In-package hydration, cooking, and pasteurization

Abstract

This invention relates to a method for combining the multiple steps of hydration, cooking, and pasteurization of a food product into one simplified process. In one embodiment, this invention relates to a method for in-package hydration, cooking and pasteurization of a food product in a single step comprising (a) combining at least one low moisture food component and an aqueous based component in a heat-stable, sealable container wherein an effective amount of the aqueous based component is present to allow proper hydration and cooking; (b) sealing the heat-stable, sealable container; and (c) treating the sealed container at a temperature and time effective to hydrate, cook, and pasteurize the low moisture food product in a single step.

Description

FIELD OF THE INVENTION

This invention generally relates to food processing. More specifically, this invention relates to a method for combining the multiple steps of hydration, cooking, and pasteurization of a low moisture food product in a single process step. The food products which can be treated using the methods of this invention include, for example, dry pasta, dry rice, dehydrated potato, and the like, as well as mixtures thereof.

BACKGROUND OF THE INVENTION

“Ready to eat” and “ready to heat” food products are high in consumer demand. The manufacture of these high quality processed foods typically involves multiple time consuming and labor intensive processes. Specifically, separate processes of hydration, cooking, and pasteurization are involved in the manufacture of these high quality processed food products and are performed separately from each other. As a result, such conventional processes require the use of multiple containers and process steps and utilize unnecessary energy. Moreover, excess solid and/or liquid wastes are produced from the execution of these processes in separate steps and containers.

The separate processes of hydration, cooking, and pasteurization are not new in the art. In fact, in-package pasteurization is well known. For example, U.S. Pat. No. 6,797,308 (Sep. 28, 2004) relates to the stabilization of cooked pasta compositions against the development of toxins and other contaminates. In essence, U.S. Pat. No. 6,797,308 teaches a method of pasteurizing a food product inside its final package.

U.S. Pat. No. 5,695,801 (Dec. 9, 1997) provides a method for producing shelf-stable, uncooked or partially cooked moist pasta by treating the pasta with steam, immersing the pasta in an aqueous solution containing acidulants and/or humectants, allowing the pasta to dry, sealing the pasta into a container, and pasteurizing the pasta within the container using conventional thermal processes.

U.S. Pat. No. 6,136,355 (Oct. 24, 2000) provides a process for the manufacture of instant cooking pasta or noodles by heating dry pasta with either wet or dry heat, drying the surfaces of the pasta if the heating is effected with wet heat, and packaging the pasta into a sealable container. The food product is then later reheated within the package.

U.S. Patent Application, publication no. 20040156960, filed Feb. 10, 2003, entitled “Food Product Preservation Method” teaches a method for preservation of a food product which comprises combining a food product with an amount of an edible acid to obtain an acidified food product, placing the acidified food product in a heat-stable, sealable container, sealing the container, pasteurizing the food product and then rapidly reducing the temperature to below about 55° F. The food product is then stored under refrigerated conditions and then later reheated.

Although previous methods have produced acceptable “ready to eat” and “ready to heat” food products, there remains a need for even further improvements. These previous methods only teach in-package pasteurization. They neither teach nor suggest in-package hydration, cooking and pasteurization in a single step. The present invention addresses these needed improvements. Indeed, the present method allows the various manufacturing processes of hydration, cooking, and pasteurization to be completed in a single step to obtain high quality finished products with consistent, and organoleptic pleasing, textural properties.

SUMMARY OF THE INVENTION

The present invention provides a method which allows the combination of the multiple steps of hydration, cooking, and pasteurization in a single step that occurs within a food product's sealed and final container. The present invention reduces the number of containers and/or process steps, which can be translated into consumer friendly and lower cost products. In contrast to separate process steps using conventional processes, the present invention, by combining heating steps (e.g. cooking and pasteurization), also minimizes the total heat treatment received by the finished food products, thus improve the organoleptic and nutritional quality. Further advantages of the present method are the reduction of liquid and solid waste, the utilization of less energy in the manufacture of these high quality processed food products, and reduced risk of contamination since transfer of the food product from one process to the next is eliminated.

