Patent Application
20110023320
1. Field
The present disclosure relates generally to commercial drying of produce; more specifically, it relates to removal of surface liquids from produce, including but not limited to leafy vegetables, using vertical or canted drum centrifugal driers.
2. Related Art
The commercial processing of fresh produce requires that once harvested, it be washed clean followed by sanitizing to provide a safe product with a useful shelf-life. In order to accomplish this cleaning and sanitizing, large volumes of water are used to provide mechanical cleaning while also being used to carry cleaners and sanitizers, like chlorine. While this results in a clean and sanitary product, the water added must be separated from the produce and either be sent to drain, recycled, or further processed for disposal.
Moisture that remains on the produce after packaging has a negative impact on shelf-life and product appeal. The amount of moisture can vary for many reasons including the product mix, piece sizes, time of year, and other factors. The removal of residual water from the surfaces of fresh, packaged produce is an important process for extending the shelf-life and maintaining the aesthetic appeal of the product after packaging. It is desired that the product be as dry as possible without causing dehydration of the leaves.
Drying can be accomplished in many ways: fluidized bed drying, spiral coolers, horizontal and vertical/canted drum drying, infrared, and many others. During processing, fresh vegetables are preferably maintained at or slightly below 4° C. This preference has commonly resulted in the use of centrifugal drum driers to both dewater and dry the product after washing and sanitation of the product. This preference has also led to less than successful or inconsistent removal of this surface water. During centrifugal drying, the produce is compacted by the weight of the produce on top of it and by the centrifugal force created by the dryer. This compaction of the produce and the resulting increased density of the produce are referred to as matting. Matting contributes to the problem of inconsistent drying and also causes bruising of the produce. As a spin cycle in a conventional centrifugal dryer nears completion, the produce is denser near the bottom and outer parts of the basket, and less dense near the top and inner parts of the basket. Since the produce becomes more difficult to dry as its density increases, the produce near the top of the basket is drier at the end of a spin cycle than the produce near the bottom of the basket. Inconsistent drying has an adverse impact on the quality of the product.
What is needed are processes and devices to dry produce thoroughly and consistently while minimizing drying cycle time and damage to the produce.
A process for drying of produce, particularly suited to drying leafy vegetables, is described herein. The process employs a multi-volume basket apparatus that allows for the removal of additional water at a given rotational speed and duration of a drying cycle, as compared to a process using a single-volume basket. This results in improved shelf-life of the products and greater aesthetic appeal of the products due to enhanced water removal and minimized damage to the produce.
The following description sets forth exemplary drying processes, parameters, and the like. It should be recognized, however, that such description is not intended as a limitation on the scope of the present proposed invention but is instead provided as a description of exemplary embodiments.
A commercial process for drying produce including but not limited to leafy vegetables in a centrifugal drier and a multi-volume basket apparatus for use in the drying process are set forth below.
Vertical or canted drum centrifugal driers are commonly used for drying produce during processing and prior to packaging.
The drier 100 shown in
While not required, driers such as those of
Cylindrical baskets for holding produce are commonly used with the type of vertical or canted drum centrifugal drier described above. The commonly used baskets typically have a single interior volume defined by the bottom and the side walls of the basket.
Dividing the interior volume of a cylindrical basket into multiple, concentric volumes separated by a perforated divider allows more water to be removed from produce at a given rotational speed and drying cycle duration, as compared to a process using a single-volume basket. Using a multi-volume basket reduces matting and results in longer shelf-life of the produce, greater aesthetic appeal of the produce, less damage to the produce, and more consistent drying.
The basket 200 in this example is constructed of stainless steel. In other variations, the basket may be constructed of any food-grade material such as metal, plastic, composite, other material, or a combination of materials.
The multi-volume basket shown in
The cylindrical divider 203 in this example has a diameter that is approximately 70% of the diameter of the walls of the basket. In other variations, the ratio of the diameter of the divider to the diameter of the walls may range from 20-80% or the divider may be another shape.
The volume defined by the cylindrical divider in the example of
The divider in this example is attached to the bottom of the basket by welded brackets (not shown). The divider is secured to the walls by three welded steel support rods 206 which run radially from the outside surface of the inner divider to the inside surface of the walls of the basket. In other variations, fewer or more support rods may be used. The support rods in this example are attached at approximately the midpoint of the height of the walls and run perpendicular to the bottom of the basket. In other variations, the divider may be attached at another height, or may be attached to the bottom and/or walls of the basket by other means. In other variations, the divider may itself have a bottom, thereby being a basket within a basket.
The process set forth herein is typically used to dry produce that has been washed and rinsed yielding wet produce. The wet produce is loaded into a multi-volume basket through the open top. Typically produce is loaded into the first volume, second volume, and third volume of the basket, but in some variations, wet produce may be loaded into only one of the first volume or second volume and may or may not be loaded into the third volume. Loading of the volumes may occur sequentially in any order or contemporaneously. If additional dividers are used as described above, produce may be loaded in the additional volumes defined by the additional dividers.
