Claims:WE CLAIM
1. A retort pasteurization process for solid foods in retort pouches comprising of:-
- increasing the temperature of a retort machine between around 95 to around 99Degrees Celsius for about a first predefined time period, after keeping the retort pouch filled with the solid food in the retort machine.
2. The retort pasteurization process as claimed in claim 1, wherein the first predefined time period is in range of 10 minutes to 20 minutes.
3. The retort pasteurization process as claimed in claims 1 or 2 , wherein increasing the temperature of a retort machine between around 96 to around 99 Degrees Celsius for about a first predefined time period.
4. The retort pasteurization process as claimed in claim 3, wherein temperature is thereafter reduced to around 34 to around 37 Degree Celsius for a second predefined time period, after keeping the retort pouch filled with the solid food in the retort machine.
5. The retort pasteurization process as claimed in claim 4, wherein the second predefined time period is 10-20 minutes.
6. The retort pasteurization process as claimed in claim 1 , wherein the retort pouches are vacuum sealed before being introducing into the retort machine.
7. A semi cooked flat bread product of a desired shape prepared using the retort pasteurization process having water activity of 0.73- 0.76, which gives the semi cooked flat bread product a soft texture, wherein the soft texture is maintained, when sealed in an inert atmosphere and stored at refrigeration temperatures, for a period of at least 6 months.
8. The semi cooked flat bread product as claimed in claim 7, is prepared using a dough consisting of about 52 to about 54% flour, about 9 to about 10% edible oil, about 1 to 2 % xanthum gum, about 0 to 2 % glycerine, about 0.1 to 0.3 % of salt, about 34 to 37 % water.
9. The semi cooked flat bread as claimed in claim 7 or 8, wherein the dough consists of flat bread softener consisting of atleast one of CaCO3, monoglycerides, enzyme substrate, or combination thereof.
10. The semi cooked flat bread as claimed in claim 8 wherein the flour is selected from a group consisting of Rice flour, Bengal gram flour, Amaranth flour, Bajra flour , Tapioca flour , whole wheat flour, or combination thereof.
, Description:For the purpose of promoting an understanding of the principles of this disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
Figure 1 illustrates the flow diagram for process of the retort pasteurization process. The process includes the preparation of the raw flatbread to be included in the retort pouches. The raw flatbread is made from flattening the dough. This flattened dough is made in to a desirable shape and is placed in a retort pouch. In one embodiment, the retort pouches which are a type of food packaging are made from a laminate of flexible plastic. In another embodiment the retort pouches are made from metal foils. The embodiment allows for sterile packaging of a wide variety of food to be handled in a sterile environment and is used as an alternative to traditional industrial canning methods. The method further includes the vacuum sealing of the pouches to be placed within the retort machine. The pouches are connected to a vacuum source and sealed. The sealed pouches are thereafter kept in a tray and the tray is further introduced in to the retort machine.
As known in the prior art, a retort pasteurization process which may be used as a means of sterilizing the food substance by heating, and thereafter their sudden cooling of the retort machine in order to destroy the microorganisms without causing major chemical alteration of the food. The retort pouches prevent the heat from destroying the nature of the food. The method further includes placing the retort pouches in trays and further placing the trays in the retort machine.
The "retort pouches" packed in plastic films and canned goods which can be sterilized in a retort at a high temperature and in a short time, it is necessary to increase the sterilizing temperature to decrease the sterilizing interval for the purpose of preventing the contents from deteriorating. An increase in the sterilizing temperature, however, increases the cooling time thereby increasing the time necessary for one cycle of the operation. Accordingly, it has been desired to decrease the heating up time and the cooling time when a high sterilizing temperature is used. The heating up time may be decreased by rapidly admitting a large quantity of steam into the retort in a short time.
The method further includes preheating of the retort machine, before introducing the retort pouches, In a preferred embodiment, in order to sterilize the air within is done using the saturated steam process, wherein the process allows all of the air be evacuated from the retort machine by flooding the vessel with steam and allowing the air to escape through the vents. Alternatively, the sterilization of the air of the retort vessel is also performed using other heating methods including superheated water. In one embodiment, the retort machine is heated up to 80-90 degrees Celsius to sterilize the air inside for a period of 10-20 mins. In a preferred embodiment, the retort machine is heated up to 85 degree Celsius. Alternatively, the retort machine may be heated up for a period of 15 mins. The embodiment is beneficial as it maintains the sterile environment and does not allow the air to pass through the machine, once the process begins. The embodiment is also beneficial as the steam saturations allows for the final product to maintain its texture and taste.
. The method further includes the retort Pasteurization process for solid foods in retort pouches wherein the process the temperature of a retort machine is increased between around 95 to around 105 Degrees Celsius for about 10 minutes to 20 minutes after placing the tray containing the retort pouches into the retort machine. Alternatively, the process comprises of increasing the temperature for a duration of 15 mins. In a preferred embodiment, the process comprises of increasing the temperature of a retort machine between around 96 to around 99 Degrees Celsius. The method further includes the sudden reduction in temperature immediately following the rise in temperature to ,to 34 to 37 Degree Celsius for a time period of 10-20 minutes. This reduction in temperature is done by allowing cool water to pass through the retort machine.. In a preferred embodiment, the temperature may be raised to 35 degree Celsius for a time period of 10-20 mins. Alternatively, the reduction in temperature may be carried out for 15 minutes. We have observed that this temperature and time range has the best effect on the solid food substance within the retort pouches with respect to shelf life, taste and texture.
For the purposed of the present invention, solid food is defined as any solid substance (as opposed to liquid or semi solid) that is used as a source of human or animal nourishment. Here solid food includes that food which does is not flowable in its serving or storage temperature. For instance, Indian gravy is flowable as against the Indian flat bread, which is not flowable at the storage or serving temperature.
In one embodiment, the invention also provides for a semi cooked flat bread product of a desired shape prepared using a dough by the retort pasteurization process having water activity of 0.73- 0.76, which gives the semi cooked flat bread product a soft texture, wherein the soft texture is maintained, when sealed in an inert atmosphere and stored at refrigeration temperatures, for a period of at least 6 months. In a preferred embodiment, the water activity is 0.749. The embodiment is beneficial as prevents microbial activity and increases the shelf life. In another embodiment, the water content of the semi cooked flatbread in the retort pouches has a water content of less than 5 %. Solutes dissolved in water bind the water molecules and make them not available for microorganisms to use. Microorganisms require a minimum level of water activity in order to grow and thus water activity reduction can be used to control microbial growth.
The dough making process for preparing food that will not be immediately consumed involves the kneading of the dough using the flour, water, certain preservatives, salt, oil along with certain taste and texture enhancers, either using industrial equipment or by hand depending upon the batch sizes. This kneaded dough is then made to the relevant or desired shapes before being treated and packaged.
In one embodiment, before pasteurization of the flatbread, the dough for the flatbread is prepared. The dough for the flat bread comprises of 52 to 54% flour, about 9 to about 10% edible oil, about 1 to 2 % Xanthum gum, about 0 to 2 % glycerine, about 0.1 to 0.3 % of salt and about 34 to 37 % Water. In another embodiment, the dough also consists of flat bread softener wherein the softener comprises of CaCO3, monoglycerides, enzyme substrate and their mixtures thereof. In a preferred embodiment, the flour is selected from a group consisting of Rice flour, Bengal gram flour, Amaranth flour, Bajra flour , Tapioca flour , whole wheat flour and their mixtures thereof.
While specific language has been used to describe the invention, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
The figures and the foregoing description give examples of embodiments. For example, order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.