABLE 5 Experiment 3
Microbiological Data (total plate count) Total Plate Count Total
Plate Count Treatment Whole Sliced Unwashed 2,042,820 8,260,363
Sulfite treated 352,745 918,987 new wash 1 310,641 870,994 new wash
2 408,842 2,141,124 new wash 3 1,101,684 511,278 new wash 4 238,542
617,151
[0082] These microbiological results indicate that the
simultaneous, or sequential application of ozone and ultraviolet
light is superior to ultraviolet light alone. Moreover, data
suggests the superiority of combined technologies over ozone alone.
Again, the benefit of a wash process on bacterial contamination is
reinforced by this data TABLE-US-00006 TABLE 6 L-Value (whiteness)
35 degrees F. Treatment Day 1 Day 5 1 88.7 .+-. 4.0 86.4 .+-. 4.6 2
90.3 .+-. 2.4 88.7 .+-. 2.9 3 88.8 .+-. 2.3 86.5 .+-. 2.5 4 89.1
.+-. 2.6 88.9 .+-. 2.1 5 90.0 .+-. 2.8 89.7 .+-. 2.3 6 90.6 .+-.
1.0 88.9 .+-. 2.2
[0083] TABLE-US-00007 TABLE 7 a value (red/blue) 35 degrees F.
Treatment Day 1 Day 5 1 10.6 .+-. 1.1 9.8 .+-. 1.5 2 9.8 .+-. 0.7
9.7 .+-. 0.9 3 10.5 .+-. 1.0 10.2 .+-. 0.7 4 10.2 .+-. 0.9 9.8 .+-.
0.8 5 10.1 .+-. 1.1 9.4 .+-. 0.6 6 9.6 .+-. 0.7 9.7 .+-. 0.8
[0084] TABLE-US-00008 TABLE 8 b value (yellow/brown) 35 degrees F.
Treatment Day 1 Day 5 1 5.7 .+-. 1.9 7.7 .+-. 2.0 2 5.7 .+-. 2.0
6.6 .+-. 1.9 3 6.3 .+-. 1.6 8.2 .+-. 1.9 4 5.7 .+-. 1.2 6.8 .+-.
0.9 5 5.6 .+-. 1.5 6.2 .+-. 1.3 6 5.4 .+-. 1.2 7.1 .+-. 1.7
[0085] For each of the above values, measurements were taken on 5
mushrooms per treatment, and 3 measurements per mushroom. Minolta
calorimeter was used to measure Lab values. The whiteness data,
L-values, given above indicate that the wash process results in
slightly increased whiteness, and less variability within a package
of mushrooms on day 0. This trend was exacerbated by day 5 storage
at 35 degrees F. Sulfite treatment, a commonly acknowledged
commercial standard in the industry and commonly known to bleach
mushrooms, is no whiter than the new wash treatment. Further, the
new wash treatment 4 (U.V. and ozone simultaneously), is less
yellow/brown than sulfite treatment.
[0086] As can be easily understood from the foregoing, the basic
concepts of the present invention may be embodied in a variety of
ways. It involves both maintaining integrity of produce techniques
as well as well as devices to accomplish the appropriate
maintenance of produce. In this application, the systems for
maintaining the integrity of produce are disclosed as part of the
results shown to be achieved by the various devices described and
as steps which are inherent to utilization. They are simply the
natural result of utilizing the devices as intended and described.
In addition, while some devices are disclosed, it should be
understood that these not only accomplish certain methods but also
can be varied in a number of ways. Importantly, as to all of the
foregoing, all of these facets should be understood to be
encompassed by this disclosure.
[0087] The discussion included in this application is intended to
serve as a basic description. The reader should be aware that the
specific discussion may not explicitly describe all embodiments
possible; many alternatives are implicit. It also may not fully
explain the generic nature of the invention and may not explicitly
show how each feature or element can actually be representative of
a broader function or of a great variety of alternative or
equivalent elements. Again, these are implicitly included in this
disclosure. Where the invention is described in device-oriented
terminology, each element of the device implicitly performs a
function. Apparatus claims may not only be included for the device
described, but also method or process claims may be included to
address the functions the invention and each element performs.
Neither the description nor the terminology is intended to limit
the scope of the claims.
[0088] It should also be understood that a variety of changes may
be made without departing from the essence of the invention. Such
changes are also implicitly included in the description and its
application to a variety of reducible support systems. They still
fall within the scope of this invention.
