Patent Application
20160000099
The present invention relates to food products and related methods. More specifically, the present invention relates to food products arranged in a monolayer.
Because most foods have a tendency to spoil relatively quickly, food preservation techniques have been developed over many years to extend the amount of time that a given food product will remain fresh. Food preservation techniques can include drying, freezing, fermenting, pickling, curing, canning, heat treating, irradiating, adding preservative agents and the like.
While food preservation techniques have been successful at extending the time until food spoils, it has been found that various food preservation techniques can have adverse effects on food products including, diminishing the taste and appearance of the food, reducing nutritional qualities of the food, adding calories, and the like.
Embodiments of the invention include food products and related methods. In an embodiment, the invention includes a method for producing a food product. The method can include arranging one or more discrete pieces of a food material into a monolayer inside a pouch, sealing the pouch, and exposing the sealed pouch to a sterilization or pasteurization cycle effective to reduce the number of viable microorganisms and/or their spores in the food product.
In an embodiment, the invention includes a food product. The food product can include a pouch comprising a front wall and a back wall, the front wall and the back wall attached to one another and defining an interior volume. The food product can further include a food material disposed within the interior volume, the food material comprising one or more discrete pieces of a food material, the pieces arranged in a monolayer between the front wall and the back wall. The pieces can have a thickness, wherein the thickness is greater than or equal to 0.25 inches and less than or equal to 1.25 inches; and the food material comprising a plant or animal food material.
This summary is an overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details are found in the detailed description and appended claims. Other aspects will be apparent to persons skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which is not to be taken in a limiting sense. The scope of the present invention is defined by the appended claims and their legal equivalents.
The invention may be more completely understood in connection with the following drawings, in which:
While the invention is susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings, and will be described in detail. It should be understood, however, that the invention is not limited to the particular embodiments described. On the contrary, the intention is to cover modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
The embodiments of the present invention described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the present invention.
All publications and patents mentioned herein are hereby incorporated by reference. The publications and patents disclosed herein are provided solely for their disclosure. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate any publication and/or patent, including any publication and/or patent cited herein.
As described above, while food preservation techniques have been successful at extending the time until food spoils, it has been found that various food preservation techniques can have adverse effects. By way of example, heat treatments can be quite effective at preserving food products, however, exposure to heat can diminish taste, texture, nutritional value, appearance and the like. Particularly in the case of fresh vegetables and fruits, taste, appearance and texture can be unacceptably reduced in quality.
The applicants herein have found that by arranging pieces of a food product as a monolayer within a package, an effective amount of a microorganism killing treatment can be applied, while minimizing the adverse impact on taste, appearance and texture.
Referring now to
Referring now to
While it will be appreciated that there are many ways in which pieces of a food product can be arranged into a monolayer, in some embodiments the package or pouch can be placed within a cavity in order to assist with the process of arranging the food product pieces. Referring now to
Other techniques for arranging pieces of a food product as a monolayer can include depositing the pieces on a top of a first wall (or side) of the pouch then placing the second wall (or side) over the food products and then attaching the first wall to the second wall along the peripheral edges to seal the two walls or sides to one another.
Referring now to
It will be appreciated that while being arranged as a monolayer, the pieces of the food product can be arranged in various ways as viewed from the front of the package. In some embodiments, the plurality of pieces wherein the pieces of food can be arranged in a square or a rectangle as viewed from the side. In other embodiments, the pieces of food can be arranged to form other shapes as viewed from the side. By way of example, referring now to
Various numbers of discrete pieces of the food material can be used. In some embodiments, there are one or more discrete pieces. In some embodiments, the number of discrete pieces is from 1 to 1000. In some embodiments, the number of discrete pieces is from 1 to 100. In some embodiments, the number of discrete pieces is from 2 to 40. In some embodiments, the number of discrete pieces is from 4 to 30. Referring now to
In some embodiments, an accessory device can be included with the food product in order to absorb water that may be released from the pieces of the food product when it is processed to reduce the numbers of microorganisms. Referring now to
Referring now to
The water permeable container wall can be formed of various materials. In some embodiments, the container wall can be formed of a porous material. In some embodiments, the container wall can be formed of a material that is perforated in order to render it water permeable. The container wall can be formed of various materials including polymers, foils, cellulosic materials, and the like.
The water absorbing edible material can include a food material that absorbs water. In this manner, water that might be liberated from the discrete pieces in the food package during the sterilization or pasteurization process (or during other processing steps) can be absorbed. In some embodiments, the water absorbing edible material can be a plant product. In some embodiments, the water absorbing edible material can be a material that is high in starch. In some embodiments, the water absorbing edible material can include, but is not limited to, grains such as rice, wheat, quinoa, oats, barley, corn, amaranth, buckwheat, millet and the like. In some embodiments, the water absorbing edible material can include, but is not limited to, dried fruit or vegetables, or their peels, or legumes.
