METHOD FOR PACKAGING A COMMINUTED COMPOSITION SUSCEPTIBLE TO DEGRADATION BY OXYGEN

Abstract

An improved method of packaging compositions susceptible to degradation by oxygen comprises: (1) providing a composition to be comminuted in premixed form in a first vessel; (2) transferring the premixed composition through a hollow first transfer means from the first vessel to a second vessel; (3) comminuting the composition in the second vessel, the second vessel including at least two sets of multiple spaced inlets for inert gas such that the inert gas backflows into at least the hollow first transfer means, and such that the first set of spaced inlets is located closest to the hollow first transfer means; (4) transferring the comminuted composition to a second transfer means, the second transfer means including an inlet for an inert gas so that inert gas permeates the second transfer means and the comminuted composition within the second transfer means; (5) transferring the comminuted composition from the second transfer means to an opaque, oxygen impermeable pouch; (6) expelling oxygen from the pouch by introducing an inert gas from an inlet for an inert gas in communication with the pouch; and (7) sealing the pouch. The inert gas is typically nitrogen. A variety of compositions can be packaged, including foodstuffs.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is related to the subject matter of application Ser. No. 606,073, filed Feb. 23, 1996, by Erasmus et al., entitled “Dietary Food Supplement and Method of Preparing”, now U.S. Pat. No. 5,656,312, issued Aug. 12, 1997, and application Ser. No. 850,273, by Erasmus et al., entitled “Dietary Food Supplement”, filed May 3, 1997, now U.S. Pat. No. 5,834,048, issued Nov. 10, 1998. The contents of these patents are incorporated herein by this reference.

BACKGROUND OF THE INVENTION

[0002] The present invention is directed to methods for packaging a composition, such as a foodstuff, susceptible to degradation by oxygen in order to minimize the degree of degradation of the composition being packaged.

[0003] Diet is important in determining general health, work performance, energy level, and appearance. A diet must include proper amounts of essential nutrients. Essential nutrients are those that a human or an animal is incapable of synthesizing. Therefore, essential nutrients must be obtained from their diet. Essential nutrients are different for humans and for different animals. Of the approximately 40 essential nutrients necessary for humans, 14 are minerals, 14 are vitamins, 10 are amino acids and 2 are essential fatty acids. Other non-essential, but beneficial factors include enzymes, beneficial bowel, bacteria, and certain kinds of fiber. These factors can become essential when the diet contains highly processed foods.

[0004] Extensively processed foods cannot provide all the nutritional requirements for optimum animal or human health because processing destroys chemically fragile essential nutritional elements. For example, processing steps may expose the carbon-carbon double bonds and hydrocarbon chains of essential fatty acids to oxidizing agents such as light and oxygen. Oxidized fatty acids lose their nutritional value. Humans and animals suffer from a nutritional deficiency as a result of consumption of a diet which is largely composed of processed foods. Despite the deficiencies of processed foods, they have become popular due to the ease, speed and convenience with which meals can be prepared.

[0005] In recent years, as the deficiencies of commercially-available processed foods have become recognized, a need has arisen for rapid processing methods that preserve the nutritional value of foodstuffs and prevent oxidation of fatty acids and other oxidation-sensitive ingredients of such foodstuffs. Similar packaging needs exists for the packaging of other substances and compositions that are susceptible to degradation by oxygen, such as by the process of oxidation or other reactions, such as chemical reactions occurring by a free radical mechanism, in which atmospheric oxygen is a participant.

[0006] There is therefore a need for an improved packaging method to package compositions, such as foodstuffs, to minimize exposure to oxygen and prevent degradation of components of the composition. Preferably, such an improved method would be suitable for use with a broad range of compositions, including, but not limited to, foodstuffs suitable for administration to humans and animals. Preferably, such a method would be rapid and economical.

SUMMARY

[0007] An improved method of packaging substances susceptible to degradation as a result of exposure to atmospheric oxygen uses multiple sites to introduce an inert gas and purge oxygen from the system. In general, this method comprises:

[0008] (1) providing a composition to be packaged in a first vessel;

[0009] (2) transferring the composition through a hollow first transfer means from the first vessel to a second vessel;

[0010] (3) transferring the composition to a second transfer means;

[0011] (4) transferring the composition from the second transfer means to an opaque, oxygen impermeable container via a filler, where at least two of the second vessel, the second transfer means, and the filler include an inlet for the inert gas to purge oxygen from the composition; and.

[0012] (5) sealing the container.

[0013] Preferably, the second vessel includes an inlet for the inert gas.

[0014] Preferably, both the second transfer means and the filler include an inlet for the inert gas. Also, preferably, the filler includes an inlet for the inert gas and the filler further includes a fritted plate or metal tube or tubing.

[0015] Typically, the second vessel includes at least two inlets for the inert gas. Preferably, in this alternative, the second vessel includes multiple sets of inlets for the inert gas, each set being spaced equidistantly around the perimeter of the second vessel. Most preferably, the second vessel includes two sets of four inlets for the inert gas, although other arrangements are possible.

