Dried Vegetables And A Process For Producing The Same
Abstract:
The present invention relates to a process to prepare a dried vegetable product comprising the sleps of- subjecting a vegetable to a hypertonic heat shock by contacting (preferably submerging) the vegetable with (in) a hypertonic heal shock solution comprising at least one cdihlc salt, at a temperature of 101 to 112 degrees C; - coaling the hypcnotiically heal shocked vegetable with a coaling mix and - drying the coated hypertonieally Ileal shocked vegetable.
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Notices, Deadlines & Correspondence
HINDUSTAN LEVER HOUSE,
165-166 BACKBAY RECLAMATION,
MUMBAI - 400 020,
INDIA
Inventors
1. ABDEL-FATTAH EI-SAYED
MEET ABO ALI, ZAGAZIG SHARKIA, EGYPT
2. MUELLER RUDI GUNTER
UNILEVER BESTFOODS DEUTSCHLAND GMBH,
KNORRSTRASSE 1, 74074 HEILBRONN,
GERMANY
3. DEY-WEISBECKER VICKI CLARISSA
UNILEVER BESTFOODS DEUTSCHLAND GMBH,
KNORRSTRASSE 1, 74074 HEILBRONN,
GERMANY
Specification
FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
DRIED VEGETABLES AND A PROCESS FOR PRODUCING THE SAME
HINDUSTAN UNILEVER LIMITED, a company incorporated under
the Indian Companies Act, 1913 and having its registered office
at 165/166, Backbay Reclamation, Mumbai -400 020, Maharashtra, India
The following specification particularly describes the invention and the manner in which it is to be performed
Dried vegetables and a process for producing the same
The present invention relates to the field of dried food products, in particular dried vegetabfes like broccoli and a process for producing the same.
The green broccoli florets form a visually attractive ingredient because of the distinctive form and green colour. Fresh broccoli is unsurpassed in flavour, colour and "bite". In addition, broccoli is rather nutritious in terms of the high level of antioxidants and vitamins. However, the limited shelf stability of fresh broccoli creates a need for other forms. Frozen broccoli is a well known alternative although it is rather expensive and depends on the availability of freezing cabinets. In contrast dried broccoli provides an ambient stable alternative and processes to dry broccoli are known. For example, dried soups and dried meals which typically need to be prepared with hot water may contain pieces of dried broccoli. However, broccoli dried by known processes typically has lost the "bite" of blanched fresh broccoli.
Background of the invention
One could simply dry e.g. fresh broccoli by lyophilisation without prior heat treatment to obtain a dried broccoli. Such dried broccoli has an unacceptable short life because it would still contain relatively high levels of enzymes. Such products are unsuitable for use in food industry as mass produced food products need to have a long shelf life. The prior art discloses various examples of dried broccoli. High amounts of salt, sugar, glycerol, sorbitol, however, severely limit the application as the dried product inherently tastes very sweet or very salty and has lost the "bite". Relatively high amounts of water are undesirable as the water may migrate to other components in the dried food product and cause it stick together like in dried soups.
One example of a very sweet dried vegetable and a process for producing the same is disclosed in US 4 832 969. In example 7 thereof, a process is disclosed for producing dried broccoli florets comprising heating the florets in distilled water containing 0.06wt% of MgC03 at 212 degrees F {=100 degrees C) for 70 seconds. The vegetable solids content of a dehydrated material prepared according to
description is only 28 wt% for broccoli florets. The dried vegetable product comprises typically more than 40 % of glycerol and sugar resulting in a very sweet product with limited application. In fact, the product is so sweet it is recommended to add a bittering agent like potassium chloride to moderate the sweet taste.
GB-2 114 865 discloses a process to prepare dried vegetables. However, all examples show that the resultant dried vegetable contains more than 50 wt% of additives such as NaCI, monosodium glutamate (MSG), proteins or sugars and thus relatively low amounts of vegetable solids. The resultant products have a limited application due to the high levels of additives and sweet/salty/umami taste. Moreover the dried vegetables prepared according GB-2 114 865 are chewy and do not have a good "bite".
F.S.Jayaraman et al. (International Journal of Food Science and Technology (1990) 25, 47-60) discloses a process for drying cauliflower whereby cauliflower is incubated in a solution comprising 3 wt% NaCI and 6 wt% of sucrose for 12-16 hrs at 0-4 C. Jayaraman et al explicitly teaches that more than 3 wt% of NaCI does not provide added benefits. However, this process results in a dried vegetable with a sugar content of 39 wt%, NaCI content of 16 wt% and less than 40 wt% vegetable solids. Again the high levels of salt and sugar limit the application of such products. Perhaps more importantly, the long soak causes important nutrients like vitamin C to leach out of the vegetable: only 14% of the vitamin C remained in the dried vegetable. The bite is not good but chewy.