More specifically, this invention relates to a method for in-package hydration, cooking, and pasteurization of a low moisture food product in a single step, said method comprising (a) combining at least one low moisture food component and an aqueous based component in a heat-stable, sealable container wherein an effective amount of the aqueous based component is present to allow proper hydration and cooking; (b) sealing the heat-stable, sealable container; and (c) treating the sealed container at a temperature and time effective to hydrate, cook, and pasteurize the low moisture food product in a single step. The food product within the sealed container preferably is agitated for at least a portion of the time when it is treated at a temperature and time effective to hydrate, cook, and pasteurize the food product in a single step. The low moisture food components which can be used in the methods of this invention include, but are not limited to, dry pastas, dry rice, dehydrated potatoes, dried cereals or grains, dried beans or legumes, dried vegetables, dried meats, dried seafood, dried spices or herbs, and the like, as well as mixtures thereof. Generally, the preferred low moisture food components for use in the present invention are dry pastas, dry rice, and dehydrated potatoes. The aqueous based components which can be used in the methods of this invention include, for example, water, aqueous solutions, aqueous emulsions, aqueous dispersions, sauces, gravies, milk, whey, cream, syrups, juices, extracts, and the like, as well as mixtures thereof.

In a preferred embodiment, this invention relates to a method for in-package hydration, cooking, and pasteurization of a low moisture food product in a single step, said method comprising (a) combining at least one low moisture food component and an aqueous based component in a heat-stable, sealable container wherein an effective amount of the aqueous based component is present to allow proper hydration and cooking; (b) adding at least one ingredient selected from the group consisting of preservatives, antioxidants, acidulants, stabilizers, salt, sweeteners, flavors, colorants, and combinations thereof; (c) sealing the heat-stable, sealable container; (d) treating the sealed container at a temperature and time effective to hydrate, cook, and pasteurize the low moisture food product in a single step; (e) agitating the sealed container during at least a portion of step (d); and (e) cooling the hydrated, cooked, and pasteurized food product to a proper storage temperature. The at least one ingredient in step (b) may be added or introduced into the container as a separate ingredient and/or with the low moisture food component or aqueous based component in step (a).

DETAILED DESCRIPTION

This invention relates to a method for combining the multiple steps of hydration, cooking, and pasteurization of a food product into a simplified, one-step process. This invention relates to a method for in-package hydration, cooking, and pasteurization of a low moisture food product in a single step, said method comprising (a) combining at least one low moisture food component and an aqueous based component in a heat-stable, sealable container wherein an effective amount of the aqueous based component is present to allow proper hydration and cooking; (b) sealing the heat-stable, sealable container; and (c) treating the sealed container at a temperature and time effective to hydrate, cook, and pasteurize the low moisture food product in a single step. The sealed container is preferably agitated during at least a portion of step (c). The low moisture food components which can be treated using the methods of this invention include, but are not limited to, dry pastas, dry rice, dehydrated potatoes, dried cereals, dried grains, dried beans, dried legumes, dried vegetables, dried meats, dried seafood, dried spices or herbs, and the like, as well as mixtures thereof. Generally, the preferred low moisture food components for use in the present invention are dry pastas, dry rice, and dehydrated potatoes. The aqueous based components which can be used in the methods of this invention include, for example, water, aqueous solutions, emulsions, or dispersions (e.g., acidulants, nisin-containing ingredients, broths, and the like), sauces, gravies, milk, whey, cream, syrups, juices, extracts, and the like, as well as mixtures thereof.

The relative amounts of the low moisture food component and the aqueous based component should be maintained at levels to provide an acceptable finished food product. In one embodiment, the amount of aqueous based component should be sufficient to cover the low moisture food component. In another embodiment, the relative amounts should be adjusted so that, for the finished food product, most (e.g., greater than about 50 percent), and in some cases essentially all of the water is absorbed. In another embodiment, the amount of the aqueous based component in the form of a sauce should be sufficient to maintain a sauce in the finished food product. In another embodiment, the relative amounts of low moisture food component and aqueous based component should be adjusted so that, the food component reaches optimum degree of hydration and texture after the process. In yet another embodiment, the ratio of low moisture food component and aqueous based component is in the range of about 10:90 to about 70:30, and preferably about 20:80 to about 60:40. For a given low moisture food component, a given aqueous based component, and a given desired finished product, one of ordinary skill in the art can readily determine appropriate relative amount. By controlling the amount of aqueous based component added to each sealed container common textural defects due to under- or over-hydration that can occur with traditional hydration processes can be avoided.