[0016] Typically, the second vessel includes means for performing size reduction and blending of the composition, such as a comminutor. Also, typically, the second transfer means includes an auger.

[0017] The inert gas can be selected from the group consisting of nitrogen, helium, argon, neon, and xenon. In most applications, the inert gas is preferably nitrogen.

[0018] In more detail, a preferred method according to the present invention comprises:

[0019] (1) providing a composition to be comminuted in premixed form in a first vessel;

[0020] (2) transferring the premixed composition through a hollow first transfer means from the first vessel to a second vessel;

[0021] (3) comminuting the composition in the second vessel, the second vessel including at least two sets of multiple spaced inlets for inert gas such that the inert gas backflows into at least the hollow first transfer means, and such that the first set of spaced inlets is located closest to the hollow first transfer means;

[0022] (4) transferring the comminuted composition to a second transfer means, the second transfer means including an inlet for an inert gas so that inert gas permeates the second transfer means and the comminuted composition within the second transfer means;

[0023] (5) transferring the comminuted composition from the second transfer means to an opaque, oxygen impermeable container;

[0024] (6) expelling oxygen from the container by introducing an inert gas from an inlet for an inert gas in communication with the container; and

[0025] (7) sealing the container.

[0026] The method is adaptable for a number of described compositions.

[0027] Preferably, the first set of multiple spaced inlets for an inert gas comprises four inlets spaced equidistantly around the perimeter of the second vessel and the second set of multiple spaced inlets for an inert gas comprises four inlets spaced equidistantly around the perimeter of the second vessel.

[0028] Preferably, the process is carried out at a temperature of less than about 100° F and in the presence of light of a wavelength not greater than that of red light and of an intensity not greater than that of a darkroom light to thereby inhibit oxidation of the components of the comminuted composition.

[0029] Typically, the ingredients of the composition are reduced to a size where about 5% to about 35% of the components can pass through a #30 U.S. Standard Screen. Preferably, the ingredients of the composition are reduced to a size where about 8% to about 25% of the ingredients can pass through a #30 U.S. Standard Screen.

[0030] Another aspect of the present invention is a packaging apparatus for carrying out the method described above. In general, this apparatus comprises:

[0031] (1) a first vessel;

[0032] (2) a hollow first transfer means communicating with the first vessel and a second vessel, the second vessel including at least one inlet for an inert gas;

[0033] (3) a second transfer means communicating with the second vessel; and

[0034] (4) a filler to transfer the composition from the second transfer means to an opaque, oxygen impermeable container, where at least one of the second transfer means and the filler includes an inlet for the inert gas to purge oxygen from the composition.

[0035] Preferred variations in the method of the present invention, as described above, are reflected in the apparatus. For example, both the second transfer means and the filler can include an inlet for the inert gas. Typically, the filler includes an inlet for the inert gas and the filler further includes a fritted plate. Typically, the second vessel includes at least two inlets for the inert gas. Preferably, the second vessel includes multiple sets of inlets for the inert gas, each set being spaced equidistantly around the perimeter of the second vessel. Most preferably, the second vessel includes two sets of four inlets for the inert gas. Typically, the second vessel includes means for mixing the composition, such as a comminutor. Typically, the second transfer means includes an auger.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The above-identified invention will be better understood with reference to the accompanying specification, appended claims, and drawings, where:

[0037] FIG. 1 is a schematic diagram of an apparatus suitable for carrying out a process according to the present invention;

[0038] FIG. 2 is a top view of the second vessel of the apparatus showing the first set of multiple spaced inlets for the inert gas; and

[0039] FIG. 3 is a bottom view of the second vessel showing the second set of multiple spaced inlets for the inert gas.

DESCRIPTION

[0040] An improved method for packaging a composition susceptible to degradation by oxygen is based on the principle of infusion of an inert gas such as nitrogen into the packaging apparatus at at least one site upstream from the point at which the composition is packaged into the packaging container. The inert gas can be infused at multiple sites, at least one of which is upstream from the point at which the composition is actually packaged. Therefore, in its broadest aspect, a method according to the present invention comprises:

[0041] (1) providing a composition to be packaged in a first vessel;

[0042] (2) transferring the composition through a hollow first transfer means from the first vessel to a second vessel;

[0043] (3) transferring the composition to a second transfer means;

[0044] (4) transferring the composition from the second transfer means to an opaque, oxygen impermeable container via a filler, where at least one of the second vessel and the second transfer means and the filler includes an inlet for an inert gas to purge oxygen from the composition and to suffuse the composition; and

[0045] (5) sealing the container.

[0046] It is generally preferred to provide multiple sites of infusion or introduction of the inert gas. In its broadest aspect, such a method, employing multiple sites, comprises:

[0047] (1) providing a composition to be packaged in a first vessel;

[0048] (2) transferring the composition through a hollow first transfer means from the first vessel to a second vessel;

[0049] (3) transferring the composition to a second transfer means;

[0050] (4) transferring the composition from the second transfer means to an opaque, oxygen impermeable container via a filler, where at least two of the second vessel, the second transfer means and the filler include an inlet for the inert gas to purge oxygen from the composition; and

[0051] (5) sealing the container.

