U.S. patent application number 15/432875 was filed with the patent office on 2018-08-16 for process for maintaining freshness of vegetable pieces.
The applicant listed for this patent is Kraft Foods Group Brands LLC. Invention is credited to Kwaku Bandoh, Rachel Catherine Brown.
Application Number | 20180228189 15/432875 |
Document ID | / |
Family ID | 61074510 |
Filed Date | 2018-08-16 |
United States Patent
Application |
20180228189 |
Kind Code |
A1 |
Bandoh; Kwaku ; et
al. |
August 16, 2018 |
PROCESS FOR MAINTAINING FRESHNESS OF VEGETABLE PIECES
Abstract
A packaged food product and methods of making and using it. In
some embodiments. The packaged food product may comprise a cup
containing multiple ingredients in sealed pouches suitable for use
in making an omelet or other egg-based entrees, with the cup being
suitable for microwave cooking of an egg-based entree. The
ingredients may include vegetable components that offer
organoleptic properties similar to those of fresh vegetables after
an extended period of time. Ideally, time required for processing,
shipment, storage, etc., which may be, e.g., several weeks, may
pass without unacceptable degradation of taste, texture, mouth
feel, flavor, aroma, color, nutritional content or other important
qualities. In some embodiments, the ingredients may also include
additional components, such as, for example, one or more meats,
and/or one or more varieties of cheese.
Inventors: |
Bandoh; Kwaku; (Round Lake,
IL) ; Brown; Rachel Catherine; (Evanston,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kraft Foods Group Brands LLC |
Chicago |
IL |
US |
|
|
Family ID: |
61074510 |
Appl. No.: |
15/432875 |
Filed: |
February 14, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23L 3/0155 20130101;
B65D 77/24 20130101; A23L 3/3418 20130101; A23L 19/03 20160801;
A23B 7/06 20130101; A23L 3/3508 20130101; B65B 2220/18 20130101;
B65D 2581/3425 20130101; A23L 19/12 20160801; B65B 25/041 20130101;
B65D 81/3233 20130101; A23B 7/045 20130101; B65B 2220/14 20130101;
B65D 81/3453 20130101; B65D 77/04 20130101; A23V 2002/00 20130101;
A23B 7/04 20130101; B65B 29/08 20130101; A23B 7/154 20130101; A23L
5/13 20160801; A23B 7/10 20130101 |
International
Class: |
A23L 19/12 20060101
A23L019/12; A23B 7/06 20060101 A23B007/06; A23B 7/10 20060101
A23B007/10; A23B 7/045 20060101 A23B007/045 |
Claims
1. A process for preparing, protecting and packaging vegetable
pieces comprising: blanching the vegetable pieces for a
predetermined period of time at a temperature effective to inhibit
enzyme action detrimental to organoleptic properties, and to have
an antimicrobial effect; acidifying the vegetable pieces in an acid
media for a period of time sufficient to have a further
antimicrobial effect without unacceptably affecting organoleptic
properties; freezing the vegetable pieces to a temperature of below
5.degree. F. using an IQF technique; sealing the frozen vegetable
pieces in containers; thawing the vegetable pieces; and subjecting
the vegetables to an HPP process; wherein the process enables
freshness of the vegetable pieces to be maintained in the sealed
containers at refrigerated temperatures for 75 to 90 days.
2. The process of claim 1 wherein the vegetable pieces are
acidified during or after blanching.
3. The process of claim 2 wherein acidifying the vegetable pieces
comprises immersing the vegetable pieces in acid media.
4. The process of claim 3 wherein the vegetable pieces comprise
diced vegetable pieces, each having a minimum dimensions greater
than about 1/8 inch, and a maximum dimension of less than 7/8
inch.
5. The process of claim 3 wherein the vegetable pieces comprise
diced potato pieces having dimensions of about 1/4 inch.times.3/8
inch.times.3/8 inch, and other vegetable pieces having dimensions
of about 3/8 inch.times.3/8 inch.times.3/8 inch, and wherein the
vegetables increase in weight by about 1% to about 12% as a result
of absorption of acid media during acidification.
6. The process of claim 5 wherein acidifying the vegetable pieces
comprises exposing the vegetable pieces to acid media having a pH
of between 2.0 and 3.0 comprising about 2% citric acid and about 3%
sugar in distilled water for a time period of between 1 and 20
minutes.
7. The process of claim 6 wherein acidifying the vegetable pieces
comprises exposing potato pieces to acid media having a pH of
between 2.0 and 3.0 comprising about 2% citric acid and about 3%
sugar in distilled water media for a time period of about 8
minutes, and exposing other vegetable pieces to acid media having a
pH of between 2.0 and 3.0 comprising about 2% citric acid and about
3% sugar in distilled water for a time period of about 4.5
minutes.
8. The process of claim 1 wherein acidifying the vegetable pieces
comprises reducing the pH of the vegetable pieces to less than
5.
9. The process of claim 1 wherein freezing the vegetable pieces
comprising reducing the temperature of the vegetable pieces to
about 0.degree. F.
10. The process of claim 1 wherein the vegetable pieces include
potato pieces, and the potato pieces are not exposed to ambient air
for more than 10 minutes prior to blanching.
11. A process for preparing and packaging diced potato pieces
having dimensions of about 1/4 inch.times.3/8 inch.times.3/8 inch,
and other diced vegetable pieces having dimensions of about 3/8
inch.times.3/8 inch.times.3/8 inch, comprising: steam blanching
raw, washed potato pieces by exposing the raw potato pieces to
steam at a temperature of 200 to 212.degree. F. for 4 to 6 minutes,
with the steam blanching of the raw potato pieces being effective
to inhibit enzyme action detrimental to organoleptic properties,
and to having an antimicrobial effect; steam blanching other raw,
washed vegetable pieces by exposing them to steam at a temperature
of about 210.degree. F. for a period of 40 to 50 seconds, with the
steam blanching of the other vegetable pieces being effective to
inhibit enzyme action detrimental to organoleptic properties, and
having an antimicrobial effect; thereafter acidifying the blanched
potato pieces with acid media comprising about 1% citric acid in
water for a period of 5 to 11 minutes to reduce the pH of the
blanched potato pieces to less than about 5, and acidifying the
other blanched vegetable pieces with acid media comprising about 1%
citric acid and 3% dextrose in water for a period of 1 to 8 minutes
to reduce the pH of the other vegetable pieces to less than about
5; reducing the temperature of the blanched, acidified vegetable
pieces to about 0.degree. F. using an IQF process to preserve them
for later use; thereafter hermetically sealing the blanched,
acidified, frozen vegetable pieces in flexible pouches under vacuum
with a nitrogen atmosphere; thereafter thawing the blanched,
acidified vegetable pieces in the pouches; thereafter pressurizing
the thawed vegetable pieces to an HPP process at about 86,500 psi
for about 3 minutes at a temperature of about 41.degree. F.;
thereafter inserting each of the pouches containing thawed
vegetable pieces into a cup; and thereafter providing a lid on the
cup to provide an enclosed environment for the pouches containing
thawed vegetable pieces.
