The present invention relates to a process for faster curing of vanilla beans and production of vanilla concentrate thereby from fresh vanilla pods
Vanilla plan/folia Andr. is herbaceous, perennial vine a tropical orchid. This spice crop is grown for its pleasant aromatic essence "Vanillin". Annual world production is estimated at 3000-4000 MT. In India vanilla crop is getting established as an important spice crop (Sreekrishna Bhat and Sudharshan 2002). The genus vanilla belongs to the monocotyledonous family Orchidaceae, and perhaps is the only orchid crop, which is of economic importance as a spice, the others being valued as ornamentals. Over 100 species of vanilla have been described in scientific literature, but only three if these are considered important for commerce and cultivation. There are Vanilla fragrans Salish Ames also known as Vanilla planifolia Andrews b) Vanilla pompna Shiede and c) Vanilla tahitensis J.W Moore, of these, Vanilla planifolia is the most valued fruits flavor qualities and is therefore widely cultivated and used (Persleglove 1981). Vanilla pompna and Vanilla tahitensis yield vanilla beans of poorer quality. Green vanilla pods are almost odourless and the characteristic flavour of vanilla develops only when the mature beans are subjected to a controlled curing and conditioning process.
For Vanilla producing countries, it is mainly an export oriented flavouring material and the international market is very competitive and quality conscious for vanilla beans and vanilla based products. Hence, it will be important for the growers/processors to adopt suitable methods for processing of vanilla. The first critical phase is vanilla process is known as curing. Green vanilla pods are almost odourless and the characteristic flavour of vanilla develops

only when the mature beans are subjected to a controlled curing process. A number of procedures have been evolved for curing of vanilla but they are all characterized by 4 phases where by the green mature beans are transferred into a commercially desirable product. These phases are called killing, sweating, drying and conditioning. Killing or wilting brings about physiological death of the living tissues by respiratory function of the disrupting the cells. The cell-disruption can be carried out by subjecting the fresh beans to any one of the treatments such as hot water scalding, sun and oven wilting, scarification treatment with ethylene gas or freezing. Sweeting helps the beans to develop their characteristic color, aroma and flavoring properties. During the drying step moisture is reduced and beneficial chemical changes take place. Due to conditioning stage, the beans are stored in closed boxes and this rests for several months. Various chemical and biochemical reactions take place in this step, producing various volatile aroma constituents enhancing the overall flavour quality of the cured beans (Purseglove 1981, Randire 1984).
There are several patents on vanilla, relating to the following aspects: (i). Vanilla bean drying and curing: reference may be made to a patent (GB1205829) relates that to vanilla bean drying and curing, where mature green vanilla beans made in to half an inch long pieces and dried in elevated temperature and ambient humidity to produce cured vanilla beans, (ii) Process for curing vanilla beans: reference may be made to a US patent (2.274.120, 1942) relates that to a process for curing vanilla beans, where vanilla beans may be frozen either in air or other suitable gases, or submerged in water; thereafter thawing the beans and then drying and aging.