[0052] It is generally preferred that the second vessel includes an inlet for the inert gas. However, various arrangements are possible, including one in which the two inlets are located in the second transfer means and the filler.

[0053] Although it is not required, it is generally preferred that the second vessel includes multiple inlets for the inert gas. For example, the second vessel can include two sets of inlets for the inert gas, the members of each set being located equidistantly around the vessel. In this arrangement, it is generally preferred for each set to include four inlets. Alternatively, however, the second vessel can have two inlets, one located closer to the junction of the first transfer means and the second vessel and the other located closer to the junction of the second transfer means and the second vessel. The use of the term “inlet” in the specification includes multiple inlets unless specifically excluded.

[0054] It is also generally preferred to have inlets for inert gases in communication with both the second transfer means and the filler.

[0055] Preferably, the second transfer means comprises an auger of suitable dimensions.

[0056] Typically, the opaque, oxygen impermeable container is a pouch, but other opaque, oxygen impermeable containers can be used instead of the pouch.

[0057] When the filler includes an inlet for inert gas, it is also generally preferred for the filler to include diffusor, such as a fritted metal plate or tubing, to minimize disruption of the composition that would otherwise be caused by the flow of the inert gas when it passes through the filler.

[0058] It is also generally preferred that the second vessel includes means for performing blending and size reduction of the composition. In one preferred embodiment, as shown below, the means for performing blending and size reduction of the composition is a comminutor.

[0059] In one particularly preferred embodiment of a method according to the present invention, the composition in the first vessel is premixed, and, during the packaging process, the composition is comminuted in the second vessel.

[0060] In general, such a method comprises:

[0061] (1) providing a composition to be comminuted in premixed form in a first vessel;

[0062] (2) transferring the premixed composition through a hollow first transfer means from the first vessel to a second vessel;

[0063] (3) comminuting the composition in the second vessel, the second vessel including at least two sets of multiple spaced inlets for inert gas such that the inert gas backflows into at least the hollow first transfer means, and such that the first set of spaced inlets is located closest to the hollow first transfer means;

[0064] (4) transferring the comminuted composition to a second transfer means, the second transfer means including an inlet for an inert gas so that inert gas permeates the second transfer means and the comminuted composition within the second transfer means;

[0065] (5) transferring the comminuted composition from the second transfer means to an opaque, oxygen impermeable container;

[0066] (6) expelling oxygen from the container by introducing an inert gas from an inlet for an inert gas in communication with the container; and

[0067] (7) sealing the container.

[0068] Typically, the present invention is used with dry ingredients, but the present invention can also be adapted to the use of ingredients containing a coating liquid, which is typically a liquid with viscosity greater than water containing carbohydrate or related components that can impart stickiness or tackiness.

[0069] A schematic diagram of an apparatus suitable for the performance of a preferred process according to the present invention is shown in FIG. 1. The device 100 has a first vessel 102. The first vessel 102 can typically be a holding tank such as is suitable for holding premixed compositions including ingredients such as grains, seeds, vitamins, plant products, and other nutrients.

[0070] The first vessel 102 is in communication with a hollow first transfer means 104 such as a pipe. The diameter of the pipe can be chosen to be suitable for the flow characteristics of the material being processed and for the volume of material being processed. The hollow first transfer means 104 is also in communication with a second vessel 106. The material in the first vessel or holding tank 102 can flow to the second vessel 106 by way of the hollow first transfer means 104. The hollow first transfer means can be equipped with conventional material-handling mechanisms to facilitate this transfer. The second vessel 106 is typically a comminutor that performs size reduction and blending of the material added to it. Details of the comminutor, including details of its construction and operation, are given below. The second vessel 106 includes a first set of spaced inlets for inert gas 108, 110, 112, and 114 and a second set of spaced inlets for inert gas 116, 118, 120, and 122. The first set of spaced inlets for inert gas 108, 110, 112, and 114 is located closer to the connection of the hollow first transfer means 106 and the second vessel 106 than is the second set of spaced inlets 116, 118, 120, and 122. Typically, the members of first set of spaced inlets 108, 110, 112, and 114 are spaced equidistantly around the perimeter of the second vessel 106. This is shown in FIG. 2, which shows a top view of the second vessel 106. Similarly, typically, as shown in FIG. 3, the members of the second set of spaced inlets 116, 118, 120, and 122 are also spaced equidistantly around the perimeter of the second vessel or comminutor 106. This is shown in FIG. 3, which shows a bottom view of the second vessel 106. The first and second set of spaced inlets 108, 110, 112 and 114 and 116, 118, 120, and 122 are connected to a tank of inert gas 124. The inert gas can be nitrogen, helium, argon, neon, or xenon. Preferably, in most applications, the inert gas is nitrogen. However, if a component in the composition reacts with nitrogen, another inert gas can be used. The tank 124 is connected with the first and second sets of spaced inlets 108, 110, 112, and 114 and 16, 118, 120, and 122 through a distribution pipe 126 and a manifold/regulator 128, as is conventional in the art of gas distribution.