12. The process of claim 11 wherein the blanched vegetable pieces
have a pH of between 5 and 6 prior to acidification, and between
4.4 and 4.6 after acidification.
13. A packaged food product comprising packaged vegetables pieces,
wherein the product has a refrigerated shelf life of at least 75
days, and wherein the vegetable pieces have been prepared by: steam
blanching raw, washed potato pieces by exposing the raw potato
pieces to steam, the steam blanching of the raw potato pieces being
effective to inhibit enzyme action detrimental to organoleptic
properties, and the steam blanching having an antimicrobial effect;
steam blanching other raw, washed vegetable pieces by exposing them
to steam, the steam blanching of the other vegetable pieces being
effective to inhibit enzyme action detrimental to organoleptic
properties, the steam blanching also having an antimicrobial
effect; thereafter acidifying the blanched potato pieces with
citric acid media to reduce the pH of the blanched potato pieces to
less than about 5; and acidifying the other blanched vegetable
pieces with citric acid media to reduce the pH of the other
vegetable pieces to less than about 5; reducing the temperature of
the blanched, acidified vegetable pieces to about 0.degree. F.
using an IQF process to preserve them for later use; thereafter
hermetically sealing the blanched, acidified, frozen vegetable
pieces in flexible pouches under vacuum with a nitrogen atmosphere;
thereafter thawing the blanched, acidified vegetable pieces in the
pouches; and thereafter pressurizing the thawed vegetable pieces to
about 86,500 psi for about 3 minutes at a temperature of about
41.degree. F. in an HPP process.
14. The packaged food product of claim 13 wherein the other
vegetable pieces comprise one or more of green bell peppers,
onions, and red bell peppers.
15. The packaged food product of claim 14 wherein the packaged food
product further comprises a cup containing the packaged vegetable
pieces, and additional, separately packaged food items.
16. The packaged food product of claim 15 wherein the additional,
separately packaged food items include one or more of meat, cheese
and mushrooms.
17. The packaged food product of claim 16 wherein the meat
comprises one or more of ham, bacon and sausage, and wherein the
cheese comprises one or more of sharp cheddar and Swiss cheese.
18. The packaged food product of claim 17 wherein the cup is of
sufficient size to accommodate the liquid components of an egg, and
wherein the packaged food product further comprises a removable lid
on the cup, a shrink label on the cup, and instructions for making
an egg-based entree by adding the liquid components of an egg to
the cup, combining the vegetable components and additional,
separately packaged food items with the egg in the cup, and heating
the combination in a microwave oven.
19. The packaged food product of claim 18 wherein the vegetable
pieces include diced potato pieces having dimensions of about 1/4
inch.times.3/8 inch.times.3/8 inch, and include diced pepper and
onion pieces having dimensions of about 3/8 inch.times.3/8
inch.times.3/8 inch.
20. The packaged food product of claim 13 wherein the blanched,
acidified vegetable pieces include, in addition to the vegetable
pieces, citric acid, sugar and water, but are substantially free of
other ingredients.
Description
FIELD
[0001] This application relates generally to food products, and
more specifically to microwavable food products that include
vegetable components, and processes for maintaining freshness of
vegetable components.
BACKGROUND
[0002] Omelets and scrambled egg items that include meats and
vegetables are often prepared by manually dicing meat ingredients
and fresh vegetables. Such processes tend to be labor-intensive,
and often result in leftover portions of various ingredients
requiring storage for later use, or being wasted. A packaged food
product comprising components suitable for making one or more
individual omelets or other egg-based entrees has been thought to
be useful. However, development of a high quality, nutritious
product suitable for high-volume commercial production and sale has
proven challenging. In addition to addressing problems generally
applicable to development and production of packaged food products,
e.g., cost control, quality control, shelf-stability, avoidance of
unduly high mass or volume of packaging materials, etc., provision
of vegetable items suitable for inclusion in such a product must
address particularly challenging organoleptic issues.
SUMMARY
[0003] Described herein are a packaged food product and methods of
making and using it. In some embodiments, the packaged food product
comprises a cup containing multiple ingredients in sealed pouches
suitable for use in making an egg-based food item or entree with
similarities to an omelet, breakfast scramble, or other egg-based
entrees, with the cup being suitable for microwave cooking of an
egg-based food item. In some embodiments, the ingredients include
vegetable components that offer organoleptic properties similar to
those of fresh vegetables after an extended period of time.
Preferably, time required for processing, shipment, storage, etc.,
which may be, e.g., several weeks, may pass without unacceptable
degradation of taste, texture, mouth feel, flavor, aroma, color,
nutritional content or other important qualities. In some
embodiments, the ingredients may also include additional
components, such as, for example, one or more meats, e.g., ham,
sausage, bacon, Canadian bacon or the like; one or more cheeses;
and/or mushrooms. The packaged food product may be provided with or
without a liquid egg component.
[0004] In some embodiments, the packaged food product may include
instructions for the consumer to perform some or all of the
following steps, either in the order set forth below or in a
different order: [0005] 1. Remove or otherwise open a lid of the
cup [0006] 2. Remove the pouches from the cup [0007] 3. Add an egg
to the cup, e.g., by cracking a fresh egg (not provided with the
packaged food product) and adding the liquid egg component to the
cup [0008] 4. Mix or stir the egg in the cup (either before or
after step 5) [0009] 5. Open the pouches and add some or all of the
pouch contents to the cup [0010] 6. Heat or cook the contents of
the cup, e.g., by placing the cup in a microwave oven [0011] 7. Add
a component such as shredded cheese, from one of the pouches or
from another source, during and/or after microwave heating
[0012] In some embodiments, vegetable components are prepared by
the following process: [0013] blanching the vegetable pieces for a
predetermined period of time at a temperature effective to inhibit
enzyme action detrimental to organoleptic properties, and to have
an antimicrobial effect; [0014] acidifying the vegetable pieces in
acid media for a period of time sufficient to have a further
antimicrobial effect without unacceptably affecting organoleptic
properties; [0015] freezing the vegetable pieces to a temperature
of below 5.degree. F. using an IQF technique; [0016] sealing the
frozen vegetable pieces in containers; [0017] storing the vegetable
pieces; [0018] thawing the vegetable pieces; and [0019] subjecting
the vegetables to an HPP process; [0020] wherein the process
enables freshness of the vegetable pieces to be maintained in the
sealed containers at refrigerated temperatures for 75 to 90
days.
