Patent Application
20210195925
The present invention relates to a packaged tuber food product that contains a fat based seasoning disk in a first embodiment that is stable during shipment and storage of the product. In a second embodiment, it can contain a fat based seasoning disk. When the food product and disk are heated for cooking the food product, the fat liquefies, allowing the fat and seasoning contained within the disk to coat at least a portion of the tubers; and in the second embodiment, be mixed with the potatoes during mashing.
An important aspect of food for human consumption is to have it convenient for preparation. Another important aspect of food is to provide seasoning for the food to enhance its organoleptic properties for consumption. It is known in the art to provide packaged food products with seasoning sold with the food product, typically in packets, for application to the food just prior to consumption. The seasoning in the packets has typically been in dry form. However, the adhesion of the seasoning to the food may not be adequate to maintain the seasoning in contact with the food, wherein the effectiveness of the seasoning is reduced, or additional seasoning needs to be provided to obtain the desired level of seasoning impact.
It is also desirable to have food products that are shelf stable. Storage of food at refrigerated temperatures is both costly and inconvenient. The requirement for refrigerated storage limits how and where a product can be displayed for sale. Fresh whole potatoes can be displayed on non refrigerated counters and can be stored in the storeroom in the back of the store outside of expensive refrigerators. They can also be displayed in a non produce section of a store if shelf stable. Additional problems with typical potatoes is the time required to cook them, even in a microwave oven, and they are not uniform in weight and must be weighed individually for sale because they are sold by the pound, leaving a consumer in doubt as to cost and quantity. When packaged, fresh potatoes are often stored in ventilated polymeric bags to allow for oxygen migration to reduce the risk of the inside of the bag becoming anaerobic, spoiling the product. Ventilated bags, though, limit the ability of particulates like herbs and spices being provided in the bags. Ventilated bags also allow moisture migration that can damage some herbs and spices. Fresh potatoes also need to “breathe” air for oxygen exchange for extended shelf life.
In a second embodiment, the potatoes are cooked in their storage package and then mashed in the package, providing a means for easily adjusting the peel to flesh ratio and providing a convenient way to provide peel on mashed potatoes.
The present invention, in a first embodiment, involves the provision of a packaged food product that is to be heated prior to consumption as, for example, in a microwave oven. The food product is provided with a solid disk containing fat and seasoning that, when heated, the fat liquefies, allowing the seasoning contained therein to be distributed on the food product.
Accordingly, it is a primary objective of the instant invention to provide a packaged food product that allows distribution of seasoning onto the food product after heating of the food product.
It is a further objective of the instant invention to provide a seasoning component that is encapsulated in a solid fat disk during storage of the packaged food product.
It is yet another objective of the instant invention to provide a food product wherein the packaged food product is stored at an ambient temperature of less than about 80° F.
In a second embodiment, the invention provides a way to store potatoes in a package that can be used additionally for cooking the contained potatoes and then for containing the potatoes for mashing and provide a fat disk, if desired, for inclusion in the final mashed potatoes with peel on.
In a third embodiment, salt in the fat containing disk is held in the disk in a manner to reduce the risk of water forming in the package, decreasing the risk of product spoilage.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof.
The package 12 can be any suitable package adapted for storage of the food product 11 and heating of the food product and seasoning disk 15 therein. The package 12 is substantially closed and has a storage chamber 19. This can be in the form of a clear polymeric material with or without means 14, such as a perforated line, to effect opening thereof without a tool, such as a knife or scissors. Such packages are well known in the art and may be made from polyethylene, polypropylene or other food acceptable material. The package 12 can be an internal package, and can be contained in an outer package like the sleeve 65 described below. The package 12, or an outer package 65, can contain suitable graphics, branding, labeling information, and preparation instructions 13, as are also well known in the art. The package 12 is ventilated to allow air/oxygen to transfer from the outer environment to the inside of the package. This can be accomplished by using a perforated material to form the package 12, for example, perforations 17 on the order of 0.002 square inches or smaller (0.050 inch diameter holes or smaller equivalent). What is meant by “substantially closed” is that the package is ventilated as described, but will retain generated steam to expand the package. The package may also be made from an oxygen permeable material as is known in the art. The permeability is adequate to preclude the ingress to the package interior of detrimental solids.