[0071] The second vessel 106 is in communication with a second transfer means 130. Preferably, the second transfer means 130 is an auger. The second transfer means 130 includes an inlet 132 for an inert gas as described above. The inlet 132 is in communication with the tank 124 of inert gas through the distribution pipe 126 and the manifold/regulator 128, as described above.

[0072] The second transfer means 130 is also in communication with a filler unit 134. The filler unit 134 includes an inlet 136 for an inert gas. The inlet 136 is in communication with the tank of inert gas 124 through the distribution pipe 126 and the manifold/regulator 128 as described above. The comminuted composition is transferred by the filler unit 134 into an opaque, oxygen impermeable container 138, such as a pouch, for sealing. The composition passes through a fritted diffusor 140, preferably a metal housing fitted with fritted tubing or a plate or tubing with pores that diffuse the inert gas into the composition. The size of the pores can be varied according to the size of the particles of the composition. The headspace of the filled container is then flushed with the inert gas using the fritted metal plate or tubing. The filled container is then sealed.

[0073] Typically, the process is carried out in less than about 20 minutes in a temperature of less than about 100° F. and in the presence of light of a wavelength not greater than that of red light of an intensity not greater than that of a dark room light. These conditions inhibit oxidation of the components of the composition.

[0074] The use of a comminutor as part of the second vessel 106 is described. The use of a comminutor requires the use of a high speed cutting process of size reduction/blending of the ingredients of the composition. More particularly, this method incorporates the unique concept of simultaneous size reduction and intimate blending of the premix supplement ingredients, including whole, unground grains and seeds and powdered (dry) additional ingredients, using an arrangement of equipment to rapidly move the ingredients into opaque, oxygen barrier packaging in under 5 minutes, most preferably in under 2 minutes. Specifically, the concept of, and the equipment for, accomplishing a one step process of premixed ingredients through a high speed size reduction/blending and thence directly into opaque, oxygen barrier packaging is unique.

[0075] The premix of all the formula ingredients including a whole, unground oil seed with the use of powdered forms of molasses, honey, glycerin, or similar carbohydrate-containing ingredients that promote stickiness or tackiness, allows for staged and inventoried material. This material is stable until further processing and is ready, in the quantities desired, for the comminutor process. The high speed, simultaneous size reduction and intimate blending releases the natural oils, essential fatty acids and naturally occurring antioxidants which then coat the other ingredients. This gives the supplement formulation an effective temporary stabilization against oxidation and free radical chemical reactions. The addition of special packaging and handling of the products imparts a shelf-life of up to 15 months from the date of production. Use of a reclosure method and maintenance of the package at normal room temperature imparts a period of stabilization for at least 90 days from the date of opening.

[0076] The process was developed in cooperation with Urschel Laboratories, Inc. and with Quadro Engineering, Inc., using the Urschel Comitrol Processor Model 1700 and the Quadro Comitrol Model 197. Research and cooperation with Urschel in which the concept of the present invention of using the proper combination of impellers, cutterhead design, cutterhead knife spacing and rate of operation of the machine in terms of rpm to simultaneously and intimately reduce in size and blend the formula ingredients is unique. The ability to produce a dry product by this method was a surprising and unexpected result as it was expected that the dry products would: plug or jam the machine; raise the processing temperature above 100° F. (37° C.), not be accomplished at satisfactory or economical production rates; or leave grains and seeds uncut or unsatisfactorily cut and poorly blended with the other ingredients.

[0077] Urschel equipment is size reduction equipment, not thought to be suitable for use in a simultaneous size reduction/blending process at low temperatures (under 100° F. (37° C.)). However, such equipment was unexpectedly found suitable for use with the present invention as part of the second vessel 106.

[0078] Preferably, the Urschel 1700 Comitrol Processor is fitted with a 15 to 45 horse power motor, either a 30 blade impeller or straight impeller, a type “B”, 3 inch high slicing head or cutting head with 0.010 thousandths of an inch horizontal thickness of separators, and 0.010 to 0.080 thousandths of an inch opening between horizontal separators, operating at 2200 to 6000 rpm. More preferably, the Urschel Model 1700 Comitrol Processor is fitted with a 30 horse power motor, a straight impeller, a type “B” 3 inch high cutting head with 0.010 thousandths of an inch horizontal thickness of separators, and 0.020 to 0.060 thousandths of an inch opening between horizontal separators, operating between 2500 and 5800 rpm. Most preferably, the Urschel 1700 Comitrol Processor is fitted with a 30 horse power motor, a straight impeller, type “B” 3 inch high cutting head with 0.010 thousandths of an inch thickness of separators, and 0.040 thousandths of an inch opening between horizontal separators, operating between 3600 and 5650 rpm.