[0021] In some embodiments, the vegetable pieces are acidified
during or after blanching. In some embodiments, acidifying the
vegetable pieces comprises immersing the vegetable pieces in acid
media. In some embodiments, the vegetable pieces comprise diced
vegetable pieces, each having a minimum dimension greater than
about 1/8 inch, and a maximum dimension of less than 7/8 inch. In
some embodiments, the vegetable pieces comprise diced potato pieces
having dimensions of about 1/4 inch.times.3/8 inch.times.3/8 inch,
and other vegetable pieces having dimensions of about 3/8
inch.times.3/8 inch.times.3/8 inch. In some embodiments the
vegetables increase in weight by about 1% to about 12% as a result
of absorption of acid media during acidification. In some examples,
the vegetable pieces may increase in weight by about 5% to 6%, or
by about 5.6%.
[0022] In some embodiments, acidifying the vegetable pieces
comprises exposing the vegetable pieces to a citric acid media. In
some embodiments, the acid media may have pH of between 2.0 and
3.0, or more specifically may have a pH of about 2.1 to 2.2. In
some embodiments, the acid media may comprise about 2% citric acid
and about 3% sugar in distilled water for a time period of between
1 and 20 minutes.
[0023] In some embodiments, acidifying the vegetable pieces
comprises exposing potato pieces to acid media having a pH of
between 2.0 and 3.0 comprising about 2% citric acid and about 3%
sugar in distilled water media for a time period of about 8
minutes, and exposing other vegetable pieces to acid media having a
pH of between 2.0 and 3.0 comprising about 2% citric acid and about
3% sugar in distilled water for a time period of about 4.5 minutes.
Acidifying the vegetable pieces may comprise reducing the pH of the
vegetable pieces to less than 5, and in some of these embodiments,
less than 4. In some embodiments, acidification reduces the pH of
the vegetable pieces to about 3.6 to 3.8, or more specifically to
about 3.68.
[0024] In some embodiments, freezing the vegetable pieces comprises
reducing the temperature of the vegetable pieces to about 0.degree.
F.
[0025] In some embodiments, where the vegetable pieces include
potato pieces, care may be taken to avoid exposure of the potato
pieces to ambient air for more than 5 to 10 minutes prior to
blanching, to avoid browning of the potato pieces.
[0026] In some embodiments, the process may comprise the following
sequence of steps:
[0027] providing raw, washed, diced potato pieces having dimensions
of about 1/4 inch.times.3/8 inch.times.3/8 inch, and other raw,
washed, diced vegetable pieces having dimensions of about 3/8
inch.times.3/8 inch.times.3/8 inch, comprising:
[0028] steam blanching the raw, washed diced potato pieces by
exposing them to steam at a temperature of 200 to 212.degree. F.
for 4 to 6 minutes, the steam blanching of the raw potato pieces
being effective to inhibit enzyme action detrimental to
organoleptic properties, and the steam blanching also having an
antimicrobial effect;
[0029] steam blanching other raw, washed diced vegetable pieces by
exposing them to steam at a temperature of about 210.degree. F. for
a period of 40 to 50 seconds, with the steam blanching of the other
vegetable pieces being effective to inhibit enzyme action
detrimental to organoleptic properties, and also having an
antimicrobial effect;
[0030] thereafter acidifying the blanched potato pieces with citric
acid media to reduce the pH of the blanched potato pieces to less
than about 5; and acidifying the other blanched vegetable pieces
with citric acid media to reduce the pH of the other vegetable
pieces to less than about 5;
[0031] reducing the temperature of the blanched, acidified
vegetable pieces to about 0.degree. F. using an IQF process to
preserve them for later use;
[0032] thereafter hermetically sealing the blanched, acidified,
frozen vegetable pieces in flexible pouches under vacuum with a
nitrogen atmosphere;
[0033] thereafter thawing the blanched, acidified vegetable pieces
in the pouches; and
[0034] thereafter pressurizing the thawed vegetable pieces to about
86,500 psi for about 3 minutes at a temperature of about 41.degree.
F. in an HPP process.
[0035] Also described herein is a packaged food product comprising
packaged vegetables pieces, wherein the product has a refrigerated
shelf life of at least 75 days, and wherein the vegetable pieces
have been prepared by:
[0036] steam blanching raw, washed potato pieces by exposing the
raw potato pieces to steam, the steam blanching of the raw potato
pieces being effective to inhibit enzyme action detrimental to
organoleptic properties, and the steam blanching having an
antimicrobial effect;
[0037] steam blanching other raw, washed vegetable pieces by
exposing them to steam, the steam blanching of the other vegetable
pieces being effective to inhibit enzyme action detrimental to
organoleptic properties, the steam blanching also having an
antimicrobial effect;
[0038] thereafter acidifying the blanched potato pieces with citric
acid media to reduce the pH of the blanched potato pieces to less
than about 5; and acidifying the other blanched vegetable pieces
with citric acid media to reduce the pH of the other vegetable
pieces to less than about 5;
[0039] reducing the temperature of the blanched, acidified
vegetable pieces to about 0.degree. F. using an IQF process to
preserve them for later use;
[0040] thereafter hermetically sealing the blanched, acidified,
frozen vegetable pieces in flexible pouches under vacuum with a
nitrogen atmosphere;
[0041] thereafter thawing the blanched, acidified vegetable pieces
in the pouches; and
[0042] thereafter pressurizing the thawed vegetable pieces to about
86,500 psi for about 3 minutes at a temperature of about 41.degree.
F. in an HPP process.
[0043] The other vegetable pieces may comprise, for example, one or
more of green bell peppers, onions, and red bell peppers. The
packaged food product may further comprise a cup containing the
packaged vegetable pieces, and additional, separately packaged food
items. The additional, separately packaged food items may include,
e.g., one or more of meat, cheese and mushrooms. The meat may
comprise one or more of ham, bacon, Canadian bacon, sausage, and/or
other meats. The cheese may comprise one or more of extra sharp
cheddar, sharp cheddar, mild cheddar, American cheese, Swiss
cheese, and/or other varieties of cheese.