iii) Reference may be made to a Japanese patent (JP5095764, 1993) relates that to a method for aging vanilla bean subjecting to curing treatment and heating and aging the beans in the presence of ethanol vapour in a closed container to obtain good flavour, (iv) Method for preparation of vanilla extract: reference may be made to a Japanese patent (JP8308528, 1996) relates that to preparation of vanilla extract from cured beans using water and /or a water-soluble organic solvent, in the presence of an alkali or alkali salt; reference may be made to a Japanese patent (JP8168355, 1966) relates to the preparation of vanilla extract from cured beans employing water and /or aqueous organic solvent using the irradiation of ultrasonic waves. Another patent (JP2002038188, 2001) relates to preparation of vanilla extract from cured vanilla beans employing cocoa butter to enhance the vanilla flavour, (v) Reference may be made to the patents (JP9111285, 1997; KR255037, 2000) that relate to preparation of vanilla perfume by treating vanilla pods with specific microorganisms followed by extraction with an organic solvent, (vi) Reference may be made to a series of pants involving the use of enzymes for vanilla extract ion: (GB812443, 1959) relates to green vanilla beans being extracted in substantial absence of oxygen and the extract cured. An enzyme system can be added during or prior to the curing and concentration of the extract preferably precedes curing; W09325088, 1993 deals with bringing vanilla beans in contact with enzymes of the pectinase, cellulase and /or hemicellulase type and making a beta-glucosidase enzyme react and extracting natural vanilla flavour thus obtained; GR3022203T, 1997 relates to a process for the production of natural vanilla extract, consisting in processing crushed green vanilla pods by means of an enzymatic system capable of
destroying plant cell membrane systems and hydrolysing glycoside precursors of volatile compounds; JP2001181671,2001 relates to preparing vanilla extract by treating cured vanilla beans or its extract with at least one enzyme selected from protease, astringency / bitterness splitting enzyme and hesperidin splitting enzyme; WO2004091316, 2004 relates to a process for the preparation of a vanilla extract, the process consisting of subjecting green vanilla beans to accelerated browning followed by extractive / enzymatic treatment. US4956192, 1990 relates to the preparation of natural vanilla flavour comprising freezing green vanilla beans at 5 degree and -30 degree, thawing and then extracting the flavour constituents from the beans; US5705205, 1998 relates to enzymatic treatment of a hydrated slurry of ground dehydrated green vanilla pods, addition of enzyme consisting of 10-1000 units of beta-glucose activity per gram of green vanilla pods followed by incubation and phase separation to obtain vanilla extract (vii). Reference may be made to a byconversion process for the production of vanillin (US5279950, 1994) wherein vanillin is produced through bioconversion of vanilla precursor with a tissue culture of undifferentiated callus cells derived from a vanilla plant and / or enzymes obtained there from in the presence of a water soluble sulfhydryl compound and an assimilable carbon source. Production of novel vanilla extract using Co2 of a supercritical state (JP4214799, 1992) wherein, preparation of vanilla extract from cured beans initially by supercritical carbon di-oxide and subsequently with a polar organic solvent is reported. (Viii). Preparation of enhanced vanilla flavour: (JP58056654, 1983) has also been reported relating to preparation of vanilla flavour with enhanced fragrance by extracting a mixture of pulverized vanilla
eans or dried material with spice vegetable material of allspice, caraway, cardamom, cassia or cinnamon with a water-miscible organic solvent.The present invention deals with a process for faster curing of vanilla beans and vanilla concentrate produced thereby from fresh vanilla pods that is quite different from those reported in the above patents.
The object of present invention is to provide a method for faster curing of vanilla beans from fresh vanilla pods using controlled scalding, mechanical drying, sweating and conditioning. Another object of present invention is to prepare vanilla powder from cured bean by using suitable mill and vanilla concentrate by counter current extraction.
In the vanilla/ flavour industry, vanilla extract is produced by extraction of cured vanilla pods with aqueous alcohol followed by desolventisation to get a brown/red coloured, viscous material called the vanilla extract. The extract contains the constituents responsible for flavour namely vanillin, and other soluble components such as fats, fiber and waxes. Vanillin/ vanilla extract is useful as a flavourant in foods and confectionary items. The industry aims at producing the pure natural vanillin/vanilla extract with a high flavor value, but the quality gets restricted due to the natural composition of the vanilla with respect to flavour. The present invention aims at enhancing the extractability of vanilla constituents with acceptable flavour by a combination of suitable scalding, dehydration, sweating, conditioning, grinding, followed by extraction.
