Patent Application
20140272017
The present invention is directed to a consumer-oriented system for the delivery of frozen fruit pieces that promotes dietary fruit intake, including convenient and accessible single serving packaging that enhances the consumer's ease of use, reduces the presence of pathogens, increases frozen shelf life, and reduces spoilage.
It is a universal desire to eat healthy that transcends all cultures, societies, and beliefs. This desire to consume more unprocessed fruits and vegetables is borne through the realization that the fresher the food, the better it is. By way of contrast, it is widely believed, and supported through a panoply of empirical scientific research, that the addition of various preservatives, and conventional pasteurization processes inexorably attenuates the nutritional value and attendant health benefits of eating fruits and vegetables.
To fulfill this desire, public health officials and other leading nutritionists uniformly agree that eating several servings of fresh fruits and vegetables per day is an integral part of eating and living a healthy lifestyle. For example, it is generally accepted that a healthy diet should include 2-5 servings of fruit per day, with each serving consisting of one-half to three-quarters of a cup. Unfortunately, attaining these goals is stifled by several logistical and safety issues, such that most inhabitants of the U.S. and other developed nations fall far short of these dietary guidelines.
Aside from certain fruits that naturally occur in single-serving portions, like bananas, apples and peaches, most fruit involves considerable processing effort before it can be rendered into a form suitable for consumption. For example, many types of fruit require peeling, cutting, cracking, dicing, or other methods to be rendered suitable for individual servings. These methods oftentimes require a substantial amount of time, a kitchen or similar facility, knives, or special equipment, which may not be available to someone who is on her/his lunch break, is on the go, or is in school or at the beach. This is particularly the case for larger fruits, like pineapples and melons, where the fruit typically must first be washed, cut into pieces, and have the rind removed. Such processing steps usually require access to a sink, cutting board, trash receptacle, dishes, and utensils, are messy, and take a substantial investment of time in both preparation and clean-up.
While some fruits are available in processed form (e.g., canned), the typical processing steps involve high temperature pasteurization, which can denature the essential nutrients, as well as the addition of sugary syrups and preservatives. To avoid these drawbacks, some grocery stores have begun carrying packages of pre-cut fruit, such as melon, in the refrigerated sections. While such packages obviate many of the difficulties associated with fruit preparation, these packages generally contain multiple servings, and/or include preservatives. Such bulk packages require continual refrigeration, and therefore do not meet the time constraints imposed by modern society. For example, refrigerated multi-serving packages must be repackaged for daily consumption, and oftentimes the contents of the bulk packages spoil before they can be completely consumed.
Grocery stores similarly may carry packages of frozen fruit, such as berries. Such packages may contain multiple servings of frozen fruit that is intended to be consumed at home. The fruit may include sugary syrups, and may be individually quick frozen but more frequently is frozen into a single, solid lump. To consume only a portion of such a package, the user may need to mechanically separate the desired portion from the lump, which may require manual strength or the use of a utensil, which is inconvenient and possibly even dangerous. Alternatively, the user may need to partially or fully thaw the entire package so as to more easily remove the desired portion, and then reclose the package and refreeze the remaining portions for future use. However, such a sequence of steps may be inconvenient and time-consuming. Moreover, the quality of the remaining portions may deteriorate upon being refrozen, and the remaining portions may solidify into a lump that is even more solid than when originally purchased. Even if it is not necessary to thaw and refreeze the fruit to obtain a portion from the package, the fruit within the reclosed package may deteriorate more rapidly within the freezer than in the original packaging, e.g., may experience freezer burn. Because of such inconveniences and inefficiencies, a household may purchase such a package of frozen fruit primarily if there is a particular recipe in which to use it, such as a smoothie or dessert.
Another category of frozen fruit-based products are single-serving snacks such as popsicles. The popsicles may include fruit puree or juice that may be mixed with a sugary syrup and frozen to form a solid bar. Such a process may remove many nutrients and fiber from the fruit, and the popsicles may be undesirably high in sugar to be eaten on a frequent basis. Low-sugar versions that contain artificial sweeteners also are available.