[0044] The above-mentioned cup may be of sufficient size to
accommodate the liquid components of an egg in addition to the
vegetable pieces and the other separately packaged food items
mentioned above, with sufficient extra room to accommodate
expansion of the egg and other food items during microwave cooking,
and wherein the packaged food product further comprises a removable
lid or membrane on the cup, a shrink label on the cup, and
instructions for making an egg-based entree by adding the liquid
components of an egg to the cup, combining the vegetable components
and additional, separately packaged food items with the egg in the
cup, and heating the combination in a microwave oven. The lid may
have microperforations therein to accommodate pressure changes.
[0045] In some embodiments, the packaged food product can include a
microwavable rigid cup having a rim defining a generally circular
opening to an interior of the cup, a base, and a sidewall extending
between the rim and the base. A first flexible pouch can be
disposed within the interior of the cup. The first flexible pouch
can contain cheese pieces. A second flexible pouch can also be
disposed within the interior of the cup. The second flexible pouch
can contain one or more vegetables, for example, acidified
vegetables having a pH of between 3.5 and 5.0. A flexible membrane
sealed to the rim of the cup, with the first and second pouches
disposed within the cup, to block the opening prior to at least
partial removal of the membrane.
[0046] In some embodiments, of the packaged food product, a
diameter of the base of the cup is less than the diameter of the
opening. For example, the diameter of the base of the cup can be
between about 55% and 75% less than the diameter of the
opening.
[0047] In some embodiments, the diameter of the opening can be
between about 120% and 140% of a height of the cup. This range can
facilitate microwave heating, as will be discussed further
below.
[0048] In some embodiments, the packaged food product can further
include a third flexible pouch containing a plurality of pieces of
one or more meat products.
[0049] In some embodiments, two or more of the pouches are
optionally joined together.
[0050] In some embodiments, the method of making a microwaved food
product using the packaged food product described herein can
include at least partially removing the membrane to provide access
to the interior of the cup; removing the first and second pouches
from the interior of the cup via the opening; adding egg (which can
optionally be supplied by the consumer) to the interior of the cup
via the opening; opening the first and second pouches (and, if
present, the third pouch); adding contents of the pouches to the
interior of the cup via the opening; and microwaving the cup
containing the egg and the contents of the pouches. The egg can
either be added before or after the addition of the contents of the
pouches, or after the addition of only some or one of the pouches
and before the addition of others or another of the pouches.
[0051] In some embodiments, the step of microwaving the cup
containing the egg and the contents of the pouches further
comprises the steps of microwaving for a first time period,
followed by stirring the egg and the contents of the pouches,
followed by microwaving for a second time period. The first time
period can be between 30 and 50 seconds, and can be about 40
seconds. The second time period can be between 30 and 50 seconds,
and can be between about 40 and 45 seconds. The second time period
can be less than the first time period. The first time period and
the second time period can be cumulatively less than 90
seconds.
[0052] In some embodiments, a method of assembling the packaged
food product described herein can include depositing the first
pouch through the opening and into the interior of the cup;
depositing the second pouch through the opening and into the
interior of the cup; and closing the opening of the cup using the
membrane. The method of assembling can optionally include elevating
one of the pouches using another or others of the pouches.
Preferably, though not necessarily, the pouch containing the
vegetables is disposed closest to the opening of the cup.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 is a side elevation view of a packaged food product
showing a cup and a membrane closing an opening of the cup;
[0054] FIG. 2 is a cross-section of the packaged food product of
FIG. 1 taking along a centerline thereof, showing three pouches
disposed in an interior of the cup, with each of the pouches
containing a different food product (shown schematically for
illustrative purposes);
[0055] FIG. 3 is a top plan view of the packaged food product of
FIG. 1, rotated 90 degrees clockwise and showing the membrane along
with a tab portion thereof;
[0056] FIG. 4 is a cross-section view of only the cup and membrane
of the packaged food product of FIG. 1, with the three pouches
omitted for illustrative purposes;
[0057] FIG. 5 is a top plan view of a first of the pouches;
[0058] FIG. 6 is a top plan view of the second and third pouches,
showing the pouches joined by an optional saddle;
[0059] FIG. 7 is a diagram of assembly steps for the packaged food
product of FIG. 1;
[0060] FIG. 8 is a diagram of preparation steps for the packaged
food product of FIG. 1;
[0061] FIGS. 9 and 10 are flow charts illustrating steps of a
process described herein;
[0062] FIGS. 11-16 illustrate effects of acidification on pH and
weight of 100 g batches of vegetable pieces immersed in 100 g
quantities of citric acid media and ascorbic acid media;
[0063] FIGS. 17-23 illustrate effects of acidification on pH and
weight of 1015 g batches of vegetable pieces immersed in 1600 g
quantities of citric acid media and ascorbic acid media;
[0064] FIGS. 24-28 illustrate effects of acidification on pH and
weight of batches of vegetable pieces immersed in 1000 g quantities
of citric acid media of varying concentrations; and
[0065] FIGS. 29-31 illustrate an embodiment of a vegetable pouch as
described herein.
DETAILED DESCRIPTION
[0066] Described herein are a packaged food product and methods of
making and using it. In some embodiments, the packaged food product
comprises a cup containing multiple ingredients in sealed pouches
suitable for use in making an omelet or other egg-based entrees,
with the cup being suitable for microwave cooking of an egg-based
entree. The pouches may be transparent, and may be flexible,
thermoformed pouches. In some embodiments, the ingredients include
vegetable pieces such as diced vegetables that offer organoleptic
properties similar to those of fresh vegetable pieces after an
extended period of time. In some embodiments, after being prepared
and processed as described herein, the vegetables may be maintained
in refrigerated conditions, e.g., at temperatures of about
40.degree. F. or 45.degree. F., for a period of time required for
processing, shipment, storage, etc., which may be, e.g., 75 to 90
days, without unacceptable degradation of taste, texture, mouth
feel, flavor, aroma, color, nutritional content or other important
qualities. In some embodiments, in addition to the vegetable pieces
mentioned above, the ingredients may also include components such
as, for example, one or more meats, e.g., ham, sausage, bacon,
Canadian bacon or the like; one or more cheeses; and/or mushrooms.
The packaged food product may be provided with or without a liquid
egg component.