The present invention represents a significant simplification in the manufacturing of high quality prepared foods (e.g., “ready to eat” or “ready to heat” foods). This simplified manufacturing process is made possible by combining hydration, cooking, and pasteurization in a single processing step and a single container. Secondary microbiological barriers (e.g., acidulants, salt, chemical preservatives, biological preservatives, and the like, as well as mixtures thereof) may also be combined with this simplified manufacturing process.

Preferably, the food products of this invention are contained in a heat-stable, sealable plastic pouch such that the food products can be hydrated, cooked, and pasteurized directly in the pouch. Similar heat-stable, sealable containers that may be used in the method of this invention include cans, glass bottles, tubs, trays, and the like. Indeed, one of the advantages of the present invention is that the multiple processes of hydration, cooking, and pasteurization, which would conventionally occur in separate steps, can now occur in a simplified process in a single step thereby eliminating multiple processes and multiple containers.

In addition to the low moisture food component and the aqueous based component, additional ingredients may be added before the heat-stable container is sealed. Such ingredients may include preservatives, acidulants, antimicrobials, bactericins, antioxidants, flavorants, colorants, spices, salt, seasonings, sweeteners, stabilizers, and the like, as well as mixtures thereof. The addition of preservatives (e.g., sorbic acid, benzoic acid, propionic acid, lactic acid, diacetic acid, and salts thereof as well as combinations thereof, acidulants (e.g., food grade acids such as hydrochloric acid, sulfuric acid, metal acid sulfates, phosphoric acids, tartaric acid, fumaric acids, citric acid, lactic acid, gluconic acid, and the like), antimicrobials (e.g., nisin, nisin-containing cultured whey or milk, poly-L lysine, lysozyme, natamycin, and the like as well as combinations thereof), bactericins, and antioxidants will not only extend the shelf life of the finished products, but it will also provide additional safety and/or preservation. Such additives may be added as separate ingredients or may be added with the aqueous based component (e.g., solution, slurry, emulsion, dispersion, or the like) and/or the low moisture food component. One especially preferred antimicrobial, nisin-containing whey, which may be used in this invention is fully described in U.S. Pat. No. 6,110,509 (Aug. 9, 2000), U.S. Pat. No. 6,113,954 (Sep. 5, 2000), U.S. Pat. No. 6,136,351 (Oct. 24, 2000), U.S. Pat. No. 6,242,017 (Jun. 5, 2001), U.S. Pat. No. 6,613,364 (Sep. 2, 2003), and U.S. Pat. No. 6,797,308 (Sep. 28, 2004).

Prior to sealing the containing, the headspace above the food product and other ingredients may optionally be flushed with an inert gas (e.g., nitrogen, carbon dioxide, steam, and the like) or may be reduced using a partial vacuum.

The sealed container containing the food product and other ingredients is treated at a temperature and time effective to hydrate, cook, and pasteurize the food product in a single step. In other words, the heating profile should be effective in hydrating, cooking, and pasteurizing in a single step. Conventional heating equipment that may be used includes, but is not limited to, water baths, submersion cookers, steamers, electrical ovens, gas ovens, infrared cookers, microwave cookers, and the like, as well as combinations thereof. Preferably, the sealed container is placed in a boiling water bath for a temperature and time effective to hydrate, cook, and pasteurize the food product. Generally, the time necessary using a boiling water bath is about 1 to about 60 minutes for a conventional sized pouch (i.e., one holding about 20 to about 1000 g of food product) depending on the specific low moisture food component used.

In the preferred embodiment, this invention also relates to a method for in-package hydration, cooking, and pasteurization of a food product in a single step, said method comprising (a) combining at least one low moisture food component and an aqueous based component in a heat-stable, sealable container wherein an effective amount of the aqueous based component is present to allow proper hydration and cooking; (b) adding at least one ingredient selected from the group consisting of preservatives, antioxidants, acidulants, and any combinations thereof; (c) sealing the heat-stable, sealable container; (d) treating the sealed container at a temperature and time effective to hydrate, cook, and pasteurize the low moisture food product in a single step; (e) agitating the sealed container for at least a portion of step d); and (f) cooling the hydrated, cooked, and pasteurized food product to a proper storage temperature.