Another public health issue, which inheres with the consumption of fruit, is the prevalence of pathogens. Each year, many people die from the consumption of pathogen-contaminated fruit. Also, each year, billions of dollars worth of fruit are lost to spoilage. In particular, grocery stores battle the complexities of logistics to maintain an adequate supply of fresh fruit. When a grocery store receives fruit, this fruit must be sold as quickly as possible, otherwise the fruit will spoil and have to be discarded. Moreover, conventional pre-cut fruit pieces have a very limited shelf-life, typically less than seven days from the packaging date.
A related issue is when a customer brings the fruit home from the grocery store. Oftentimes, the vagaries of life will result in spoiling fruit in one's refrigerator or kitchen counter. As the fruit starts to turn brown and dehydrates, many customers simply throw the fruit away. Of course, attempts have been made to mitigate the issue of fruit spoilage. Many food companies can their fruits with preservatives attendant to rigorous processing methods. What's more, many canned fruits are infused with sugars, or corn syrup, which may make the fruit less healthy. Unfortunately, these processes seriously compromise the quality and taste, as well as the aesthetic looks, the nutritional value, price, and the anticipated salutary effects of the fruit.
Despite the ubiquitous recognition that increased fruit consumption is desirable, the prior art is virtually devoid of practical solutions to provide single serving packaging for preservative-free fresh or frozen fruits, and especially convenient packaging that eliminates the need for utensils. While the patent literature describes some methods for processing fruit to improve refrigerated shelf-life, as described in U.S. Pat. No. 4,895,729 to Powrie, that patent describes methods for processing multi-serving containers, and there is ample room for further improvement.
It would therefore be desirable to provide methods of processing and packaging fresh or frozen fruit that enhance ease of use and consumption, by providing single serving packaging that eliminates the need for utensils.
It further would be desirable to provide methods of processing and packaging fresh or frozen fruit that reduce the potential for contamination with pathogens, and reduce spoilage, by providing improved single serving packaging for fresh or frozen fruit.
It still further would be desirable to provide methods of processing and packaging fresh or frozen fruit that eliminates the need for sugary syrups or preservatives to preserve freshness, by providing preservative-free single serving fruit packaging for fresh or frozen fruit.
In view of the foregoing drawbacks, the present invention provides methods of processing and packaging frozen fruit, and particularly fruit pieces, that enhance ease of use and consumption, reduce contamination and spoilage, improve frozen shelf-life and nutritional value, and facilitate the distribution of preservative-free frozen fruit pieces.
In accordance with one aspect of the invention, whole fruit is processed under aseptic, sanitary conditions to remove the rind and chop, dice or segment the fruit into conveniently-sized pieces, which are frozen or packaged in a preservative-free manner in a substantially gas impermeable single serving tray or tube. The tray or tube may be sealed so as to reduce the headspace in the package. While a utensil may be included in the tray form of the packaging, the tube preferably is constructed so that the frozen fruit pieces may be eaten, without using a utensil, by squeezing the tube from its closed end towards its open end. Preferably, the tray or tube is processed using a freezing process that avoids heating the fruit pieces, and provides extended frozen shelf life for the package. Advantageously, the freezing process does not denature the fruit pieces, and has a negligible adverse effect on freshness, texture or taste.