[0067] A packaged food product 10 is described herein and
illustrated in FIGS. 1-6. The packaged food product 10 includes a
microwavable rigid cup 20, a plurality of pouches 38, 42, 46 each
containing one or more food products 40, 44, 48 disposed within the
cup 20, and a membrane 34 closing the cup 20 with the pouches 38,
42, 46 therein. The packaged food product 10 is configured to be
used with addition of one or more eggs to prepare a food item using
microwave heating. Broadly, the packaged food product 10 can be
opened, the pouches 38, 42, 46 removed from the cup 20, contents of
the pouches 40, 44, 48 and one or more eggs added to the cup 20 to
form a mixture, and then the mixture heated to prepare the food
item. Optionally, the food item can be consumed directly from the
cup 20.
[0068] In some embodiments, the packaged food product may include
instructions for the consumer to perform some or all of the
following steps and/or the steps identified in FIG. 8, either in
the order set forth below or in a different order: [0069] 1. Remove
or otherwise open a lid to access the interior of the cup [0070] 2.
Remove the pouches from the cup [0071] 3. Add an egg to the cup,
e.g., by cracking a fresh egg (not included), or by using an
included packet of liquid egg product, and adding the liquid egg
component to the cup [0072] 4. Mix or stir the egg in the cup,
before, during or after step 5 [0073] 5. Open the pouches and add
some or all of the pouch contents to the cup [0074] 6. Heat or cook
the contents of the cup, e.g., by placing the cup in a microwave
oven [0075] 7. Add a component such as shredded cheese, from one of
the pouches or from another source, during or after microwave
heating.
[0076] In some embodiments, vegetable components are prepared by
the following process, as illustrated in FIGS. 9 and 10: [0077]
blanching 102, 104 the vegetable pieces for a predetermined period
of time at a temperature effective to inhibit enzyme action
detrimental to organoleptic properties, and to have an
antimicrobial effect; acidifying 106, 107, 108, 109 the vegetable
pieces in acid media for a period of time sufficient to have a
further antimicrobial effect without unacceptably affecting
organoleptic properties; freezing 110, 112 the vegetable pieces to
a temperature of below 5.degree. F. using an IQF technique; sealing
114 the frozen vegetable pieces in containers; storing the
vegetable pieces; thawing 116 the vegetable pieces; and subjecting
the vegetables to an HPP process 118.
[0078] In some embodiments, the process enables freshness of the
vegetable pieces to be maintained in the sealed containers at
refrigerated temperatures for 75 to 90 days.
[0079] FIGS. 29-31 illustrate a hermetically sealed pouch
containing vegetable pieces 134 after they have been processed as
described above. The illustrated pouch 132 comprises a thermoformed
back wall 124 having a cavity 126 for the vegetable pieces, a front
wall 128 that may be generally flat, and a peripheral seal area 130
at which the front and back walls are sealed to one another.
[0080] The process for preparation of the vegetable components is
preferably a commercial process suitable for mass production of
nutritious, high quality food products. In some embodiments, the
vegetable pieces are acidified during or shortly after blanching.
In some embodiments, the blanching and acidification may be carried
out at rates of more than 5,000 lbs. per hour, or more
specifically, more than 10,000 lbs. per hour. In some embodiments,
the rate of blanching and acidifying potatoes may be about 15,000
lbs. per hour and the rate of blanching other vegetables such as
peppers and onions may be about 12,000 lbs. per hour.
[0081] In some embodiments, the vegetable pieces comprise diced
vegetable pieces that are approximately cubic in shape, with sides
of greater than about 1/8 inch and less than 7/8 inch in length. In
some embodiments, the vegetable pieces comprise diced potato pieces
having dimensions of about 1/4 inch.times.3/8 inch.times.3/8 inch,
and other vegetable pieces having dimensions of about 3/8
inch.times.3/8 inch.times.3/8 inch. In some embodiments the
vegetables increase in weight by about 1% to about 12% as a result
of absorption of acid media during acidification. In some examples,
the vegetable pieces may increase in weight by 5% to 6%, or by
about 5.6%.
[0082] In some embodiments, acidifying the vegetable pieces
comprises exposing the vegetable pieces to a citric acid media. In
some embodiments, the acid media may have pH of between 2.0 and
3.0, or more specifically may have a pH of about 2.1 to 2.2. In
some embodiments, the acid media may comprise about 2% citric acid
and about 3% sugar in distilled water for a time period of between
1 and 20 minutes.
[0083] In some embodiments, acidifying the vegetable pieces
comprises exposing potato pieces to acid media having a pH of
between 2.0 and 3.0 comprising about 2% citric acid and about 3%
sugar in distilled water media for a time period of about 8
minutes, and exposing other vegetable pieces to acid media having a
pH of between 2.0 and 3.0 comprising about 2% citric acid and about
3% sugar in distilled water for a time period of about 4.5 minutes.
Acidifying the vegetable pieces may comprise reducing the pH of the
vegetable pieces to less than 5, and in some of these embodiments,
less than 4. In some embodiments, acidification reduces the pH of
the vegetable pieces to about 3.6 to 3.8, or more specifically to
about 3.68.
[0084] In some embodiments, freezing the vegetable pieces comprises
reducing the temperature of the vegetable pieces to about 0.degree.
F.
[0085] In some embodiments, where the vegetable pieces include
potato pieces, care may be taken to avoid exposure of the potato
pieces to ambient air for more than 10 minutes prior to blanching,
to avoid browning of the potato pieces.
[0086] In some embodiments, the process may comprise the following
sequence of steps: [0087] providing raw, washed, diced potato
pieces having dimensions of about 1/4 inch.times.3/8 inch.times.3/8
inch, and other raw, washed, diced vegetable pieces having
dimensions of about 3/8 inch.times.3/8 inch.times.3/8 inch,
comprising: [0088] steam blanching the raw, washed diced potato
pieces by exposing them to steam at a temperature of 200 to
212.degree. F. for 4 to 6 minutes, the steam blanching of the raw
potato pieces being effective to inhibit enzyme action detrimental
to organoleptic properties, and the steam blanching also having an
antimicrobial effect; [0089] steam blanching other raw, washed
diced vegetable pieces by exposing them to steam at a temperature
of about 210.degree. F. for a period of 40 to 50 seconds, with the
steam blanching of the other vegetable pieces being effective to
inhibit enzyme action detrimental to organoleptic properties, and
also having an antimicrobial effect; [0090] thereafter acidifying
the blanched potato pieces with citric acid media to reduce the pH
of the blanched potato pieces to less than about 5; and acidifying
the other blanched vegetable pieces with citric acid media to
reduce the pH of the other vegetable pieces to less than about 5;
[0091] reducing the temperature of the blanched, acidified
vegetable pieces to about 0.degree. F. using an IQF process to
preserve them for later use; [0092] thereafter hermetically sealing
the blanched, acidified, frozen vegetable pieces in flexible
pouches under vacuum with a nitrogen atmosphere; [0093] thereafter
thawing the blanched, acidified vegetable pieces in the pouches;
and [0094] thereafter pressurizing the thawed vegetable pieces to
about 86,500 psi for about 3 minutes at a temperature of about
41.degree. F. in an HPP process.