Contained within the package 12 is the seasoning disk 15. The disk 15 can be any suitable shape and size, with the particulars of a disk and its components being disclosed below. The disk 15 has two major components, a seasoning component designated generally 16 and a carrier component designated generally 18. The seasoning 16 can include such things as spices and herbs, for example parsley, oregano, basil, rosemary, thyme, and savory dried vegetables such as red, green and yellow peppers, onion and garlic, and salt and ground black or white pepper. Natural and artificial flavors can also be included with the other seasoning components. The spices and or herbs and other seasoning components are preferably dry (typically less than about 10% by weight water) and in particulate form. The seasoning 16 is mixed into the carrier 18, and is preferably present in an amount in the range of between about 1 gram and about 5 grams per pound of food product 11. The ratio of seasoning to carrier is in the range of between about 25:75 percent by weight and about 75:25 percent by weight, and preferably about 50:50 percent by weight. Surprisingly, it has been observed that inclusion of particulate matter (e.g., the spices and/or herbs) beneficially increases the physical rigidity of the seasoning disk 15, as compared to a disk which was composed solely of the fat.
The carrier 18 includes a fat component that has a substantial amount of fat, which allows it to form a disk 15 containing the seasoning 16 that physically is in solid form at 80° F. (26.6° C.) and cooler. Being in solid form does not preclude some of the fat in the disk from being liquid. Preferably, the carrier is at least about 99% by weight fat. The fat component of the disk 15 is substantially water free and is a continuous phase of the disk 15. In a preferred embodiment, the fat is an anhydrous fat containing at least about 99% by weight fat, and preferably at least about 99.5% fat. The fat component contains less than about 1% by weight water by weight of fat plus water. The fat is also crystalline. For flavor purposes, a preferred fat is milkfat, known commonly as butter. At least 50% by weight of the fat is milkfat; preferably at least about 95% by weight of the fat is milkfat; and most preferably, substantially all milkfat. Anhydrous butter, by Codex definition, contains at least 99.8% by weight milkfat and is derived from fresh cream or butter. By some definitions, anhydrous butter is not allowed to have additives, but is not so limited with the present invention. Butter can be made in a manner with alkali to neutralize free fatty acids. Typically, butters are made from cow's milk, but can be derived from other animal's milk. The weight of the disk 15 or plurality of disks in a package 12 is preferably in the range of between about 1 gram and about 10 grams per pound of product 11. The fat component preferably has a solids fat index (SFI) (%) of about at: 10.0° C. 33.0-21.1° C. 14.0-26.7° C. 10.0-33.3° C. 3.0-40.0° C. 0 as measured by Nuclear Magnetic Resonance or dilatometry, both well known in the art. It is to be understood that a plurality of disks 15 may be used if desired.
The seasoning disk 15 with fat and seasoning has a water activity (Aw) of less than 0.5, well below that of regular butter, which is about 0.95. Disks 15 of the present invention with the seasoning included have Aw in the range of between about 0.22 and about 0.36 when measured at 25° C. Water activity, or Aw, is the partial vapor pressure of water in a substance divided by the standard state partial vapor pressure of water. In the field of food science, the standard state is most often defined as the partial vapor pressure of pure water at the same temperature. The Aw of the disk 15 will differ depending on the ingredients added to the fat component of the carrier 18.