[0079] The mixing process of the present invention only requires that a thorough blending of the ingredients takes place and can be accomplished in a variety of mixer or blender types familiar to those skilled in the art of blending equipment. First, a suitable premix of ingredients is prepared. This is done by standard methods to provide a mixture suitable for processing in the Comitrol Processor or other suitable processor. For example, the ingredients, including a spray-dried form of blackstrap molasses and whole, unground grains or seeds, can be mixed in a “V” blender of a size appropriate for the production capacity desired. This premix can be inventoried (stored or staged) in mini bulk bags, barrels, or other suitable containers until the processing step is initiated. Operating production rates for the Comitrol Processor are between 2,000 and 3,000 pounds per hour depending on the rpm selected and how fine a grind is desired. Typically, a coarser blend is produced at 3,600 rpm at a production feed rate of 2,000 pounds per hour (see Table I). Most preferably, a finer blend is produced at 5,634 rpm at production feed rates of 2,700 pounds per hour (Table I). 1 TABLE I EFFECT OF VARIATION OF OPERATING CONDITIONS OF COMMINUTOR TEST A TEST B 3600 rpm, 2000 lb/hr 5634 rpm, 2700 lb/hr Standard % Passing Standard % Passing Gauge Size Through Screen Gauge Size Through Screen +10 trace +10  0% +16  9% +16  4% +20 22% +20 17% +30 19% +30 19% −30 50% −30 60%

[0080] Other equipment that uses the “comminutor” principle of size reduction can be used to accomplish the results found using the Urschel Model 1700. For example, the Model 194 or 197 Comitrol made by Quadro Engineering, fitted with proper impellers and cutting screens, can be used as an alternative. The Quadro equipment is preferred for small production rates.

[0081] Once the material exits the size reduction/blending step, it is directed into automatic weigher/dispenser machines (such as All Fill automated weigher/dispensers). A special component was developed to direct and divide the exiting material to several automatic weigher/dispensers, as production demands; however, the process does not require the use of multiple automated weigher/dispensers. If multiple automated weigher/dispensers are used, the key factor is to set the rate the material exits the comminutor to the rate the container lines are running. The container production line can be of any degree of sophistication to accomplish the production requirements and is readily determinable by one skilled in the art of production line engineering. The exiting composition is to be dispensed into and sealed in inert gas flushed, oxygen impermeable containers, preferably in under 5 minutes, but most preferably in under 2 minutes. Optionally, the oxygen impermeable containers that have been inert gas flushed also include an oxygen absorber packet.

[0082] Although Applicants do not intend to be bound by any particular theory, it is believed that a composition that is prepared according to the present invention, when consistently fed to humans or animals over time, results in general and specific improvements in health due to preservation of the ingredients in their natural state by the action of:

[0083] (1) an intimate blending and dispersing of the naturally occurring antioxidants over the particles;

[0084] (2) a minimization of exposure to oxygen due to the one step processing technique;

[0085] (3) a minimization of exposure to light due to the one step processing technique;

[0086] (4) the minimization of exposure to heat;

[0087] (5) the minimization of lapsed time from exiting the Comitrol to filling the composition in opaque, oxygen barrier containers due to the one step processing technique;

[0088] (6) the coating action of naturally occurring antioxidants and other related compounds, caused by the action of the premixed ingredients being guided to the center of a high speed rotating impeller in which the centrifugal force moves product outward to the empowered tips which carry it passed the cutting edges of the stationary reduction head of the Comitrol Processor;

[0089] (7) the exclusion of pro-oxidant metals; and

[0090] (8) the antioxidant properties of other ingredients included in the formulation, such as rice bran.

[0091] Natural antioxidant ingredients include compounds such as tocopherols, carotenes, quinones, sterols, terpenes, bioflavonoids, polyphenols, polycyclic anthraquinones, and antioxidant pigments.

[0092] A number of compositions can be prepared using a process according to the present invention. One example of a composition that can be prepared according to the present invention consists essentially of at least 70% by weight of an oil seed constituent, at least 8% by weight of an additional plant constituent, and at least 4% by weight of yeast. The composition can further comprise an animal constituent.

[0093] The oil seed constituent can be selected from the group consisting of flax seeds, hemp seeds, buckwheat, sunflower seeds, sesame seeds, grain germs, chia seeds, kukui seeds, perilla seeds, tung seeds, and mixtures thereof.

[0094] The additional plant constituent can be selected from the group consisting of grains, kelp, vegetables, fruits, legumes, herbs, grain germs, and mixtures thereof Other ingredients such as equisetum (horsetail) herb, garlic, and other natural products having desirable effects, can also be used.

[0095] A first particularly preferred composition that can be prepared using the method of the present invention comprises:

[0096] (1) grains and seeds;

[0097] (2) a mixture of rice, bran, liver, and yeast;

[0098] (3) a mixture comprising alfalfa, carrot, apple, bone meal, and fish meal;

[0099] (4) a mixture comprising oyster, powdered kelp, powdered garlic, deoiled soybean lecithin, yeast, essential nutrients, and natural antioxidants.

[0100] Preferably, the grains and seeds comprise about 70 to 75% of the composition. The mixture of rice bran, liver, and yeast comprise about 14% to about 16% of the composition. The mixture comprising alfalfa, carrot, apple, bone meal and fish meal comprise about 4% to about 6% of the composition. The mixture comprising oyster, powdered kelp, powdered garlic, deoiled soybean lecithin, yeast, essential nutrients, and natural antioxidants comprises about 1% to 2% of the composition.

[0101] In the specification, references to percentages of the composition always refer to percentages by weight unless otherwise specified.