[0095] Also described herein is a packaged food product comprising
packaged vegetables pieces, wherein the product has a refrigerated
shelf life of at least 75 days, and wherein the vegetable pieces
have been prepared by: [0096] steam blanching raw, washed potato
pieces by exposing the raw potato pieces to steam, the steam
blanching of the raw potato pieces being effective to inhibit
enzyme action detrimental to organoleptic properties, and the steam
blanching having an antimicrobial effect; [0097] steam blanching
other raw, washed vegetable pieces by exposing them to steam, the
steam blanching of the other vegetable pieces being effective to
inhibit enzyme action detrimental to organoleptic properties, the
steam blanching also having an antimicrobial effect; [0098]
thereafter acidifying the blanched potato pieces with citric acid
media to reduce the pH of the blanched potato pieces to less than
about 5; and acidifying the other blanched vegetable pieces with
citric acid media to reduce the pH of the other vegetable pieces to
less than about 5; [0099] reducing the temperature of the blanched,
acidified vegetable pieces to about 0.degree. F. using an IQF
process to preserve them for later use; [0100] thereafter
hermetically sealing the blanched, acidified, frozen vegetable
pieces in flexible pouches under vacuum with a nitrogen atmosphere;
[0101] thereafter thawing the blanched, acidified vegetable pieces
in the pouches; and [0102] thereafter pressurizing the thawed
vegetable pieces to about 86,500 psi for about 3 minutes at a
temperature of about 41.degree. F. in an HPP process.
[0103] The other vegetable pieces may comprise, for example, one or
more of green bell peppers, red bell peppers, onions, mushrooms,
tomatoes, cilantro, garlic, and green onions. The packaged food
product may further comprise a cup containing the packaged
vegetable pieces, and additional, separately packaged food items.
The additional, separately packaged food items may include, e.g.,
one or more of meat and/or cheese. The meat may comprise one or
more of ham (such as Applewood smoked ham or other flavored ham),
bacon, Canadian bacon, sausage (such as pork, turkey or chorizo
sausage), and/or other meats. Depending upon the type of meat, the
meat may be shredded, crumbled, diced or otherwise reduced to
suitable size pieces. The cheese may comprise one or more of extra
sharp cheddar, sharp cheddar, mild cheddar, American cheese, Swiss
cheese, mozzarella, pepper jack, and/or other varieties of
cheese.
[0104] The food products, along with various seasonings, can be
provided in the following non-limiting, exemplary combinations,
numbered 1-5:
TABLE-US-00001 Cheese Meat Vegetable(s) Sharp Bacon Bits Diced
Potato Cheddar Mild Diced Ham Green Bell Pepper & Onion, Diced
Potato Cheddar Mozzarella Turkey Red Bell Pepper, Mushroom &
Onion, Sausage Diced Potato Mild Pork Sausage Red/Green Bell Pepper
& Onion, Diced Cheddar Potato Pepper Jack Chorizo Red/Green
Bell Pepper & Onion, Sausage Tomatoes, Jalapenos, Green Onions,
Cilantro, Garlic, Diced Potato
[0105] The above-mentioned cup may be of sufficient size to
accommodate the liquid components of an egg in addition to the
vegetable pieces and the other separately packaged food items
mentioned above, with sufficient extra room to accommodate
expansion of the egg and other food items during microwave cooking
without overflowing, and wherein the packaged food product further
comprises a removable lid on the cup, a shrink label on the cup,
and instructions for making an egg-based entree by adding the
liquid components of an egg to the cup, combining the vegetable
components and additional, separately packaged food items with the
egg in the cup, and heating the combination in a microwave oven.
The lid may have microperforations therein to accommodate pressure
changes.
[0106] Blanching:
[0107] In some embodiments, the blanching process described above
is a steam blanch in which the vegetable pieces are exposed to
steam while on a continuous conveyor. In other embodiments, the
blanching process may comprise immersion of the vegetable pieces in
boiling water, a chemical blanch, or another blanch process.
[0108] In some embodiments, the blanch process for potato pieces
may comprise steam blanching the raw, washed, diced potato pieces
by exposing them to steam at a temperature of 200 to 212.degree. F.
for 4 to 6 minutes, or about 5 minutes. This steam blanching of the
raw potato pieces is believed to be effective to inhibit enzyme
action detrimental to organoleptic properties, and this steam
blanching is also believed to have an antimicrobial effect
sufficient that, in combination with other steps described herein,
no further heating of the potato pieces is required for
antimicrobial purposes.
[0109] In some embodiments, the blanch process for vegetable pieces
other than potato pieces, including, e.g., bell pepper and onion
pieces, comprises steam blanching the raw, washed, diced vegetable
pieces by exposing them to steam at a temperature of about
210.degree. F. for a period of 40 to 50 seconds, or about 45
seconds, with the steam blanching being effective to inhibit enzyme
action detrimental to organoleptic properties, and also having an
antimicrobial effect. This steam blanching of the subject vegetable
pieces is also believed to have an antimicrobial effect sufficient
that, in combination with other steps described herein, no further
heating of the vegetable pieces is required for antimicrobial
purposes. This helps to provide the vegetable pieces with
organoleptic qualities similar to those of fresh vegetables over
extended periods of refrigerated storage.
[0110] Where the blanch involves heating of the vegetable pieces,
they may be cooled by forced convection or another cooling process
after being heated. Forced convection may include, e.g., passing
the vegetable pieces through ambient airflow or other forms of
forced convection for periods of, e.g., 5 seconds to about 5
minutes, 5 seconds to 30 seconds, or about 15 seconds.
[0111] Acidification:
[0112] In some embodiments, acidification occurs after blanching.
It is believed that blanching may facilitate subsequent
acidification by opening the cell structure of vegetable pieces
and/or otherwise increasing the rate at which acid media may be
absorbed by the vegetable pieces. In some embodiments,
acidification may take place immediately after blanching, e.g.,
within 5 to 10 minutes of blanching, as part of an integrated,
in-line process.