The following examples are intended to illustrate the invention and not o limit it. Unless otherwise indicated, all percentages used in the present specification are by weight. All patents and publications referred to in the present specification are hereby incorporated by reference.

EXAMPLE 1

In-package cooked/acidified shelf stable plain pasta. Dry shell pasta (about 60 g) was placed in a heat stable polyester pouch (about 5 by about 6.5 inches; SealPAK from KAPAK Corp., Minneapolis, Minn.). A sodium acid sulfate aqueous solution (0.7%; about 86 g) was added to the pasta in the pouch. Most of the air was evacuated from the pouch and the pouch was sealed. The pouch was mixed slightly and then placed in a boiling water bath. The pouch was agitated frequently in the water bath until the liquid was absorbed by the pasta (about 20 minutes). The pouch was removed from the boiling water and immediately cooled in cold water until the product reached room temperature. This process yielded fully cooked acidified shelf stable pasta at a pH of about 3.8; the product had excellent properties and was microbiologically stable for at least six months under ambient conditions.

EXAMPLE 2

In-package cooked/acidified shelf stable macaroni and cheese. An acidified sauce mixture of 45% of 0.7% aqueous sodium acid sulfate, and 55% of acidified cheese flavor sauce was prepared. The acidified cheese flavor sauce consisted of about 1.5% cheese powder, about 4.5% starch and gums, about 11% bulking agents (i.e., corn syrup solid and maltodextrin), about 9% butterfat, about 1.6% salt, about 0.18% TiO₂, about 0.45% emulsifiers, about 0.15% colors, about 0.3% flavors. The pH of the sauce mixture was about 3.85. Dry shell pasta (about 46 g) and acidified sauce mixture (150 g) was placed in a heat stable plastic pouch, as used in Example 1. Most of the air in the package was evacuated and the pouch was sealed. The pouch was mixed slightly and then placed in a boiling water bath. The pouch was agitated frequently in the water bath in the first phase of the cooking process. The pouch containing the pasta was removed from the boiling water bath after about 22 minutes and immediately cooled in cold water until the product reached temperature. This process yielded fully cooked, acidified, and pasteurized shelf stable macaroni and cheese at a pH of about 3.8; the product was microbiologically stable for at least six months under ambient conditions.

EXAMPLE 3

Refrigeration stable in-package cooked plain pasta. A nisin-containing cultured sugar solution was prepared to contain about 500 lU/ml of nisin equivalent activity (e.g., 1.0% Danisco Guardian CS1-50 in water). Dried shelf stable pasta (about 56 g) and the nisin-containing solution (about 81 g) were placed in a heat-stable, sealable plastic pouch. Most of the air in the pouch was evacuated and the pouch was sealed. The pouch was mixed slightly and then placed in the boiling water bath. The pouch was agitated frequently in the water bath. The pouch containing the pasta was removed from the boiling water bath after about 20 minutes, when all the liquid was absorbed by the pasta. The heat treated pouch was cooled in cold water until it reached a refrigerated temperature of about 40° F. This process yielded fully cooked refrigeration stable pasta that contains about 450 lU/g of nisin equivalent activity and has a pH of about 5.2; the product had excellent sensory properties and nisin activity was maintained for at least six weeks under refrigeration storage.

EXAMPLE 4

Refrigeration stable in-package cooked pasta and sauce. Nisin-containing cultured milk was added to dairy based cheese sauce to yield a nisin equivalent activity of about 400 lU/g (e.g., 0.8% Danisco Guardian CS1-50). Dried shelf stable pasta (48 g) was placed in a heat-stable, sealable plastic pouch. The nisin-containing dairy based cheese sauce was added to the pouch and most of the air was evacuated from the pouch. Evacuating the air inside the pouch could be achieved with, among other methods, a vacuum or with nitrogen flushing. The pouch was then placed in a boiling water bath and agitated for approximately 22 minutes or until the pasta was fully cooked. The pouch was then removed from the water bath and cooled quickly in a cold water bath. The process yielded fully cooked pasta in sauce that contained about 300 lU/g of nisin equivalent activity and had a pH of about 5.22. This pasta in sauce product, which had excellent organoleptic properties, was stable under refrigerated conditions for at least about three months; nisin activity was essentially unchanged after this storage period.

Other pasta and sauce (e.g., Alfredo) combinations can be prepared and used in a similar manner.