Accordingly, the present invention provides, a process for faster curing of vanilla beans and production of vanilla concentrate thereby from fresh vanilla pods, which comprises,
a) harvesting the fresh vanilla pods at right maturity,
b) grading the vanilla pods based on the size of the pods,
c) scalding the vanilla pods at 55°C± 5°C to 75°C± 5°C for 1-5
minutes,
d) removing the excess water from the scalded vanilla pods
immediately with the help of the cotton cloth,
e) wrapping the scalded beans in woolen cloth, which are lined with
white coloured cloth,
f) sweating the above wrapped beans obtained from step (e) in
wooden boxes for 24 hours,
g) controlled drying the sweated vanilla pods in hot air drier at 45°C±
5°C to 75°C± 5°C for 1 to 4 hours,
h) rolling the dried vanilla beans in woolen cloth and kept in wooden
boxes for sweating, i) repeating the step (g and h) for 6-8 days to reduce the moisture
level from 80 to 40%, j) allowing the partially dried beans on wooden shelves for 5-10 days
in properly ventilated rooms, k) conditioning of the beans in the air-tight chests or waxed paper
lined metal containers or polythene covers for about 10-15 days to
develop desired vanilla flavour,
I) grinding of cured vanilla beans by a suitable mill and pass through
the 25-40 mesh to obtain vanilla powder,
m) charging the vanilla powder to extractors preferably three and soaking in a solvent consisting of 10-90 parts of water, mixed with 10-90 parts of alcohol preferably 30-40 parts of water, with 60-70 parts of alcohol at a temperature of 25° to 50°C, n) allowing a contact time of vanilla powder with solvent up to 2 hours followed by draining of the extract simultaneously replacing the solvent without allowing the bed to dry up. This process of solvent addition, allowing contact time (up to 1hour) and draining of the extract is repeated to a material to solvent ratio of 1:6 to 1:15, o) the extract drained out from the first extractor is employed as a solvent for the material in second extractor and so on till the third extractor and the enriched extract containing 10-20 % solids is taken for preparation of vanilla concentrate, p) mixing the first two or three fractions from third extractor to obtain
natural vanilla concentrate,
In one of embodiment of the invention, the mature green vanilla beans or partially cured vanilla beans are subjected to controlled drying by means selected from a fluidized bed drier at 150-200°C for about 1-5 minutes for 10-15 days or drying in low humidity and low temperature drier at 30-40°C and 35-40% RH for about 1-5 hours for 8-10 days or vanilla beans soaked in liquid nitrogen for about 24 h followed by shade drying at 25 -40°C, to bring down the moisture content to 25-30%.
In another embodiment of the invention, fresh or stored green vanilla beans subjected to partial curing by known art involving components of holding the beans in hot water/steam, repeated exposure to hot sun, and repeated sweating of the warm beans in wooden box, as described under claim 1, to be followed by faster curing of natural vanilla as described.
In yet another embodiment of the invention, the faster cured vanilla beans having good aroma, light brown chocolate color, lathery and its contains 1-4% vanillin with a moisture content of 25-30%.
In yet another embodiment of the invention, the natural vanilla beans and its products is useful as a pharmaceutical and neutraceutical preparation with properties of quenching oxidative stress.
In yet another embodiment of the invention, the dried vanilla beans subjected to pulverizes such as hammer mill or pin mill or cryo-grinding to obtain 25-40 mesh size powder.
In yet another embodiment of the invention, charging the vanilla powder to extractors preferably three and soaking in a solvent consisting of 10-90 parts of water, mixed with 10-90 parts of alcohol preferably 30-40 parts of water, with 60-70 parts of alcohol at a temperature of 25° to 50°C,
In yet another embodiment of the invention, as an optional step, the alcoholic vanilla extract from step 1(m) is subjected to partial desolventisation at reduced pressure and clarified by filtration to obtain vanilla concentrate containing 1 - 4 % vanillin and having desirable characteristic flavour and brown color.
In yet another embodiment of the invention, the natural vanilla concentrate which has light brown color, ethyl alcohol (10-15%) and it contains 1-4% vanillin.