In accordance with another aspect of the invention, apparatus is provided for the purpose of facilitating the consumption of frozen produce, eliminating pathogens, increasing shelf life, and for reducing spoilage. In various implementations of an embodiment, the consumer-oriented system for the delivery of frozen produce preferably includes some or all of the steps of: a) receiving fruit at a suitable temperature, e.g., between 38-50° F.; b) washing the fruit at a suitable temperature, e.g., between 38°-50° F.; c) coring, skinning, and/or removing seeds from the fruit under aseptic conditions; d) slicing the fruit into small bite-sized pieces; e) passing the fruit pieces through a metal detection system; f) placing the fruit pieces into the packaging; and g) freezing the fruit. The package may include a tube that includes a substantially gas impermeable film and has a length, first and second ends, and a tearable zone near the first end and a lateral wall. The tube may be configured so that tearing the tearable zone creates an opening providing access to the quantity of frozen fruit pieces. The length of the tube may be in a range of about 4 to 10 inches, and a diameter of the opening is in a range of about 0.7 to 1.5 inches. Preferably, the tube is configured so that squeezing the tube along the lateral wall from the second end to the first end ejects the frozen fruit pieces through the opening.
The foregoing and other aspects of the invention are described in detail below in conjunction with the following figures:
According to one embodiment of the present invention, a unique consumer-oriented system for the delivery of frozen produce, especially frozen fruit pieces, including improved methods of safety and packaging is provided for the purpose of reducing or eliminating pathogens, increasing nutritional quality, increasing frozen shelf life, and for reducing spoilage. In particular, embodiments of the present invention provide single-serving packages of frozen fruit pieces that provide numerous advantages over previously known products based on frozen fruit. For example, the packages may have a size and shape that is particularly well suited for the fruit pieces to be eaten as a frozen snack. The fruit pieces may be individually quick frozen before insertion into the packaging so that they suitably may be eaten individually either by hand or by squeezing the package to pop the pieces directly into the consumer's mouth as desired. Alternatively, the fruit pieces may be frozen together into a mass after being inserted into the package, so as to provide the user with a more popsicle-type experience that may be squeezed out of the package and into the consumer's mouth. In either case, the fruit may be conveniently enjoyed in any desired location with significantly less hassle than practicable with previously known, relatively large packages of frozen fruit.
It should be appreciated that the single-serving packages of frozen fruit provided herein also may have significantly greater nutritional value than a popsicle. Indeed, because the packages preferably contain 100% fruit with no added ingredients, the packages not only may provide a delicious snack, but also may be consumed at any desired frequency so as to provide the health benefits of eating as many servings of whole fruit in a day, if desired. In comparison, a consumer may wish to eat no more than one popsicle a day, or even less. For parents of young children, the present packages of frozen fruit may provide an appealing way of encouraging fruit consumption.
Indeed, the present single-serving packages of frozen fruit even may provide enhanced nutritional value relative to fresh fruit available at a typical grocery store. In particular, the frozen fruit within the present packages suitably may be frozen at or near the site of origin, and maintained in that frozen state to the site of purchase by a consumer. Accordingly, the fruit may be allowed to fully ripen on the vine, then picked, and then frozen within hours of picking. Providing such a short time between picking and freezing may preserve a great deal of the fruit's nutritional value. In comparison, fresh fruit such as mangoes may be picked while it is unripe, and allowed to ripen over several weeks of transit until it reaches the grocery store. During this time the nutritional value of the fruit may deteriorate, and the flavor may be significantly poorer than it would have been if allowed to ripen on the plant. Accordingly, freezing and packaging the ripe fruit in the present single-serving packages may provide significant health benefits not only in that the fruit itself has greater nutritional value, but also in that because the fruit may be more delicious and more convenient to eat, that the consumer may wish to consume it in greater quantity and thus derive still greater health benefits.
In particular, the practice of packaging preservative-free frozen fruit into bite-sized pieces in single serving containers, as discussed above, promotes safety and freshness and has heretofore not been performed due to the fact that logistical issues, compounded with spoilage, have prevented fruit distributors and processors from bringing such a product to market. This stems in no small part from the inability to properly process and freeze the fruit in such a way to prolong the frozen shelf-life of the fruit while not compromising the freshness, taste and nutritional value of the fruit, and from the lack of many of the processing features described herein. As a result of the unique packaging and processing methods and systems of the present invention, a consumer will be able to purchase a single serving package or a box or bag containing multiple single serving packages, each containing bite sized preservative-free frozen fruit pieces. This is a departure and a dramatic improvement over previously-known ways of consuming frozen fruit, which typically require a consumer to purchase a package containing a large quantity of frozen fruit and either chisel out a desired portion using a utensil or to fully or partially thaw the entire package, and then re-freeze the rest.