The packaged food product 11 is stored at a temperature of less than about 80° F., and can be stored refrigerated if desired. Refrigerated storage for produce is typically between about 40° F. and about 50° F. In use, the packaged food product 11 is removed from storage and can be immediately heated or allowed to warm, for example, come to room temperature, prior to heating. Preparation instructions can be provided on the package 12 regarding representative cooking times to effect cooking of the food product 11. Preferably, the heating/cooking is done in a microwave oven. A portion of the steam is retained in the storage chamber 16 or 53 during heating of the disk 15 and food product 11. However, venting of the package 12 is desired to prevent excessive pressure buildup in the package during product heating. Venting can be provided by package perforations 17 or by piercing or cutting the package 12 prior to heating.
As seen in the Figures, the seasoning disk 15 can be placed on the top of the food product 11. Its size resists it from moving into the food product 11 during storage. Surprisingly, during heating of the food product 11, the disk 15 disperses and does not require later mixing. However, turning the package over after heating can be done by the consumer to help distribute the disk components. While not being bound by this theory, it is believed that the steam generated from the food product during heating thereof effects dispersion of the melted disk onto the plurality of individual food pieces. Hot water does not effect such dispersion.
In use, the package 12 or 51 containing the food product 11 is stored at the appropriate temperature and is shelf stable. For consumption, the package 12 with the contained food product 11 and seasoning disk 15 is placed in the heating device, for example a microwave oven, with the disk 15 on top of the food product 11, and heated for the desired time effective to generate steam to fill the package 12. After the desired amount of heating/cooking, the package 12 can be shaken to effect additional distribution of the carrier 18 and seasoning 16 on the food product 11 if needed. After this, the package 12 can be opened and the food product 11 removed and consumed. It has been found that a cook time of about 5 minutes is effective for 1 pound of potatoes in a 1000 watt oven.
A second embodiment of the present invention is described below and is illustrated in
Any variety or combinations of varieties of potatoes 11 can be used, with Valery, Cecile, Rosara, Isabellia, Noelle and Agata being preferred varieties. The quantity of potatoes 11 in the package has a total weight in the range of between about 0.5 pounds and about 2 pounds, and preferably on the order of about 1 pound. The potatoes 11 comprise about 4 to about 35 potatoes per pound of potatoes, and preferably between about 6 and about 30 potatoes per pound of potatoes. By having a size distribution available, the ratio of peel weight to flesh weight can be easily adjusted to accommodate consumer preference. The at least one disk 15, or the plurality of disks, has a weight in the range of between about 10 grams and about 30 grams per pound of potatoes, which amount can exceed that described above for the first embodiment.
The package 12 is substantially closed with a storage chamber 19 with enough perforations 81 (only a few are illustrated) to allow the potatoes 11 to respire during storage and allow the slow exchange of air and moisture with the surrounding atmosphere, and are sufficiently vented to relieve pressure in the chamber 19 to reduce the risk of its rupture during microwave heating. The perforations can be formed by various methods, some known in the art and some proprietary to a producer. One method is a hot needle and another is by “cool” needle. Perforation size may vary across a package depending on the method used. It is estimated that the size of the perforations can be on the order of about 0.2mm in diameter. The disk 15 can be contained in a separate packet or be contained in the package 12 with the potatoes 11 as described above. In a preferred embodiment, the disk 15 is in solid form for storage and, after melting during microwave heating, comes into contact with the potatoes during or after the cooking process, so long as the contact is before mashing is completed. It has been found that the packaging material, preferably a polymer or blend of polymers, such as polyethylene and/or polypropylene can be used. It can initially have an opening for placing the potatoes 11 and disk 15 in the chamber 19, and have a portion that will be secured to form a seam to close the opening as known in the art, for example, heat sealing.
When perforations are used for respiration, it is preferred that they be no larger than what is needed for respiration and retaining steam during cooking, which steam also effects expansion of the package 12 during microwave heating. It has been surprisingly found that with perforations 81 of small enough size, the fat in the disk 15 has very low leakage out of the package 12 during microwave cooking of the potatoes 11. Location of the perforations 81 can also be used to reduce the risk of fat leakage, for example, having the perforations positioned on the package side that is the recommended “up side” for cooking.