It is an object of the invention to provide a process to prepare a dried vegetable product with the following features: a high content of vegetable solids, substantially free from polyols such as sorbitol or glycerol, having a good bite after re-hydration (not chewy), a relatively neutral taste such that it can be used in a wide variety of dry applications, a low water activity while maintaining good re-hydrating properties and good light stability, suitable to be packaged with other dried ingredients without undesirable migration of water from the dried vegetable products, and a high
retention of vitamin C. Another object of the invention is to provide a dried vegetable product for use in mass produced food products with long shelf life.
Summary of the invention According a first embodiment of the invention a process for preparing a dried vegetable product is provided comprising the steps of.
a) optionally washing and peeling of a vegetable;
b) optionally, comminuting a vegetable;
c) subjecting a vegetable to a hypertonic heat shock by contacting (preferably submerging) the vegetable with (in) a hypertonic heat shock solution comprising at least one edible salt, at a temperature of 101 to 112 degrees C, preferably of 102 to 111 degrees C, preferably for 1 to 300 seconds, more preferably for 2 to 250 seconds, most preferably for 3 seconds to 225 seconds, said heat shock solution optionally further comprising
- 0 to 10 wt% of sucrose by weight of the hypertonic heat shock solution
- 0 to 1 wt% of a polyol selected from sorbitol, glycerol and mixtures thereof;
d) coating the hypertonically heat shocked vegetable with a coating mix and
e) drying the coated hypertonically heat shocked vegetable.
According to a second embodiment of the invention a dried vegetable product is provided comprising
- from 50 to 95 wt%, preferably from 55 to 92 wt%, more preferably from 60 to 90 wt%
of vegetable solids;
-Aw from 0.1 to 0.45, preferably from 0.15 to 0.40, more preferably from 0.2 to 0.35;
- from 0.5 to 30 wt%, preferably from 2 to 27 wt%, more preferably from 4 to 25 wt% of NaCI;and
- from 0.1 to 25 wt%, preferably from 0.5 to 20 wt%, more preferably from 2 to 15 wt% . of at least one film forming compound.
Although not wishing to be bound by theory applicants believe that subjecting the vegetables to unusually high temperatures in a hypertonic aqueous environment for a short period of time followed by a coating step, combined with the other steps in the
process surprisingly caused a controlled and moderate destruction at cellular level resulting in a dried vegetable product with excellent bite without the need for high amounts of additives like sucrose, MSG, NaCI, polyols. This was rather unexpected as the hypertonic heat shock solution has a surprisingly extreme temperature of at least 101 degrees C. The heat shock process is substantially free from saccharides to avoid an unnatural sweet taste. The process is believed to inactivate enzymes resulting in an improved shelf life needed for mass produced food products.
Detailed description of the invention
The term "vegetable" is meant to describe any edible plant or edible part thereof as used in the culinary sense: a vegetable can be used as the main part of a dish. It does not include herbs: aromatic green plants which are not used as the main part of a dish but typically used in small amounts to flavour dishes such as chives, basil, oregano, thyme, lovage, parsley, dill, rosemary, celery leaves, chervil, coriander (cilantro) leaves, marjoram, tarragon, mint, lemon leaves, lemon grass, Thai basil. In contrast to broccoli where the bite is perhaps as important as its flavour, herbs are without exception used for their flavour. Herbs are usually used after cutting it such small pieces the bite thereof is irrelevant. Preservation of the flavour after drying is important for herbs and not the "bite". Some aromatic roots like ginger and laos are culinary used as herbs in small amounts and are not included in the term "vegetable". Vegetable obviously does not include grains and pulses.
The term "vegetable" preferably includes: broccoli, green beans, garden pea, green asparagus, spinach, zucchini (courgette), green onion, rucola, water crest, pak choy, green cabbage, lettuce, wine leaves, green bell pepper, green chili pepper, potato, sweet corn, mushroom, bean sprout, cauliflower, non-green cabbage, onion, white asparagus, bamboo shoots, leek, radish, celery roots, parsley roots, carrots, yellow zucchini, non-green bell pepper, non-green chili pepper and mixtures thereof.
Vegetables as used in this application do not include spices which usually are dried seeds or fruits with a very strong aroma like cumin, coriander seeds, black pepper corns, white pepper corns, mustard seeds. This is for the same reason as mentioned
above for herbs: for spices preservation of the "bite" plays an insignificant role compared to the taste. Perhaps more importantly, spices are traditionally used because of the flavour present in the dried form rather than in the fresh form.
Different embodiments of the invention may be carried out in using preferred or more preferred conditions (e.g. temperature, time) or amounts of ingredients (e.g. NaCI, film forming compound). Preferred ranges will often be described in the following format: from x1 to y1, preferably from x2 to y2, more preferably from x3 to y3, whereby x1