The water absorbent accessory can be configured in various ways. Referring now to
Embodiments herein can also include various methods including, but not limited to methods of making a food product, methods of processing a food product, methods of using a food product, and the like. Referring now to
Beyond the operations shown in
In some embodiments, placing the pouch in a rigid cavity is performed prior to placing the pieces into the pouch. In some embodiments, the rigid cavity is formed by two or more rigid pieces. In some embodiments, the steps of arranging pieces of a food material into a monolayer and placing the pieces into a pouch are performed simultaneously. In some embodiments, arranging pieces of a food material into a monolayer further comprises vibrating (or applying vibrational energy to) the pieces in order to help the pieces fit into place and form a monolayer.
In some embodiments, the method can include a step to absorb water in the pouch. Referring now to
In some embodiments, the method can include a step of mashing or otherwise crushing the pieces after placement within the pouch. Referring now to
In many figures herein, such as in
Pieces of food products herein can be of various dimensions. For purposes of reference, the pieces can all be considered to include a height, width, and thickness. In some embodiments, the thickness can be a greater than or equal to 0.25 inches and less than or equal to 1.25 inches. In some embodiments, the height can be greater than or equal to 0.25 inches and less than or equal to 12 inches. In some embodiments, the width can be greater than or equal to 0.25 inches and less than or equal to 12 inches. In some embodiments, any of these dimensions can be greater than or equal to 0.4 inches and less than or equal to 0.6 inches.
Food products herein can have a relatively high moisture content. In some embodiments, the water content (including amounts bound within the pieces) can be at least about 40% by weight. In some embodiments, the water content can be at least about 50% by weight. In some embodiments, the water content can be at least about 60% by weight. In some embodiments, the water content can be at least about 70% by weight. In some embodiments, the water content can be at least about 80% by weight. In some embodiments, the water content can be at least about 90% by weight.
In some embodiments, the plurality of pieces (as measured prior to sterilization or pasteurization) can include at least about 50 percent of the total weight of the food product. In some embodiments, the plurality of pieces (as measured prior to sterilization or pasteurization) can include at least about 60 percent of the total weight of the food product. In some embodiments, the plurality of pieces (as measured prior to sterilization or pasteurization) can include at least about 70 percent of the total weight of the food product. In some embodiments, the plurality of pieces (as measured prior to sterilization or pasteurization) can include at least about 80 percent of the total weight of the food product. In some embodiments, the plurality of pieces can include at least about 90 percent of the total weight of the food product. In some embodiments, the plurality of pieces can include at least about 100 percent of the total weight of the food product.
In some embodiments, there may a limited amount of pieces present, such as product fines or other pieces, which are not arranged in a monolayer configuration. In some embodiments, product fines can be less than or equal to 20 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 50 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 60 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 70 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 80 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 90 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 95 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 98 percent of the total weight of the food product as measured after sterilization or pasteurization. In some embodiments, the discrete pieces arranged in a monolayer can be at least about 99 percent of the total weight of the food product as measured after sterilization or pasteurization.
In some embodiments, the food product overall can have a total thickness of less than about 1.25 inches. In some embodiments, the food product can have a total thickness of less than about 1.0 inches. In some embodiments, the food product can have a total thickness of less than about 0.8 inches. In some embodiments, the food product can have a total thickness of less than about 0.7 inches. In some embodiments, the food product can have a total thickness of less than about 0.6 inches.
In some embodiments, the food product overall can have a total thickness of greater than about 0.1 inches. In some embodiments, the food product can have a total thickness of greater than about 0.2 inches. In some embodiments, the food product can have a total thickness of greater than about 0.3 inches. It will be appreciated that due to some variation in the size of discrete pieces that the thickness of the package may not be uniform. Further, in some cases, two pieces may overlap one another causing a variation in thickness. As such, in some embodiments, the thicknesses references herein can refer to average thicknesses.
The pouch (or container) that holds the food product can be formed of various materials. In some embodiments the pouch can include a polymeric retortable pouch. In some embodiments, the pouch can be formed of a flexible polymeric film. In some embodiments, the pouch walls can be formed of materials including thermoplastic and/or thermoset polymers, metal foils, cellulosic materials, laminates, composites, or the like. In some embodiments, the pouch (or container) can include other structural features such as a gusseted base, a re-closable zip seal, a tear line or tear notch. In some embodiments, the pouch can be formed of a flexible polymeric film. In some embodiments, the pouch can be peelable (e.g., peel-open) or non-peelable. In some embodiments, the pouch can be clear, translucent, or opaque.