Claims

1. A method for in-package hydration, cooking, and pasteurization of a food product in a single step, said method comprising:

(a) combining at least one low moisture food component and an aqueous based component in a heat-stable, sealable container wherein an effective amount of the aqueous based component is present to allow proper hydration and cooking;

(b) sealing the heat-stable, sealable container; and

(c) treating the sealed container at a temperature and time effective to hydrate, cook, and pasteurize the low moisture food product in a single step.

2. The method as defined in claim 1, wherein the sealed container is agitated during at least a portion of step (c).

3. The method as defined in claim 1, wherein the low moisture food component is selected from the group consisting of dry pastas, dry rice, dehydrated potatoes, dried cereals, dried grains, dried beans, dried legumes, dried vegetables, and mixtures thereof.

4. The method as defined in claim 1, wherein the aqueous based component is selected from the group consisting of water, aqueous solutions, aqueous emulsions, aqueous dispersions, sauces, gravies, milk, whey, cream, syrups, juices, extracts, and mixtures thereof.

5. The method as defined in claim 1, wherein the effective amount of the aqueous based component is an amount sufficient to cover at least the low moisture food component.

6. The method as defined in claim 1, wherein the ratio of the low moisture food component and the aqueous based component is in the range of about 10:90 to about 70:30.

7. The method as defined in claim 1, wherein at least one of the ingredients selected from the group consisting of preservatives, acidulants, antimicrobials, bactericins, antioxidants, flavorants, colorants, spices, salt, seasonings, sweeteners, stabilizers, and mixtures thereof is added to the container prior to sealing.

8. The method as defined in claim 3, wherein an acidulant is added to the container prior to sealing.

9. The method as defined in claim 3, wherein an antimicrobial agent is added to the container prior to sealing and the antimicrobial agent is selected from the group consisting of nisin, nisin-containing cultured whey or milk, poly-L lysine, lysozyme, natamycin, and combinations thereof.

10. The method as defined in claim 3, wherein a preservative is added to the container prior to sealing and the preservative is selected from the group consisting of sorbic acid, benzoic acid, propionic acid, lactic acid, diacetic acid, and salts thereof as well as combinations thereof.

11. The method as defined in claim 1, wherein an antioxidant is added to the container prior to sealing.

12. The method as defined in claim 3, wherein an antioxidant is added to the container prior to sealing.

13. The method as defined in claim 4, wherein an antioxidant is added to the container prior to sealing.

14. The method as defined in claim 1, wherein the heat-stable, sealable container is a plastic pouch.

15. The method as defined in claim 3, wherein the heat-stable, sealable container is a plastic pouch.

16. The method as defined in claim 4, wherein the heat-stable, sealable container is a plastic pouch.

17. A method for in-package hydration, cooking, and pasteurization of a food product in a single step, comprising:

(a) combining at least one low moisture food component and an aqueous based component in a heat-stable, sealable container wherein an effective amount of the aqueous based component is present to allow proper hydration and cooking;

(b) adding at least one of the ingredients selected from the group consisting of acidulants, antimicrobials, antioxidants, flavorants, and mixtures thereof;

(c) sealing the heat-stable, sealable container;

(d) treating the sealed container at a temperature and time effective to hydrate, cook, and pasteurize the low moisture food product in a single step;

(e) agitating the sealed container simultaneously with at least a portion of step (d); and

(f) cooling the hydrated, cooked, and pasteurized food product to a proper storage temperature.

18. The method as defined in claim 17, wherein the low moisture food component is selected from the group consisting of dry pastas, dry rice, dehydrated potatoes, dried cereals, dried grains, dried beans, dried legumes, dried vegetables, and mixtures thereof.

19. The method as defined in claim 18, wherein the aqueous based food component is selected from the group consisting water, aqueous solutions, aqueous emulsions, aqueous dispersions, sauces, gravies, milk, whey, cream, syrups, juices, extracts, and mixtures thereof.

20. The method as defined in claim 18, wherein the effective amount of the aqueous based component is an amount sufficient to cover at least the low moisture food component.

21. The method as defined in claim 18, wherein the ratio of the low moisture food component and the aqueous based component is in the range of about 20:80 to about 60:40.

22. The method as defined in claim 18, wherein the heat-stable, sealable container is a plastic pouch.