With the availability of the single serving “snack-packs” of bite-sized frozen fruit pieces prepared in accordance with the principles of the present invention, consumers will no longer have to worry about any of the above difficulties. Instead, with the single serving packaging prepared in accordance with the present invention, consumers may eat wholesome, preservative-free, frozen fruit anytime, anywhere.
Moreover, consumers should be able to purchase the frozen fruit packaged in accordance with the present invention from the freezer sections of most supermarkets, convenience stores or vending machines (in a manner similar to not so healthy counterpart snacks, such as popsicles) and consume that frozen fruit immediately, at the workplace, school, at the beach, or any other place conveniently, without utensils. In accordance with one aspect of the invention, the frozen fruit pieces can be pushed directly out of the single serving tube directly into the consumer's mouth, without utensils, because the frozen fruit pieces are already cut, diced, or processed to a bite-sized format that eliminates the need to wash, peel, freeze, thaw, or otherwise process the fruit prior to consumption. Alternatively, if the frozen fruit pieces are packaged in a tray, the single serve packaging also may include a fork, spoon or other disposable utensil.
In certain embodiments, the methods and packages provided herein can be used in connection with frozen fruits of all processed states. For example, the frozen fruit used in connection with currently provided methods and/or packages may be whole fruit, whole peeled fruit, sections of fruit in any size, large or small, or pureed fruit.
In one embodiment provided herein is a method for packaging frozen fruit, comprising the steps of: receiving the fruit; washing the fruit; optionally coring, skinning, and/or removing seeds from the fruit under aseptic conditions; optionally slicing the fruit into pieces; optionally passing the fruit through a metal-detection system; placing the fruit into a single-serving package; and freezing the fruit before or after placing the fruit into the package.
In certain embodiments, the term “produce” shall hereinafter refer to all fruit, vegetables, or other foods, which may be adaptable for use with the various embodiments described herein.
In certain embodiments, the term “produce” shall refer to fruit.
In certain embodiments, the term “produce” shall refer to vegetables.
Even though embodiments described below in the specification are primarily directed towards frozen fruits, frozen produce other than frozen fruits may be included.
For the purpose of the present invention, the term “fruit” shall hereinafter refer to all fruit, which are adaptable for use with the processes described herein. Given the rigorous nature of the described processes, not all fruit may be processed in accordance with the described methods. Accordingly, while certain process steps may need to be revised or eliminated entirely and cause a concomitant reduction in frozen shelf-life, other aspects of the present invention may be applied to such fruit. Furthermore, the term “produce” shall hereinafter refer to all fruit, vegetables, or other foods, which may be adaptable for use with the various embodiments described herein.
Referring now to
As shown in
A wide variety of fruits are suitable for single serving packaging in accordance with the present invention, including pineapple, mango, papaya, pomegranate, grapefruit, apple, banana, dragonfruit, guava, kiwi, guanabana, grapes, melon such as watermelon, honeydew, or cantaloupe, oranges, tangerines, peaches, nectarines and other stone fruit, as well as berries such as strawberries, blueberries, blackberries, goji berries, acai berries, or boysenberries. Depending upon the type of fruit, the fruit pieces may be either segmented, chopped, cubed, diced, sliced or cut into bar forms. In chopped, diced or cubed form, the fruit pieces may range from cubes ranging from one-quarter to one-half inches on a side. For example, a pineapple may be chopped or diced into cubes about three-eighths of an inch on a side or sliced into bars having a length of four to five inches. In the case of grapes or berries, whole units of fruit may be packaged in an individual, single serving package; such fruits alternatively may be chopped or diced.