[0113] The acidification process may comprise exposing the
vegetable pieces to an acid media. In some embodiments, the
vegetable pieces may be sprayed, washed, immersed in, and/or
otherwise exposed to a liquid acid media in continuous or batch
processes. In some embodiments, the process may involve spraying or
washing the vegetable pieces with acid media in addition to
immersing them in the acid media. The acidification process may
involve exposure of all or substantially all of the vegetable
pieces' surfaces to the acid media for sufficient time to enable
the acid media to permeate or substantially permeate each vegetable
piece. In some embodiments, the acidification process may be
carried out at or near ambient temperatures of, e.g., 70 to
80.degree. F. In other embodiments, the acidification process may
take place at elevated temperatures or below-ambient temperatures.
In particular, the vegetable pieces may begin the acidification
process at elevated temperatures as a result of the acidification
process following closely after blanching, with the acid media
beginning the process at ambient temperatures of 70 to 80.degree.
F. Alternatively, the vegetable pieces may be cooled to below
ambient temperatures after blanching and prior to acidification,
and/or the acid media may be cooled to below ambient temperatures
for the acidification process.
[0114] In one example, the acidification process comprises
immersion of vegetable pieces in acid media comprising 1% to 20%
citric acid, ascorbic acid, or pHase.TM. food grade sodium acid
sulfate in water, a product marketed by Jones-Hamilton Co. More
specifically, the acid media may comprise, for example, 0.1% to 5%,
0.5% to 2.5%, 0.5% to 1.5%, about 1%, about 2%, or about 3% or
about 2% citric acid, ascorbic acid, or pHase.TM. food grade sodium
acid sulfate in water. In some embodiments, the acid media may
include sugar in amounts of, e.g., 0.1% to 20%, 1% to 10%, 2% to
5%, 2.5% to 3.5%, or 3%. The water may be distilled water. All
percentages herein refer to weight percentages.
[0115] In some embodiments, the pH of the acid media may be, for
example, between 1 and 6.5. In some examples, the acid media may
comprise an ascorbic acid media with a pH of between 2.5 and 3. In
some examples, the acid media may comprise a citric acid media with
a pH of between 2 and 2.5, or a pHase acid media having a pH of
between 1.1 and 1.6. In some examples, the acid media may comprise
combinations of the acids and other components mentioned above,
and/or may comprise other acids and other ingredients not mentioned
above, e.g., vinegar, acetic acid, malic acid, tartaric acid,
lactic acid, benzoic acid, or sorbic acid.
[0116] Citric acid is believed to have certain advantages. As
shown, e.g., in FIGS. 11-15, on a per pound basis, citric acid is
believed to be more effective in reducing pH than ascorbic acid.
Also, the taste of vegetables acidified with citric acid media is
believed to be preferable to consumers as compared with the taste
of vegetables treated with certain other media. In particular, it
is believed that use of some acid media may result in vegetables
having an undesirable aftertaste. An additional advantage of citric
acid is that it may help to whiten potato pieces, or at least
prevent or inhibit graying of potato pieces over time.
[0117] In some embodiments, the pH of the vegetable pieces before
acidification may be, e.g., about 5 to about 8, about 5 to about 7,
about 5 to about 6, or 5.2 to 5.3. Acidification may adversely
affect taste and/or other organoleptic properties. Although this
has not been found to be problematic with potato pieces, it has
been found that inclusion of a sweetener in acid media may help to
avoid other vegetable pieces such as pepper and onion pieces, as
well as mushroom pieces, acquiring an overly tangy taste. In some
embodiments, concentrations of a sugar such as dextrose in a
concentration of e.g., 1% to 5%, 2% to 4%, or about 3% may be
suitable for this purpose. Other natural and artificial sweeteners
that might be used, alone or in combination with other sweeteners,
to provide an effect similar or equivalent to that provided by
including 3% dextrose in the acid media, may include for example
sucrose, fructose, corn syrup, high fructose corn syrup, acesulfame
K, and sucralose.
[0118] Also, reduction of acid concentration in the acid media can
help to avoid the vegetable pieces acquiring an overly tangy taste,
so long as the desired pH can be achieved with a lower acid
concentration. In some embodiments, one or more of the acid media
formulas provided in FIGS. 11-28 may be used. In some embodiments,
the blanched, acidified potato pieces include, in addition to the
potato pieces themselves, citric acid and water, but are
substantially free of other ingredients. In some embodiments, other
vegetable pieces include, in addition to the vegetable pieces,
citric acid, sugar and water, but are substantially free of other
ingredients, meaning that any other ingredients are in amounts
small enough that they need not be listed as ingredients under
labeling requirements in the United States. In some embodiments,
the pH of the vegetable pieces after acidification may be, e.g.,
about 2 to about 5.0, 2.5 to 5.0, 2.5 to 4.8, 3.0 to 5.0, 3.5 to
5.0, 4.0 to 5.0, 4.0 to 4.8, 4.4 to 4.6, or about 4.5. Values of
the pH of vegetable pieces herein may be determined by pureeing a
representative sample of a blend of the pieces.
[0119] As noted above, FIGS. 11-16 illustrate effects of
acidification on pH and weight of 100 g batches of vegetable pieces
immersed in 100 g quantities of citric acid media and ascorbic acid
media. FIGS. 17-23 illustrate effects of acidification on pH and
weight of 1015 g batches of vegetable pieces immersed in 1600 g
quantities of citric acid media and ascorbic acid media. FIGS.
24-28 illustrate effects of acidification on pH and weight of
batches of vegetable pieces immersed in 1000 g quantities of citric
acid media of varying concentrations.
[0120] In some embodiments, acidifying the potato pieces and other
vegetable pieces comprises, in each case, immersing the vegetable
pieces in acid media in a two-step continuous process wherein the
vegetable pieces are subjected to a first acidification step 106,
108 in which they are carried through an acidification vessel by a
conveyor, then subjected to a second acidification step 107, 109 in
which they are carried through an acidification flume or pipe to a
delivery location while immersed in acid media. The dwell time in
the vessel may be, e.g., about 5 to 7 minutes for potato pieces, or
about 6 minutes as indicated in FIG. 9; and to 4 minutes, or about
2.5 minutes, as indicated in FIG. 9, for other vegetable pieces.