The basket is placed into the drier so that the basket is seated in the drum of the drier such that rotating the drum will cause rotation of the drier. Produce may be loaded into the basket before and/or after the basket is placed into the drier. Loading produce into the basket and placing the basket into the drum of the drier may be performed manually or by automated equipment or by a combination of manual and automated means.
After the produce is loaded into the basket and the basket is placed in the drier, steps may be taken to evenly distribute the produce with the basket and to break up any clumps of produce in the basket. This may include manually manipulating the produce and/or manually rotating the drum. Also, the motor and drive assembly may be engaged to rotate the drum and the basket for brief intervals in one direction and then the other prior to the spin cycle.
Next, the motor and drive assembly are engaged to for the spin cycle to cause fluids to drain out of the produce toward the perforated walls or bottom of the basket and into the drier housing to yield dried produce.
The duration of a spin cycle generally ranges from 3-20 minutes, during which the rotational speed of the drum and basket generally ranges from 500-700 revolutions per minute. At the end of the spin cycle, the rotation is stopped. One or more additional spin cycles may be performed. The additional spin cycles may be at the same rotational speed, cycle duration, and spin direction, or these parameters may be changed for different spin cycles.
After the desired number of spin cycles has been completed, the basket and produce are removed from the drier. The dried produce may be removed from the basket before or after the basket is removed from the drier.
Both experiments used freshly harvested and washed Romaine lettuce or Spring Mix vegetables as the starting point. The washed produce was sampled to determine initial moisture content and then dried in a centrifugal drier using either a standard 55-gallon, polypropylene single-volume basket or a multi-volume basket design. The spin cycle times and rotational speeds were the same for all trials. The standard program for plant-made tenderleaf products was used for this experiment. The baskets were sampled after one spin cycle, subjected to an additional spin cycle, and sampled again. In the case of the multi-volume basket design, produce was sampled from both the inner volume (first volume) and the outer volume (second volume). All samples were analyzed for residual moisture using ambient air drying and gravimetric analysis.
The Romaine lettuce was found to have 8.5% surface moisture before being dried. After placing the single-volume basket in the SD-50 drier and completing the two-minute programmed spin cycle, the residual surface moisture was found to be 3.2%. After a second spin cycle, the residual surface moisture was found to be 2.9%. When using the multi-volume basket and the same drying cycle and duration, the residual moisture after one spin cycle of the produce inside the divider (first volume) was found to be 1.2% and the residual moisture of the produce residing between the divider and the walls of the basket (second volume) was found to be 1.9%. Adjusting for their proportional volumes, the overall residual moisture was approximately 1.6%. After a second spin cycle, the produce inside the divider (first volume) was found to be 1.1% and the residual moisture of the produce residing between the divider and the walls of the basket (second volume) was found to be 1.7%. Adjusting for their proportional volumes, the overall residual moisture was approximately 1.4%.
The Spring Mix was found to have 23.5% surface moisture before being dried. After placing the single-volume basket in the SD-50 drier and completing the two-minute programmed spin cycle, the residual surface moisture was found to be 4.9%. After a second spin cycle, the residual surface moisture was found to be 4.5%. When using the multi-volume basket and the same drying cycle and duration, the residual moisture after one spin cycle of the produce inside the divider (first volume) was found to be 2.4% and the residual moisture of the produce residing between the divider and the walls of the basket (second volume) was found to be 2.9%. Adjusting for their proportional volumes, the overall residual moisture was approximately 2.7%. After a second spin cycle, the produce inside the divider (first volume) was found to be 2.3% and the residual moisture of the produce residing between the divider and the walls of the basket (second volume) was found to be 2.7%. Adjusting for their proportional volumes, the overall residual moisture was approximately 2.5%.
The data for both Romaine lettuce and Spring Mix demonstrate significantly improved drying using the same speed and cycle settings with the multi-volume basket compared to the conventional single-volume basket. In both Romaine and Spring Mix, the amounts of water removed were appreciably more using a multi-volume basket compared to a single-volume basket. Appreciably more water removal was observed from Romaine lettuce as compared to Spring Mix due to Romaine's consistent cut size and shape which is less prone to entrain water. Spring Mix retained almost 25% water after the washing process (before drying) as compared to 8.5% for Romaine lettuce.
After drying in the single-volume basket, the Romaine lettuce retained less water (3.2%) when compared to Spring Mix (4.9%). Significant improvement was observed using the multi-volume basket. Use of the multi-volume basket reduced the observed overall residual moisture value by 1.5-2.0% compared to the single-volume basket. The improvement was even more pronounced in Romaine lettuce for which a 2-2.5% reduction of the overall residual moisture value was observed. Overall water removal was always better with Romaine than it was with Spring Mix when compared at each experimental step. Most likely, the more uniform size of the Romaine, as compared to Spring Mix, allowed for better drying.