In yet another embodiment of the invention, the vanilla extracts contains its constituents namely vanillic acid, 4-hydroxybenzyl alcohol, 4-hydroxy-3-methoxybenzyl alcohol, 4-hydroxybenzaldehyde and vanillin in the range of 2-4% with an antioxidant activity of 40-90%.
In yet another embodiment of the invention, method of processing of vanilla concentrate has enhanced sensory flavor perception resulting in high score for vanilla flavor, pleasantness, sweet and typical floral notes
In yet another embodiment of the invention, vanilla concentrates and extracts are free from yeasts, molds, non-sporeforming mesofelic aerobic bacteria and from Bacillus cerus, a pathogenic aerobic mesophillc sporeforming bacteria, whose presence would affect the microbiological safety of the food products
freshly harvested beans were procured from vanilla gardens of Karnataka state and were subjected to size grading by manually and processed immediately. Sorting and Grading: Size and appearance get the primary importance here, since, there is a direct relationship between the aroma (or vanillin content) and these factors. The beans are classified according to their length (1) 15 cm and> (2) 10-15 cm (3) 10 cm (4) splits, cuts damaged beans. Killing/enzyme inactivation: Graded beans are transferred to a bamboo basket and immersed in hot water at a suitable temperature for few minutes. The scalded beans are quickly dried and while still very hot are wrapped in a woollen cloth. The wrapped beans are then placed in sweating
chests, which are lined with white coloured cloth. After about 24 hours of sweating, the beans are removed from the chests and dried in the hot air drier for about 3 to 4 hours, rolled up in covers to retain as much heat as possible, and taken indoors to be placed in the sweating boxes. The process is repeated for 6 to 8 days. The beans lost moisture quite rapidly and become very flexible. At the end of this period, the beans reduced half of initial weight, turn to a shining dark brown colour, develop wrinkles and also, improve their aroma. In the next phase, which lasts for a period of 6 to 8 days, the beans are allowed to dry slowly in properly ventilated rooms. During this time the beans are regularly sorted to remove those, which are adequately dried and ready for conditioning. For conditioning, the beans are placed in the air-tight chests or waxed paper lined metal containers or polythene covers for about 10-15 days. The vanillin content in the cured beans was analysed by UV-Spectrophotometric method and HPLC.
The cured beans were subjected to pin mill or cryo-grinding to obtain 25-40 mesh sieve powder. The vanilla powder was loaded into series of extractor and extracted with 60% ethyl alcohol. This process of solvent addition, allowing contact time (up to 1hour) and draining of the extract is repeated to a material to solvent ratio of 1:6. The extract drained out from the first extractor is employed as a solvent for the material in second extractor and so on till the third extractor and the enriched extract containing 10-20 % solids is taken for preparation of vanilla concentrate/extract.
Flow chart 1- (Flow Chart Removed)
Mature green vanilla beans, immediately after harvest, cured by this process will take 28 days only which otherwise takes minimum of 120-140 days in traditional curing methods. Vanilla beans of good flavour quality with typical floral aroma are obtained and the finished products such as vanilla powder, extract / concentrate are hygienic.
The following examples are given by way of illustration of the present invention and therefore should not be construed to limit the scope of the present invention.
Example 1
Fully matured green vanilla beans (50 kg) were procured from an
orchard in a local growing area and 5 kg batch each of the beans was used in
the present studies. The beans are classified according to their length (1) 15
cm and> (2) 10-15 cm (3) 10 cm (4) splits, cuts damaged beans. Graded
beans are transferred to a bamboo basket and immersed in hot water at a
temperature of 65°C± 2°C for 3 minutes. The scalded beans are quickly dried
and while still very hot are wrapped in a woollen cloth. The wrapped beans
are then placed in sweating chests, which are lined with white coloured cloth.
After about 24 hours of sweating, the beans are removed from the chests and
dried in the hot air drier for about 4 hours, rolled up in covers to retain as
much heat as possible, and taken indoors to be placed in the sweating boxes.