The package 12 is provided with indicium denoted generally as 70. The indicium 70 will include preparation instructions 73, and can include labeling information 75 as prescribed by law, such as branding, marketing information, and/or graphics, etc. One preferred indicium 77 will include instruction language and/or a pictorial illustration regarding which side of the package should be up (on top) during cooking of the potatoes 11. The exact wording of such instructions and information can vary. For example, which side is to be up during cooking can be indicated by “This side up” on one side and/or “This side down” on the opposite side since they are equivalent statements. Another indicium 79 can include language and/or a pictorial illustration of a preferred location and/or method for opening the package after cooking has been effected. An additional indicium 73 will include language and/or a pictorial illustration providing preparation instructions including at least microwave cooking instructions 73A and potato mashing instructions 73B.
Preparation instructions 73 will include a recommended time range or ranges for cooking time 73A. Preparation instructions will also include mashing instructions 73B and, preferably, manipulation instructions for effecting mixing of the melted disk 15 with the potatoes 11 during mashing. It has been found that mashing can be easily accomplished with the potatoes 11 in the package 12 and that, surprisingly, the mashed potatoes easily release from the package 12 with almost no residual potato material (flesh and peel) being retained in the package. Mashing breaks the peel and breaks the cohesive structure of the cooked flesh. Mashing in the package eliminates the need to dirty a dish or other device. Mashing can be accomplished with a person's hand, like the heel of the palm or the fingers in a fist, or knuckles. It is preferred that, if the hand is used, an insulating member such as a towel or pot holder be used as a thermal insulator. A tool, such as a potato masher (well known in the art, not shown) can also be used to break up the cooked potatoes. The desired degree of mashing (potato break up) can be easily determined by the user. The invention provides a mashed potato product with “skin-on” (peel-on) with fat from the disc 15 and flavoring, if provided with the fat of the disk as described, in a very convenient form. While the preferred mashing process utilizes the package to contain the potatoes and melted disk, it is to be understood that the cooked potatoes and melted disk with seasoning 16 can be removed from the package 12 prior to complete mashing and after possible tossing of the cooked potatoes 11 and melted disk 15 while still in the package to assist in further distribution of the disk components onto the potatoes. The mashed potatoes, or partially mashed potatoes, can then be removed from the package and additionally mashed externally, for example, on a plate, pan or mat, such as a silicone pad. The final mashed texture can be chosen by the consumer and refined as desired. Additional mashing to a finer texture can be accomplished with an implement, such as a fork, by each individual consumer, for example, while on their plate. Weight loss by mashing internally or externally of the package as described results in about the same loss of product weight, about 3-4 grams with a product starting weight of a pound. Such weight loss includes loss of water, as well as potato solids and fat.
In the potato business, potatoes command a price by several factors: variety, visual quality and importantly, size. To the consumer, size is often ignored. Small potatoes, designated creamers by the FDA, i.e., less than 1 ⅝″ in diameter (as defined by the FDA), command premium pricing. Large potatoes, as designated by the FDA, i.e. larger than 3″ in diameter, also command a premium price. Potatoes sized between these sizes, for example, grade B as designated by the FDA, find very low consumer appeal and use, and thus are low in price to encourage sales. The present invention is able to effectively use these potatoes to make a value-added product, do not require peeling or other undesirable or tedious processing steps, and have been found to provide a peeling weight to flesh weight that is desirable for consumers. Additionally, with the present invention, the whole potato is used without undesirable consumer processing steps; and the nutrients in the peel and adjacent the peel which are lost from peeling the potatoes, are also retained and not wasted. The peel contains a significant portion of the potato's total fiber. The present invention allows for an adjustment of the weight of peel to weight of flesh, and hence the percent of fiber in the cooked product for consumption to be easily adjusted.
The potatoes are cooked by microwave energy to produce a mashable texture. It has been found that about 7 minutes in a 1300 watt output oven (as rated by the manufacturer) is adequate when using all grade B potatoes. Cook time can vary by potato size and consumer preference. It is desired to gelatinize a majority of the starch in the potatoes during cooking as indicated by loss of birefringence under polarized light. It has been found that when the starchy part of the potato, i.e., the internal flesh, reaches a temperature of at least about 90° C., the potato can be readily mashed and the peel readily torn adequately for mixing with the starchy potato interior.