[0102] Another particularly preferred composition that can be prepared by methods according to the present invention comprises:

[0103] (1) flaxseed;

[0104] (2) yeast;

[0105] (3) rice and bran;

[0106] (4) liver;

[0107] (5) alfalfa;

[0108] (6) bone;

[0109] (7) carrot;

[0110] (8) fish meal;

[0111] (9) oyster;

[0112] (10) kelp;

[0113] (11) lecithin;

[0114] (12) garlic; and

[0115] (13) taurine.

[0116] Preferably, the flax seeds comprise about 71% to about 73% of the composition, the yeast comprises about 5% of the composition, the rice and bran comprise about 5% of the composition, the liver comprises about 4% of the composition, the alfalfa comprises about 2% of the composition, the bone comprises about 1% of the composition, the carrot comprises about 1% of the composition, the fish meal comprises about 1% of the composition, the oyster comprises about 1% of the composition, the kelp comprises about 0.15% of the composition, the lecithin comprises about 0.05% of the composition, the garlic comprises about 0.01% of the composition, and the taurine comprises about 0.05% of the composition. This composition is formulated for cats.

[0117] Another composition that can be prepared by methods according to the present invention comprises:

[0118] (1) flax seeds;

[0119] (2) yeast;

[0120] (3) rice and bran;

[0121] (4) liver;

[0122] (5) alfalfa;

[0123] (6) bone;

[0124] (7) carrot;

[0125] (8) fish meal;

[0126] (9) oyster;

[0127] (10) kelp;

[0128] (11) lecithin; and

[0129] (12) garlic.

[0130] In this composition, preferably, the flax seeds comprise about 71% to about 73% of the composition, the yeast comprises about 5% of the composition, the rice and bran comprise about 5% of the composition, the liver comprises about 4% of the composition, the alfalfa comprises about 2% of the composition, the bone comprises about 1.5% of the composition, the carrot comprises about 1% of the composition, the fish meal comprises about 0.5% of the composition, the oyster comprises about 0.1% of the composition, the kelp comprises about 0.1% of the composition, the lecithin comprises about 0.05% of the composition, and the garlic comprises about 0.01% of the composition. This composition is formulated for dogs.

[0131] Another composition that can be prepared by methods according to the present invention comprises:

[0132] (1) flax seeds;

[0133] (2) yeast;

[0134] (3) rice and bran;

[0135] (4) liver;

[0136] (5) alfalfa;

[0137] (6) bone;

[0138] (7) carrot;

[0139] (8) apple;

[0140] (9) kelp;

[0141] (10) lecithin; and

[0142] (11) garlic.

[0143] Preferably, in this composition, the flax seeds comprise from about 71% to about 73% of the composition, the yeast comprises about 4% of the composition, the rice and bran comprise about 6% of the composition, the liver comprises about 1% of the composition, the alfalfa comprises about 3.5% of the composition, the bone comprises about 0.5% of the composition, the carrot comprises about 2.5% of the composition, the apple comprises about 1.5% of the composition, the kelp comprises about 0.02% of the composition, the lecithin comprises about 0.03% of the composition and the garlic comprises about 0.01% of the composition. This composition is formulated for horses.

[0144] Another composition that can be prepared according to the methods of the present invention comprises:

[0145] (1) flax seeds;

[0146] (2) yeast;

[0147] (3) rice and bran;

[0148] (4) liver;

[0149] (5) alfalfa;

[0150] (6) bone;

[0151] (7) carrot;

[0152] (8) fish meal;

[0153] (9) oyster;

[0154] (10) kelp;

[0155] (11) lecithin;

[0156] (12) garlic; and

[0157] (13) taurine.

[0158] Preferably, the flax seeds comprise about 71% to about 73% of the composition, the yeast comprises about 5% of the composition, the rice and bran comprise about 5% of the composition, the liver comprises about 4% of the composition, the alfalfa comprises about 2% of the composition, the bone comprises about 1% of the composition, the carrot comprises about 1% of the composition, the fish meal comprises about 0.1% of the composition, the oyster comprises about 0.1% of the composition, the kelp comprises about 0.1% of the composition, the lecithin comprises about 0.03% of the composition, the garlic comprises about 0.01% of the composition, and the taurine comprises about 0.02% of the composition. This composition is formulated for mink and foxes.

[0159] Another composition that can be prepared by methods according to the present invention comprises:

[0160] (1) flax seeds;

[0161] (2) yeast;

[0162] (3) rice and bran;

[0163] (4) liver;

[0164] (5) alfalfa;

[0165] (6) bone;

[0166] (7) carrot;

[0167] (8) fishmeal;

[0168] (9) apple;

[0169] (10) kelp;

[0170] (11) lecithin; and

[0171] (12) garlic.