The methodology was similar to that of Example 1 above. For these experiments, stainless steel baskets were tested, a second spin cycle was not used, and spin cycles of varying duration were tested. Freshly harvested and washed produce was used as the starting point. The washed produce was sampled to determine initial moisture content and then dried in a centrifugal drier using a single-volume basket or a multi-volume basket design. The rotational speeds were the same for all trials. The baskets were sampled after one spin cycle. In the case of the multi-volume basket design, produce was sampled from both the inner volume (first volume) and the outer volume (second volume). Three samples were taken from each volume. For each volume, the average residual % moisture and the standard deviation were calculated. All samples were analyzed for residual moisture using ambient air drying and gravimetric analysis.
The Chopped Romaine was observed to have 18.64% surface moisture before being dried. After one drying cycle using a single-volume basket and a 15 minute spin cycle duration, the average residual surface moisture of the samples was observed to be 7.67%. Using the multi-volume basket and the same drying cycle and duration, the average residual moisture of the samples of the produce inside the divider (first volume) was observed to be 6.27% and the average residual moisture of the samples of the produce from between the divider and the walls of the basket (second volume) was observed to be 5.79%. Adjusting for their proportional volumes, the overall residual moisture was approximately 6.00%.
The Classic Iceberg (1st Trial) was observed to have 27.21% surface moisture before being dried. After one drying cycle using a single-volume basket and a 15 minute spin cycle duration, the average residual surface moisture of the samples was observed to be 10.67%. Using the multi-volume basket and the same drying cycle and duration, the average residual moisture of the samples of the produce inside the divider (first volume) was observed to be 11.54% and the average residual moisture of the samples of the produce from between the divider and the walls of the basket (second volume) was observed to be 10.83%. Adjusting for their proportional volumes, the overall residual moisture was approximately 11.14%.
The Classic Iceberg (2nd Trial) was observed to have 22.27% surface moisture before being dried. After one drying cycle using a single-volume basket and a 10 minute spin cycle duration, the average residual surface moisture of the samples was observed to be 9.17%. Using the multi-volume basket and the same drying cycle and duration, the average residual moisture of the samples of the produce inside the divider (first volume) was observed to be 9.74% and the average residual moisture of the samples of the produce from between the divider and the walls of the basket (second volume) was observed to be 8.61%. Adjusting for their proportional volumes, the overall residual moisture was approximately 9.10%.
The Shredded Iceberg was observed to have 27.26% surface moisture before being dried. After one drying cycle using a single-volume basket and a 5 minute spin cycle duration, the average residual surface moisture of the samples was observed to be 10.43%. Using the multi-volume basket and the same drying cycle and duration, the average residual moisture of the samples of the produce inside the divider (first volume) was observed to be 9.43% and the average residual moisture of the samples of the produce from between the divider and the walls of the basket (second volume) was observed to be 9.24%. Adjusting for their proportional volumes, the overall residual moisture was approximately 9.32%.
The Coleslaw was observed to have 30.83% surface moisture before being dried. After one drying cycle using a single-volume basket and 10 minute spin cycle duration, the average residual surface moisture of the samples was observed to be 15.69%. Using the multi-volume basket and the same drying cycle and duration, the average residual moisture of the samples of the produce inside the divider (first volume) was observed to be 15.72% and the average residual moisture of the samples of the produce from between the divider and the walls of the basket (second volume) was observed to be 16.36%. Adjusting for their proportional volumes, the overall residual moisture was approximately 16.08%.
The European Blend was observed to have 17.26% surface moisture before being dried. After one drying cycle using a single-volume basket and a 10 minute spin cycle duration, the average residual surface moisture of the samples was observed to be 7.35%. Using the multi-volume basket and the same drying cycle and duration, the average residual moisture of the samples of the produce inside the divider (first volume) was observed to be 7.05% and the average residual moisture of the samples of the produce from between the divider and the walls of the basket (second volume) was observed to be 6.36%. Adjusting for their proportional volumes, the overall residual moisture was approximately 6.66%.
The Greener Selection was observed to have 17.80% surface moisture before being dried. After one drying cycle using a single-volume basket and 10 minute spin cycle duration, the average residual surface moisture of the samples was observed to be 8.67%. Using the multi-volume basket and the same drying cycle and duration, the average residual moisture of the samples of the produce inside the divider (first volume) was observed to be 7.37% and the average residual moisture of the samples of the produce from between the divider and the walls of the basket (second volume) was observed to be 7.50%. Adjusting for their proportional volumes, the overall residual moisture was approximately 7.44%.
The data demonstrate improved drying of all of the varieties of produce that were tested using the multi-volume basket as compared to the single-volume basket, at the same speed and cycle settings. For all products, the amount of water removed was appreciably greater using the multi-volume basket as compared to the single-volume basket.