Referring now to
Referring to
Laminate film 30 preferably has a thickness in a range of 30 to 200 microns. When used for high turnover stock, such as school lunch programs where frozen shelf life typically need not exceed one to two months, a thinner laminate of 30 to 80 microns, and more preferably 65-75 microns may be desired. If the frozen fruit pieces are chopped, diced or cubed, or if the frozen shelf life is expected to exceed six months or even twelve months, it may be preferable to use a thicker laminate film, such as 80 to 120 microns, to make the single serving package sufficiently rigid so as not to sag during handling. For retail packaging of bar form or chopped frozen fruit pieces, such as for sale in a grocery store, a thicker laminate film of 80 to 120 microns preferably is used to resist damage to the fruit pieces during transit and handling. Further, for retail packaging of bar form or chopped frozen fruit pieces, where a shelf life of from six months, twelve months, or more is desired, the thicker laminate film of 80 to 120 microns is preferred to withstand the freezing process.
Referring again to
With respect to
In accordance with one aspect of the invention, the single serving package of the present invention may include a bar code or QR code, such as bar code 65 in
Referring now to
In accordance with the principles of the present invention, during packaging, bowl portion 73 of base 71 may be filled with a single serving of fruit pieces, e.g., one-half to three-quarters of a cup of preservative-free fruit pieces. As for the preceding embodiments, tray 70 is filled with 100% fruit, without chemical preservatives or syrups. Once a measured serving of fruit pieces is deposited in bowl portion 73, top film 72 is shrink wrapped onto the fruit pieces by partially evacuating the air from within bowl portion 73 beneath top film 72. When application of top film 72 is completed, top film 72 serves as an artificial substantially gas impermeable “skin” over the fruit pieces.
In accordance with another aspect of the invention, base 71 and top film 72 permit single serving tray 70 to be frozen using the process described below with respect to
Referring now to
In accordance with one aspect of the present invention, the first step of the process involves receiving the fruit through a cold chain logistics system at a suitable temperature, for example between 38-50° F., at 101, to ensure that handling, processing, and packaging are done under a suitable temperature, for example at a consistently maintained ambient temperature of 38°-50° F. If the fruit is processed at a site other than where it is grown, it is preferably shipped in a refrigerated truck directly from the groves, orchards, or the like. Subsequently, the fruit will be received in a loading bay of the processing facility within a suitable temperature range. This is hereinafter referred to as the “cold chain”. The process described herein preferably maintains a temperature within the target range of 38-50° F. for the purpose of ensuring the freshness and sanitation of the fruit, although other temperatures suitably may be used.
At 102, Step 2, the fruit is washed to remove dirt and pathogens. Different types of fruit have varying degrees of thickness and durability. Different types of fruit also have unique differences in the extent to which the rind or outer surface holds potential pathogens. Thus, for example, a pineapple may have to be washed at a different pressure or temperature as compared to an orange. Preferably, the step for washing the fruit is performed at a suitable temperature, for example between 38-50° F. under aseptic conditions, e.g., the employees wear hair-nets and the facility observes standard regulations associated with handling food facilities, e.g., that reduce the presence of pathogens and fungi.
At 103, Step 3, the fruit is cored, skinned, and/or the seeds are removed from the fruit under aseptic conditions to prepare the fruit for insertion into packaging. This exact procedure used to carry out this step will vary due to the particular type of fruit to be processed. For certain fruits, such as berries, stems or caps may be removed, if present. At 104, Step 4, the fruit is segmented, sliced, diced or chopped into small bite-sized pieces. For certain fruits, such as grapes, the fruit may be removed from a stem, or in the case of pomegranates, the arils removed from the husk. In keeping with the requirement that the introduction of pathogens be kept to a minimum, the tools used to process fruit should be rigorously washed with heat, soap, water, and/or may be sterilized. Steps 3 and 4 similarly may be performed at a suitable temperature, for example between 38-50° F. to maintain the cold chain.