[0089] Further, each of the various elements of the invention and
claims may also be achieved in a variety of manners. This
disclosure should be understood to encompass each such variation,
be it a variation of an embodiment of any apparatus embodiment, a
method or process embodiment, or even merely a variation of any
element of these. Particularly, it should be understood that as the
disclosure relates to elements of the invention, the words for each
element may be expressed by equivalent apparatus terms or method
terms--even if only the function or result is the same. Such
equivalent, broader, or even more generic terms should be
considered to be encompassed in the description of each element or
action. Such terms can be substituted where desired to make
explicit the implicitly broad coverage to which this invention is
entitled. As but one example, it should be understood that all
actions may be expressed as a means for taking that action or as an
element which causes that action. Similarly, each physical element
disclosed should be understood to encompass a disclosure of the
action which that physical element facilitates. Regarding this last
aspect, as but one example, the disclosure of a "treatment" should
be understood to encompass disclosure of the act of
"treating"--whether explicitly discussed or not--and, conversely,
were there effectively disclosure of the act of "treating", such a
disclosure should be understood to encompass disclosure of a
"treat" and even a "means for treating." Such changes and
alternative terms are to be understood to be explicitly included in
the description.
[0090] All patents, publications, or other references mentioned in
this application for patent or listed in an attached information
disclosure statement are hereby incorporated by reference. In
addition, as to each term used it should be understood that unless
its utilization in this application is inconsistent with such
interpretation, common dictionary definitions should be understood
as incorporated for each term and all definitions, alternative
terms, and synonyms such as contained in the Random House Webster's
Unabridged Dictionary, second edition are hereby incorporated by
reference. Finally, as to all references listed or specifically
mentioned, each is hereby appended and hereby incorporated by
reference, however, as to each of the above, to the extent that
such information or statements incorporated by reference might be
considered inconsistent with the patenting of this/these
invention(s) such statements are expressly not to be considered as
made by the applicant(s).
[0091] Thus, the applicant(s) should be understood to have support
to claim at least: i) each of the produce integrity maintenance
system devices as herein disclosed and described, ii) the related
methods disclosed and described, iii) similar, equivalent, and even
implicit variations of each of these devices and methods, iv) those
alternative designs which accomplish each of the functions shown as
are disclosed and described, v) those alternative designs and
methods which accomplish each of the functions shown as are
implicit to accomplish that which is disclosed and described, vi)
each feature, component, and step shown as separate and independent
inventions, vii) the applications enhanced by the various systems
or components disclosed, viii) the resulting products produced by
such systems or components, ix) methods and apparatuses
substantially as described hereinbefore and with reference to any
of the accompanying examples, x) the various combinations and
permutations of each of the elements disclosed, and xi) each
potentially dependent claim or concept as a dependency on each and
every one of the independent claims or concepts presented. In this
regard it should be understood that for practical reasons and so as
to avoid adding potentially hundreds of claims, the applicant may
eventually present claims with initial dependencies only. Support
should be understood to exist to the degree required under new
matter laws--including but not limited to European Patent
Convention Article 123(2) and United States Patent Law 35 U.S.C.
.sctn. 132 or other such laws--to permit the addition of any of the
various dependencies or other elements presented under one
independent claim or concept as dependencies or elements under any
other independent claim or concept. Further, when used, the use of
the transitional phrase "comprising" is used to maintain the
"open-end" claims herein, according to traditional claim
interpretation. Thus, unless the context requires otherwise, it
should be understood that the term "comprise" or variations such as
"comprises" or "comprising", are intended to imply the inclusion of
a stated element or step or group of elements or steps but not the
exclusion of any other element or step or group of elements or
steps. Such terms should be interpreted in their most expansive
form so as to afford the applicant the broadest coverage legally
permissible.
[0092] In addition, the claims set forth later in this
specification are hereby incorporated by reference as part of this
description of the invention, and the applicant expressly reserves
the right to use all of or a portion of such incorporated content
of such claims as additional description to support any of or all
of the claims or any element or component thereof, and the
applicant further expressly reserves the right to move any portion
of or all of the incorporated content of such claims or any element
or component thereof from the description into the claims or
vice-versa as necessary to define the matter for which protection
is sought by this application or by any subsequent continuation,
division, or continuation-in-part application thereof, or to obtain
any benefit of, reduction in fees pursuant to, or to comply with
the patent laws, rules, or regulations of any country or treaty,
and such content incorporated by reference shall survive during the
entire pendency of this application including any subsequent
continuation, division, or continuation-in-part application thereof
or any reissue or extension thereon.
* * * * *