For both potatoes and other vegetables, the acidification flume
transfer steps 107 and 109 may take, e.g., 1 to 3 minutes, or about
2 minutes as indicated in FIG. 9. Economies may be realized by
using a common source of acid or acid media such as a stock acid
tank, shown at 136 in FIG. 9, to supply acid media to the separate
parallel acidification operations for the potato pieces and the
other vegetable pieces. Where different acid media are to be used
for potato pieces and other vegetable pieces that are being
acidified simultaneously, separate sources of acid media may be
employed, or alternatively a common source of an acid solution may
be employed, with one or more additives being supplied separately
to customize parallel simultaneous acidification processes. For
example, a common source of a 1% citric acid solution may be used
for both potato and other vegetable processes, with dextrose being
added to the other vegetable process.
[0121] The flume or pipe empties the vegetable pieces onto a
conventional conveyor shaker, which may remove excess acid media
prior to IQF freezing. Excess acid media may be returned to a stock
acid tank, acidification flume, or other location for re-use, or
otherwise recycled for later use.
[0122] Freezing:
[0123] The IQF freezing process herein enables vegetable pieces,
mushroom pieces, and/or other food components to be stored for
later use. This provides flexibility with regard to throughput
rates and time frames for processes downstream of the IQF process,
e.g., bulk tote packaging, shipping of bulk totes, blending 122 of
potato pieces and other vegetable pieces, etc.
[0124] Cup:
[0125] The cup 20 is preferably circular and has a bottom or base
24, an upper rim 28 surrounding an opening 26 and including an
outwardly extending flange, and a sidewall 22 extending between the
rim 28 and the base 24. The diameter of the base 24 is less than
the diameter of the opening 26 such that the sidewall 22 is
inwardly tapered toward the base 24 during at least part of the
span between the opening 26 and the base 24. In one embodiment,
illustrated in FIGS. 1-4, the diameter of the base 24 of the cup 20
is between about 55% and 75% less than the diameter of the opening
26, and the diameter of the opening 26 is between about 120% and
140% of the height of the cup 20. If the diameter of the opening 26
is below about 120% of the height of the cup 20, then the middle
portion of the mixture in some embodiments can take longer to heat
a sufficient amount as compared to if the diameter of the opening
26 is about 120% of the height of the cup 20. Of course, the
greater amount that the diameter of the opening 26 is below about
120% of the height of the cup 20, the more time will be required to
heat the middle portion of the mixture a sufficient amount. Also in
the preferred embodiment shown in FIGS. 1-4, the opening 26 of the
cup 20 has a diameter of about 3.7 inches and the height of the cup
20 is about 2.8 inches. These dimensions contribute to a cup 20
that is sized to contain the mixture without spilling during
microwave heating, including when either one egg is used or two
eggs are used. The cup 20 is made from a material that is suitable
for microwave heating, such as polypropylene, and can be made using
a thermoforming process.
[0126] Immediately below the rim 28 is an upper section 30 of the
sidewall 22 that is slightly outwardly tapered toward the base 24.
The upper section 30 of the sidewall 22 extends between the rim 28
and an inwardly extending step 32, where the sidewall 22
transitions to a lower section that tapers inwardly toward the base
24. The step 32 and upper section 30 of one cup 20 cooperate with
like parts of another cup 20 when the cups are nested together to
assist with denesting during assembly of the packaged food
product.
[0127] Membrane:
[0128] The flexible lid or membrane 34 can be a multilayer film,
which can optionally include layers of polyethylene, ethylene vinyl
acetate, and polypropylene. The flexible membrane 34 can be heat
sealable to the flange of the rim 28 of the cup 20, optionally in a
hermetic manner. As mentioned above, the membrane 34 may have
microperforations therein to accommodate pressure changes within
the sealed cup, such as may arise during transportation. The
membrane 34 can optionally have a tab portion 36, shown in FIG. 3,
that can be grasped by a consumer to initiate removal of the
membrane 34 from the cup 20.
[0129] Pouches:
[0130] The flexible pouches 38, 42, 46 are optionally formed of
transparent film, and have a sealed periphery surrounding an
interior containing the food products 40, 44, 48. The pouches 38,
42, 46 can optionally include a thermoformed pocket formed in a
bottom sheet of film that is then filled and covered with a second
sheet of film. The two films are then joined together, such as with
a heat seal, about the thermoformed pocket. An unsealed region
between the two films outwardly of the sealed periphery can provide
an easy open feature to initiate pulling the two films apart to
open the pouch. Instead of a thermoformed pocket, two films can be
joined together about a food product 40 (or a single film folded
over and sealed) to form the pouch 38, as shown in FIG. 5, with top
and bottom seals 39 along with an unsealed starter portion 41.
[0131] With reference to FIGS. 29-31, a pouch 132 can contain
pieces of a food product 134 disposed within a thermoformed pocket
124 of a bottom film 126. A seal 130 can be formed between a
portion of the bottom film 126 disposed outwardly from the pocket
124 and a top film 128. An unsealed area between top film 128 and
the bottom film 126 and outwardly of the seal 130 can be used to
facilitate separation of the films 126, 128 to open the pouch
132.
[0132] Two of the pouches 42, 46 can be joined together using a
saddle 50 to form a saddle pack, as shown in FIG. 6. More
specifically, the bottom sheet of film can have two thermoformed
pockets spaced apart, and the second sheet of film can be sealed
around each of the pockets in a sealing margin 52 such that the
contents of the two pouches 44', 48 are separated but the pouches
42, 46 are joined together. Unsealed areas 54, 56 outward of the
sealing margin 52 can be used to facilitate opening of the
respective pouches 42, 46. Such a saddle pack can advantageously
reduce the number of assembly steps for the packaged food product.
Specifically, instead of having to deposit two separate pouches
into the interior of the cup, a single saddle pack can be used
instead. Of course, other pouches can also be deposited into the
interior of the cup 20 in addition to the saddle pack.
[0133] In addition to the food components, the pouches may include
nitrogen or a mixture of nitrogen and carbon dioxide, e.g., 75%
nitrogen, 25% carbon dioxide.
[0134] Packaged Food Product Assembly:
[0135] To assemble the packaged food product, such as using the
steps shown in FIG. 7, the cup is denested from other cups, such as
in a stack of cups, the cheese ingredient pouch and the meat
ingredient pouch are both deposited into the interior of the cup
through the opening. Next, the vegetable ingredient pouch is
deposited into the interior of the cup through the opening. While
the order of insertion of the pouches can be switched, it is
preferred to insert the vegetable ingredient pouch after the cheese
and meat ingredient pouches so that the latter can elevate the
former from the base of the cup and present the former to the
consumer upon opening of the membrane. The membrane is sealed to
the flange of the cup, such as by using a heat seal, after the
pouches have been deposited into the interior of the cup.
* * * * *