At 105, Step 5, the fruit pieces are passed through metal detector system 120 that identifies and removes any metallic particles, which may be found within or upon the fruit pieces. Preferably, the environment of metal-detection system 120 is maintained at a suitable temperature, for example between 38-50° F. to maintain the cold chain. In one embodiment, metal detection system 120 further comprises semi-sealed unit 121 with integrated refrigeration system 122 within housing 124, which is disposed near metal detector 123. Metal detector system 120 may include a series of gates or air nozzles to eject metallic particles or fruit pieces having such metallic particles, to a discard bin (not shown). As discussed above, the step of passing the fruit pieces through a metal detection system may be performed after the packaging step and/or after the freezing step, and optionally may be omitted.
At 106, Step 6, the fruit pieces are inserted into a plurality of single serving packages, illustratively tubes 10 described above with respect to
At 107, Step 7, the sealed and labeled packages then are inserted into freezer 130 to freeze the fruit pieces; preferably, this process is performed at a temperature well below water's freezing point, causing the water inside the fruit to freeze in a very short period without forming large crystals, thus inhibiting damage to the fruit's cell membranes. Such a process may be referred to as “quick freezing.” In one example, the packages are frozen with refrigerated air at a temperature between −50 to +30° F., e.g., between −20 to 0° F. In another example, the packages are frozen by immersion in or blasting with liquid nitrogen (N2) at a temperature of approximately −321° F. In still another example, the packages are frozen by immersion in a mixture of ethanol (EtOH) and dry ice at a temperature of approximately −108° F. After the freezing process, the packages may washed with water or a food-safe solvent, if appropriate, and be maintained at a temperature of less than 32° F., e.g., at a temperature of about 10-30° F.
Alternatively, as noted above, the fruit pieces may be frozen at 107, Step 7 before the fruit is packaged at 106, Step 6. In such embodiments, after slicing the fruit 104, Step 4, and passing the fruit through a metal detection system 105, Step 5, if used, the fruit may be inserted into freezer 130 to freeze the fruit pieces. Preferably, the fruit pieces are spaced apart from one another, so that the pieces may be individually frozen, and preferably are individually quick frozen. The frozen fruit pieces then may be packaged 106 as described above, Step 6.
Additionally, note that different steps of the above process may be performed at different times, and in different locations, than one another. For example, the fruit may be received, washed, cored or skinned if appropriate, sliced if appropriate, and individually quick frozen at or near the site of origin, so as to allow the fruit to be picked in a fully ripe state, and to inhibit deterioration that otherwise may occur during transit. The frozen fruit then may be shipped to a separate facility for packaging into single-serving packages.
Advantageously, the packaging and freezing processes provided herein have has negligible effect on the taste, shape, texture and integrity of the fruit other than for placing it into a frozen state. Indeed, as noted above, the frozen fruit may have a higher nutritional value and greater sweetness than fruit that may have been picked in an unripe state and allowed to ripen during a relatively long transit from the site of origin to the grocery store.
The single serving package of the present invention may contain only one type of frozen fruit. Alternatively, the single serving package may comprise two or more different types of frozen fruit, which may be selected based upon their intrinsic nutritional makeup or flavor combination. The composite of these frozen fruits with their particular vitamins and nutrients may be used to meet or achieve the parameters of a particular physiological goal or predetermined level in the body of the consumer. For instance, if one type of frozen fruit is relatively high in Vitamin C, and may be low in Magnesium, a second type of fruit may be included in the package that is relatively high in Magnesium. Therefore, in one embodiment, the variety of frozen fruits may be mixed and matched to achieve a particular nutritional metric in terms of vitamins, minerals, calories, carbohydrates, acids, or other quality, or to achieve a desirable flavor combination such as a “tropical” mixture of pineapple, mango, and banana. Alternatively, a box or bag of single serving packages of frozen fruit pieces may contain a selection of different frozen fruits in the individual single serving packages.
It will be apparent to the skilled artisan that there are numerous changes that may be made in embodiments described herein without departing from the spirit and scope of the invention. As such, the invention taught herein by specific examples is limited only by the scope of the claims that follow.