[0172] In this composition, preferably, the flax seeds comprise about 71% to about 73% of the composition, the yeast comprises about 5% of the composition, the rice and bran comprise about 6% of the composition, the rice and bran comprise about 6% of the composition, the liver comprises about 1% of the composition, the alfalfa comprises about 3.5% of the composition, the bone comprises about 0.5% of the composition, the carrot comprises about 2.5% of the composition, the fish meal comprises about 0. 1% of the composition, the apple comprises about 0.5% of the composition, the kelp comprises about 0.2% of the composition, the lecithin comprises about 0.03% of the composition, and the garlic comprises about 0.01% of the composition. This composition is formulated for rabbits.

[0173] Another composition that can be prepared according to methods of the present invention comprises:

[0174] (1) flax seeds;

[0175] (2) yeast;

[0176] (3) rice and bran;

[0177] (4) liver;

[0178] (5) alfalfa;

[0179] (6) bone;

[0180] (7) carrot;

[0181] (8) apple;

[0182] (9) kelp;

[0183] (10) lecithin;

[0184] (11) garlic;

[0185] (12) taurine;

[0186] (13) equisetum herb; and

[0187] (14) carnitine.

[0188] Preferably, the flax seeds comprise about 71% to about 73% of the composition, the yeast comprises about 5% of the composition, the rice and bran comprise about 6% of the composition, the liver comprises about 2% of the composition, the alfalfa comprises about 2% of the composition, the bone comprises about 1% of the composition, the carrot comprises about 2% of the composition, the apple comprises about 2% of the composition, the kelp comprises about 0.07% of the composition, the lecithin comprises about 0.01% of the composition, the garlic comprises about 0.01% of the composition, the taurine comprises about 0.02% of the composition, the equisetum herb comprises about 0.01% of the composition, and the carnitine comprises about 0.01% of the composition. This composition is formulated for humans.

[0189] Other ingredients can also be included, such as vitamins, antioxidants, lipids, minerals, and other ingredients commonly found in food supplements.

[0190] Another aspect of the present invention is an apparatus for carrying out the above process.

[0191] In general, the apparatus comprises:

[0192] (1) a first vessel;

[0193] (2) a hollow first transfer means communicating with the first vessel and a second vessel;

[0194] (3) a second transfer means communicating with the second vessel; and

[0195] (4) a filler to transfer the composition from the second transfer means to an opaque, oxygen impermeable container, such as a pouch, where at least two of the second vessel, the second transfer means and the filler include an inlet for the inert gas to purge oxygen from the composition.

[0196] Preferred embodiments of the process described above are reflected in the apparatus. For example, it is generally preferred that the second vessel includes multiple inlets for the inert gas. In one preferred arrangement of the apparatus, the second vessel can include two sets of inlets for the inert gas, the members of each set being located equidistantly around the vessel. In this arrangement, it is generally preferred for each set to include four inlets. Alternatively, however, the second vessel can have two inlets, one located closer to the junction of the first transfer means and the second vessel and the other located closer to the junction of the second transfer means and the second vessel.

[0197] It is also generally preferred to have inlets for inert gases in communication with both the second transfer means and the filler.

[0198] When the filler includes an inlet for inert gas, it is also generally preferred for the filler to include a fritted metal tube or tubing to minimize disruption of the composition that would otherwise be caused by the flow of the inert gas when it passes through the filler.

[0199] It is also generally preferred for the second vessel to include a comminutor or other type of mixer to blend, grind, homogenize, or reduce to powder the contents of the second vessel as described above.

[0200] It is also generally preferred for the second transfer means to include an auger, as described above.

ADVANTAGES OF THE PRESENT INVENTION

[0201] Methods according to the present invention provide improved processing of perishable materials such as foodstuffs, protecting them from degradation caused by oxygen. These methods are rapid, efficient, and suitable for packaging a wide variety of such materials. They provide increased stability and shelf life of the packaged materials. These methods are adaptable to wide variations in the volume of the materials to be packaged.

[0202] Although the present invention has been described herein in detail with respect to certain preferred embodiments thereof, it will be clear to those skilled in the art that various changes and modifications can be made without departing from the invention. Therefore, the scope of the invention is to be determined by the following claims.

Claims

1. A method for packaging a composition susceptible to degradation by oxygen comprising the steps of:

(a) providing a composition to be packaged in a first vessel;

(b) transferring the composition through a hollow first transfer means from the first vessel to a second vessel;

(c) transferring the composition to a second transfer means;

(d) transferring the composition from the second transfer means to an opaque, oxygen impermeable container via a filler, where at least two of the second vessel, the second transfer means, and the filler include an inlet for the inert gas to purge oxygen from the composition; and

(e) sealing the container.

2. The method of

claim 1 wherein the second vessel includes an inlet for the inert gas.

3. The method of

claim 1 wherein both the second transfer means and the filler include an inlet for the inert gas.

4. The method of

claim 1 wherein the filler includes an inlet for the inert gas and the filler further includes a fritted diffusor.

5. The method of

claim 1 wherein the second vessel includes at least two inlets for the inert gas.

6. The method of

claim 5 wherein the second vessel includes multiple sets of inlets for the inert gas, each set being spaced equidistantly around the perimeter of the second vessel.

7. The method of

claim 6 wherein the second vessel includes two sets of four inlets for the inert gas.

8. The method of

claim 1 wherein the second vessel includes means for performing size reduction and blending of the composition.