The above described food product 11 was produced and put into normal refrigerated storage for subsequent distribution. The potato weight was about 1 pound and the disk 15 weight was about 20 grams containing about 2 grams of salt (table salt, NaCl). The relative humidity in a packaged fresh potato can readily reach 100% at refrigerated temperature. It was discovered that in some cases, liquid, that appeared to be water, was found inside the package. Some of these packages had spoiling potatoes. Water in a package of fresh whole potatoes is detrimental to the potatoes and a potential cause of spoilage.
Experiments were conducted to identify the liquid and find the source or sources of the collected liquid. The liquid was identified as water. There were several possible sources of the water. One possible source was humidity from the contained air in the package condensing. Another possible source was water being given up by the potatoes to the package interior to increase the package humidity and condensing. The collected liquid was analyzed by tasting and was found to be salty water. The first two sources of water were eliminated as possibilities. However, in the fat containing disk, there was about 2 grams of salt. The salt was contained in the fat, and therefore was initially believed to not be exposed to the package interior and not available to the package humidity. The fat component of the disk basically has no water, not as much as was in liquid formed in the package.
Further analysis was done by an examination of the disk 15, even though it contained basically no water and was first considered as not being a source of the water. However, upon closer examination, it was discovered that the salt added to the disk 15 was denser than the fat, and when the salt is added to liquid fat during disk formation, the salt settled to the bottom of the formed disk. Even then, the salt was thought to be mostly encapsulated in the fat and thus was not exposed to the air in the package. It was also observed that when a package was stored at room temperature, no collected water was observed. Also, when the disk 15 contained no salt, no collected water was observed.
Further experimentation showed that there was enough exposure of the salt to the air to allow it to absorb enough water to form a saturated solution and produce liquid water that was released to and captured in the package interior. It was a surprising discovery that the salt in the fat was the cause of the condensed water in the package.
Salt is hygroscopic and attracts and can absorb and/or adsorb water. Wikipedia defines hygroscopy as the phenomenon of attracting and holding water molecules via either absorption or adsorption from the surrounding environment, which is usually at normal or room temperature. If water molecules become suspended among the substance's molecules, adsorbing substances can become physically changed, e.g., changing in volume, boiling point, viscosity or some other physical characteristic or property of the substance. While not wishing to be bound by any theory, it is believed that the humidity adjacent the salt is absorbed by the salt in the disk and some of the salt becomes fully saturated and liquefied, and the liquid with contained salt is released to the interior of the package since it is lipophobic. Salt water is more problematic than plain water to storage stability of fresh potatoes.
It was discovered that enhanced encapsulation of the salt in the disk fat solved the liquid water formation problem. In a preferred embodiment, the seasoning includes salt in an amount of at least about 1 gram and preferably in the range of between about 1 gram and about 3 grams per pound of potatoes. Encapsulation for food ingredients and other products, like pharmaceuticals, is known in the art and can be effected with various encapsulants as set forth in the following articles. See for example, https://pubmed.ncbi.nlm.nih.gov/10627837/ and haps://www.sciencedirect.com/topics/food-science/encapsulation-technology, the disclosures of which are incorporated herein by reference.