The process is repeated for 8 days. The beans lost moisture quite rapidly
and become very flexible. At the end of this period, the beans reduced 50% of
initial weight, turn to a shining dark brown colour, develop wrinkles and also,
improve their aroma. In the next phase, which lasts for a period of 8 days, the
beans are allowed to dry slowly in properly ventilated rooms. During this time
the beans are regularly sorted to remove those, which are adequately dried
and ready for conditioning. For conditioning, the beans are placed in the
polythene covers (250 Gaze) for about 12 days. In that period beans are
regularly inspected to ensure the development of desired finished product.
The vanilla constituents were analysed during curing process once in 8days
by HPLC and results were presented in Fig.1 and table. 1
Figure 1. HPLC pattern of Vanilla extract
(Figure Removed)
Table 1. Quantification of vanilla constituents by HPLC

Figure Removed)
Example 2
The beans (5 kg batches) are loaded into perforated cylindrical baskets
which are then immersed into vats containing hot water which is maintained at about 65° C for about 5 minutes (depend up on size), while splits and beans inferior are scalded for two minutes or less. The scalded beans (10 KG) are quickly dried and while still very hot are wrapped in a woollen cloth. The wrapped beans are then placed in sweating chests, which are lined with white coloured cloth. After about 12 hours of sweating, the beans are removed from the chests and dried in the hot air drier for about 6 hours, rolled up in covers to retain as much heat as possible, and taken indoors to be placed in the sweating boxes. The process is repeated for 6 days. The beans (4 kg) lost moisture quite rapidly and become very flexible. At the end of this period, the beans reduced half of initial weight, turn to a shining dark brown colour, develop wrinkles and also, improve their arorna.
In the next phase, which lasts for a period of 6 days, the beans are allowed to dry slowly in properly ventilated rooms. During this time the beans are regularly sorted to remove those, which are adequately dried and ready for conditioning. For conditioning, the beans are placed in the air-tight chests for about 15 days. In that period beans are regularly inspected to ensure the development of desired finished product. Satisfactorily cured beans (2.9 kg) are again graded according to size and quality then bundled and stored. The moisture present in the cured beans was analyzed using toluene co-distillation method. The vanillin content in the cured beans was analyzed by UV-Spectrophotometric method.
Example 3
The cured beans were soaked in liquid nitrogen for 24 hours and beans were subjected to pin mill to obtain 25-30 rnesh sieve powder. The vanilla powder was loaded into series of extractor and extracted with 60% ethyl alcohol. This process of solvent addition, allowing contact time (up to 1hour) and draining of the extract is repeated to a material to solvent ratio of 1:6. The extract drained out from the first extractor is employed as a solvent for the material in second extractor and so on till the third extractor and the enriched extract containing 10-20 % solids is taken for preparation of vanilla concentrate. The first 1.8 lit. of vanilla concentrate contains 3.5% vanillin, another 1.5 liters of concentrate contains 2.4% vanillin and third fraction of concentrate contains 1.8% vanillin. These extracts/ concentrates were used for food application studies
Example 4
Vanilla flavoured milk was prepared incorporating 0.1% of fractionl and 0.2% of fraction 2 and 3 obtained from example 3. The flavoured milk was evaluated using Quantitative Descriptive Analysis (QDA) among the trained panelists who had earlier participated in the evaluation of vanilla flavoured products.
As given in figure, the sample 1 is having more of vanilla concentration which is reflected in having high score for vanilla flavour, pleasantness and typical floral notes compared to milk prepared with vanilla concentrate samples 2 and 3. Milk prepared with samples 2 and 3 are having almost same sensory profile.
Fig. 2 SENSORY PROFILE OF MILK WITH VANILLA CONCENTRATE

(Figure Removed)
Example 5
Vanilla concentrates and extracts were subjected to microbiological studies. Results were presented in Table 2. Table 2. Microbiological analysis of vanilla concentrates and extracts

(Table Removed)
* Sample code 1 to 4 vanilla concentrate Sample code 5 to 7 vanilla extract
The only bacterial groups recovered are the aerobic mesophelic spore formers whose spores have survived the heat given to the samples. Bacillus
(Figure Removed)
cereus, a pathogenic aerobic mesophilic sporeformer, however, was not recovered from any of the samples.