9. The method of

claim 8 wherein the means for performing size reduction and blending of the composition is a comminutor.

10. The method of

claim 1 wherein the second transfer means includes an auger.

11. The method of

claim 1 wherein the inert gas is selected from the group consisting of nitrogen, helium, argon, neon, and xenon.

12. The method of

claim 11 wherein the inert gas is nitrogen.

13. A method for packaging a comminuted composition susceptible to degradation by oxygen comprising the steps of:

(a) providing a composition to be comminuted in premixed form in a first vessel;

(b) transferring the premixed composition through a hollow first transfer means from the first vessel to a second vessel;

(c) comminuting the composition in the second vessel, the second vessel including at least two sets of multiple spaced inlets for inert gas such that the inert gas backflows into at least the hollow first transfer means, and such that the first set of spaced inlets is located closest to the hollow first transfer means;

(d) transferring the comminuted composition to a second transfer means, the second transfer means including an inlet for an inert gas so that inert gas permeates the second transfer means and the comminuted composition within the second transfer means;

(e) transferring the comminuted composition from the second transfer means to an opaque, oxygen impermeable container;

(f) expelling oxygen from the pouch by introducing an inert gas from an inlet for an inert gas in communication with the container; and

(g) sealing the container.

14. The method of

claim 13 wherein the inert gas is selected from the group consisting of nitrogen, helium, argon, neon, and xenon.

15. The method of

claim 14 wherein the inert gas is nitrogen.

16. The method of

claim 13 wherein the process is carried out at a temperature of less than about 100° F. and in the presence of light of a wavelength not greater than that of red light and of an intensity not greater than that of a darkroom light to thereby inhibit oxidation of the components of the comminuted composition.

17. The method of

claim 13 wherein the ingredients of the composition are reduced to a size where about 5% to about 35% of the components can pass through a #30 U.S. Standard Screen.

18. The method of

claim 17 wherein the ingredients of the composition are reduced to a size where about 8% to about 25% of the ingredients can pass through a #30 U.S. Standard Screen.

19. The method of

claim 13 wherein the second transfer means comprises an auger.

20. The method of

claim 13 wherein the first set of multiple spaced inlets for an inert gas comprises four inlets spaced equidistantly around the perimeter of the second vessel.

21. The method of

claim 13 wherein the second set of multiple spaced inlets for an inert gas comprises four inlets spaced equidistantly around the perimeter of the second vessel.

22. A method for packaging a comminuted composition susceptible to degradation by oxygen comprising the steps of:

(a) providing a composition to be comminuted in premixed form in a first vessel;

(b) transferring the premixed composition through a hollow first transfer means from the first vessel to a second vessel;

(c) comminuting the composition in the second vessel, the second vessel including:

(i) a first set of multiple spaced inlets for nitrogen that includes four inlets spaced equidistantly in the perimeter of the second vessel; and

(ii) a second set of multiple spaced inlets for nitrogen that includes four inlets spaced equidistantly in the perimeter of the second vessel;

such that the nitrogen backflows into at least the hollow first transfer means, and such that the first set of spaced inlets is located closest to the hollow transfer means;

(d) transferring the comminuted composition to a second transfer means, the second transfer means including an auger, the second transfer means further including an inlet for nitrogen so that nitrogen permeates the second transfer means and the comminuted composition transferred to the second transfer means;

(e) transferring the comminuted composition from the second transfer means to an opaque, oxygen impermeable container;

(f) expelling oxygen from the container by introducing nitrogen from an inlet for nitrogen in communication with the container; and

(g) sealing the container.

23. An apparatus for packaging a composition comprising:

(a) a first vessel;

(b) a hollow first transfer means communicating with the first vessel and a second vessel;

(c) a second transfer means communicating with the second vessel; and

(d) a filler to transfer the composition from the second transfer means to an opaque, oxygen impermeable container, where at least two of the second vessel, the second transfer means and the filler includes an inlet for the inert gas to purge oxygen from the composition.

24. The apparatus of

claim 23 wherein the second vessel includes an inlet for the inert gas.

25. The apparatus of

claim 23 wherein both the second transfer means and the filler include an inlet for the inert gas.

26. The apparatus of

claim 23 wherein the filler includes an inlet for the inert gas and the filler further includes a fritted diffusor.

27. The apparatus of

claim 23 wherein the second vessel includes at least two inlets for the inert gas.

28. The apparatus of

claim 27 wherein the second vessel includes multiple sets of inlets for the inert gas, each set being spaced equidistantly around the perimeter of the second vessel.

29. The apparatus of

claim 28 wherein the second vessel includes two sets of four inlets for the inert gas.

30. The apparatus of

claim 23 wherein the second vessel includes means for performing size reduction and blending of the composition.

31. The apparatus of

claim 30 wherein the means for performing size reduction and blending of the composition is a comminutor.

32. The apparatus of

claim 23 wherein the second transfer means includes an auger.

34. The apparatus of

claim 23 wherein the inert gas is selected from the group consisting of nitrogen, helium, argon, neon, and xenon.

35. The apparatus of

claim 34 wherein the inert gas is nitrogen.