The encapsulation of the salt is sufficient to reduce contact between the salt in the disk 15 and the water in the package, be it humidity in the air or water in the potatoes. The encapsulation of the salt is sufficient so that less than 10% of the salt and preferably less than 5% by weight of the salt in the disk 15 has contact with the package air and/or potatoes during storage and prior to cooking, preventing contact with water in liquid and/or vapor form in the package. Stated otherwise, the salt is contained in the disk such that at least about 90% and preferably at least about 95% by weight of the salt is encapsulated sufficiently that it does not contact water in the package during storage as measured by the encapsulation test described herein. This can be done by encapsulating the salt prior to combining the salt with the fat component or by using the fat in the fat component. In the latter case, the fat is softened and it and the salt are mixed together prior to casting the mixture to form the disk. By controlling the rheologic properties of the fat during disk formation, it has been found that the salt will not settle out, due to the difference in density of salt and fat, to one side, exposing itself to the surrounding environment. In this method of encapsulation, when using anhydrous milk fat, the fat is heated to a temperature of between about 78° F. and about 82° F., soft but not in liquid form in bulk (it is pointed out that food fat is a mixture of fats, some being liquid and some solid, the proportion being dependent of temperature and is denoted by SH), and then mechanically mixing the softened fat and salt along with the other seasoning, if any, wherein the salt is generally fixed against movement relative to the fat during disk formation as by casting or molding. It is noted that when the fat component, for example, the above described clarified butter/anhydrous milk fat is in this temperature range, that about 18% of the fat is in crystalline phase and about 82% is liquid, by weight. This allows for casting or molding of the disk. The seasoning and salt can be formed as a separate piece and deposited on the first deposited non liquid fat described above to form a disk precursor and then the remaining fat deposited on the precursor.
The above amount of salt that might solubilize and cause water in the package is determined by the following encapsulation test.
1) Weigh an empty metallic weigh boat which has an internal volume of ˜40-50 cc. (tare wt.).
2) Place the salt containing product (disk) in the weigh boat. Record weight.
3) Fill the weigh boat with distilled water.
4) Hold weigh boat with sample at room temperature for approximately 2 hours.
5) Remove product (disk) from the weigh boat.
6) Place weigh boat in a drying oven (at approx. 200-220° F.) and dry until no water visually remains.
7) Re-weigh boat, which will contain any salt dissolved from the product (disk).
8) Weight from Step 7 minus weight from Step 1 equals the salt which was unprotected (i.e. not adequately encapsulated).
This modified disk 15 can be used with both product embodiments described above.
Experiments were conducted to compare the performance of the original disk to the disk with enhanced encapsulation as described above. As described above, the disk or plurality of disks 15 have a total weight in the range of between about 1 gram and about 30 grams, and preferably in the range of between about 10 grams and about 30 grams per pound of potatoes. The total amount of salt in the disk 15 or disks 15 in a package with the potatoes is at least about 0.2 grams. The results are tabulated below. The three rows designated “Suspended salt” are the enhanced encapsulation product, and the two rows designated “Settled salt” are the original disks where the salt settled to the bottom. It can be seen that the enhanced encapsulation performed much better. The improved disk was tried with packaged potatoes, and after 3 weeks of refrigerated storage showed no liquid water in the packages. Disks contained approximately 2 grams of salt, 0.4 grams of white pepper and 16.6 grams of clarified butter.
1) Disks were placed in metal cupcake type molds that had an internal volume of 40 cc.
2) The cups were then filled with distilled water and held at 40 F for 24 H.
3) Disks were then removed and the metal cups were placed in a drying over @ 250 F until all of the water was evaporated.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
In accordance with 37 C.F.R 1.76, a claim of priority is included in an Application Data Sheet filed concurrently herewith. Accordingly, the present invention is a Continuation-In-Part of U.S. patent application Ser. No. 17/071,222, entitled “SEASONED FOOD PRODUCT AND METHOD”, filed Oct. 15, 2020, which is a Continuation-In-Part of U.S. patent application Ser. No. 15/606,559, entitled “SEASONED FOOD PRODUCT AND METHOD”, filed May 26, 2017, which claims priority to U.S. Provisional Application 62/342,407, entitled “SEASONED FOOD PRODUCT AND METHOD” filed on May 27, 2016. The contents of the above referenced applications are herein incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62342407 | May 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17071222 | Oct 2020 | US |
| Child | 17201097 | US | |
| Parent | 15606559 | May 2017 | US |
| Child | 17071222 | US |