Advantages of this process are
1. Green vanilla beans can be stored from 3 months to 1 year and withdrawn
for
processing into extract as and when needed.
2. Down stream processing for making faster curing of natural vanilla starting
from fresh vanilla pods or partially cured vanilla beans is highly economical
compared to traditional method, which takes enormous time and required
high energy.
3. Vanilla concentrate prepared with out using any chemicals / enzymes or
any preservatives
4. The end products such as vanilla powder, extract/concentrate are high
vanillin content and more hygienic compared to traditional curing

We claim,
1. A process for faster curing of vanilla beans and production of vanilla
concentrate thereof from fresh mature green vanilla pods, which
comprises,
a) harvesting the fresh vanilla pods at right maturity,
b) grading the vanilla pods based on the size of the pods,
c) scalding the vanilla pods at 55°C± 5°C to 75°C± 5°C for 1-5
minutes,
d) removing the excess water from the scalded vanilla pods
immediately with the help of the cotton cloth,
e) wrapping the scalded beans in woolen cloth, which are lined with
white coloured cloth,
f) sweating the above wrapped beans obtained from step (e) in wooden
boxes for 24 hours,
g) controlled drying the sweated vanilla pods in hot air drier at 45°C±
5°C to 75°C± 5°C for 1 to 4 hours,
h) rolling the dried vanilla beans in woolen cloth and kept in wooden
boxes for sweating, i) repeating the step (g and h) for 6-8 days to reduce the moisture level
from 80 to 40%, j) allowing the partially dried beans on wooden shelves for 5-10 days
in properly ventilated rooms, k) conditioning of the beans in the air-tight chests or waxed paper lined
metal containers or polythene covers for about 10-15 days to
develop desired vanilla flavour,
I) grinding of cured vanilla beans by a suitable mill and pass through
the 25-40 mesh to obtain vanilla powder,
m) charging the vanilla powder to extractors preferably three and soaking in a solvent consisting of 10-90 parts of water, mixed with 10-90 parts of alcohol preferably 30-40 parts of water, with 60-70 parts of alcohol at a temperature of 25° to 50°C, n) allowing a contact time of vanilla powder with solvent up to 2 hours followed by draining of the extract simultaneously replacing the solvent without allowing the bed to dry up. This process of solvent addition, allowing contact time (up to 1hour) and draining of the extract is repeated to a material to solvent ratio of 1:6 to 1:15, o) the extract drained out from the first extractor is employed as a solvent for the material in second extractor and so on till the third extractor and the enriched extract containing 10-20 % solids is taken for preparation of vanilla concentrate, q) mixing the first two or three fractions from third extractor to obtain
natural vanilla concentrate,
2) A process as claimed in claim 1, wherein, the mature green vanilla beans or partially cured vanilla beans are subjected to controlled drying by means selected from a fluidized bed drier at 150-200°C for about 1-5 minutes for 10-15 days or drying in low humidity and low temperature drier at 30-40°C and 35-40% RH for about 1-5 hours for 8-10 days or vanilla beans soaked in liquid nitrogen for about 24 h followed by shade drying at 25 -40°C, to bring down the moisture content to 25-30%.3) A process as claimed in claim 1- 2 wherein the faster cured vanilla beans
having good aroma, light brown chocolate color, lathery and its contains
1-4% vanillin with a moisture content of 25-30%.
4) A process as claimed in claim 1-3 wherein, the natural vanilla beans and its
products is useful as a pharmaceutical and neutraceutical preparation with properties of quenching oxidative stress
5) A process for faster curing of vanilla beans and production vanilla
concentrate thereof from fresh mature green vanilla pods substantially as herein described with reference to the examples comprising this specification