The plant or animal food material of which the pieces are formed can include various different types of plant or animal components. In some embodiments, the pieces are formed from a fruit or vegetable. The fruit or vegetable can be selected from the group consisting of potatoes, sweet potatoes, squash, pumpkin, carrots, yams, apples, mango, pears, zucchini, spinach, and the like.
Brine solutions can sometimes be added to food products prior to sterilization or pasteurization cycles to aid in heat transfer through the food product, amongst other functions. Brine solutions can be formed with various salts. By way of example, brine solution salts can include compounds that dissociate in an aqueous environment into food grade cations and anions. Brine solution salts can specifically include, but are not limited to, compounds that dissociate into sodium, potassium, magnesium, calcium as cations and chloride, carbonate, bicarbonate, or lactate as anions.
In various embodiments herein, the food product lacks a brine solution. In various embodiments, no exogenous brine solution is added to the food product prior to it being sealed in a pouch or other container. Stated differently, in various embodiments no salts are added to the food product. As such, in various embodiments, the food product includes a salt content that is substantially equal to the amount of the salt components in the discrete pieces of the food material by themselves prior to being disposed within the pouch. In various embodiments, the food product includes a salt content that is substantially equal to the amount of salts that are natively in the plant or animal food material prior to processing steps.
It will be appreciated that in various embodiments other components can be added to the food product. By way of example, food products herein can also include components such as, but not limited to, flavoring agents (including herbs, spices, flavors, sweeteners and the like), additives, preservatives, pH modifiers such as acidulants, and the like.
It will be appreciated that various parameters and conditions can be used in the course of subjecting the food product to a sterilization or pasteurization cycle. In various embodiments, the total duration of the sterilization or pasteurization cycle is less than about 45 minutes, less than 30 minutes, less than 20 minutes, less than 15 minutes, or less than 10 minutes.
In some embodiments, the sterilization or pasteurization cycle is effective to substantially reduce the number of viable microorganisms in the food product. In some embodiments, the sterilization cycle is effective to achieve commercial sterility of the food product. In some embodiments, the sterilization cycle is effective to produce a 12 log reduction in viable C. botulinum spores. In some embodiments, the sterilization cycle is effective to produce a 5 log reduction in viable C. perfringens spores. In some embodiments, the sterilization or pasteurization cycle can be divided up into a series of phases. By way of example, in some embodiments, the sterilization or pasteurization cycle can include a warm-up phase. In some embodiments, sterilization or pasteurization cycle can include a cool down phase. In some embodiments, the sterilization or pasteurization cycle can include a high pressure phase and/or a high pressure phase with high temperatures. In some embodiments, the total sterilization or pasteurization cycle time less than about 45 minutes with cooking time less than about 12 min.
A sample of carrots was obtained and they were washed, peeled, and then cut into pieces of approximately 0.5 inches. These pieces were arranged in a monolayer. A thermocouple was placed within the carrot, and the carrot was subjected to conditions simulating a retort cooker. A retort cycle was initiated and the temperature inside the carrot was recorded with the thermocouple. After initially increasing the temperature to hit a target commercial sterilization temperature of 243 degrees Fahrenheit, the carrot sample was then held at a high temperature until commercial sterilization was achieved. Finally, the temperature was reduced rapidly.
The temperature data are shown in
The carrots arranged as a monolayer were able to achieve the target sterilization temperature much faster than the typical package and also cool down much more quickly. Visual inspection of these carrots after the sterilization cycle showed that the color of the monolayer carrots was more like a fresh color and manipulation of the carrots showed that they had a firmer texture. This example shows that monolayer food products can be processed to achieve commercial sterility without sustaining as much thermal degradation as would be experienced by otherwise similar food products that are not arranged as a monolayer.
This experimental procedure was repeated for pears. The temperature data are shown in
It should be noted that, as used in this specification and the appended claims, the singular forms ‘a,’ ‘an,’ and ‘the’ include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing ‘a compound’ includes a mixture of two or more compounds. It should also be noted that the term ‘or’ is generally employed in its sense including ‘and/or’ unless the content clearly dictates otherwise.
It should also be noted that, as used in this specification and the appended claims, the phrase ‘configured’ describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration to. The phrase ‘configured’ can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, and the like.
All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated by reference.
The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 62/006,591, filed Jun. 2, 2014, the content of which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62006591 | Jun 2014 | US |
