CA1238231A - Shelf stable pasta product and process for producing same - Google Patents
Shelf stable pasta product and process for producing sameInfo
- Publication number
- CA1238231A CA1238231A CA000467819A CA467819A CA1238231A CA 1238231 A CA1238231 A CA 1238231A CA 000467819 A CA000467819 A CA 000467819A CA 467819 A CA467819 A CA 467819A CA 1238231 A CA1238231 A CA 1238231A
- Authority
- CA
- Canada
- Prior art keywords
- meat
- pasta
- sauce
- acidified
- component
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L3/00—Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs
- A23L3/16—Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs by heating loose unpacked materials
- A23L3/165—Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs by heating loose unpacked materials in solid state
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
- A23L7/10—Cereal-derived products
- A23L7/109—Types of pasta, e.g. macaroni or noodles
- A23L7/11—Filled, stuffed or multilayered pasta
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
- A23L7/10—Cereal-derived products
- A23L7/109—Types of pasta, e.g. macaroni or noodles
- A23L7/111—Semi-moist pasta, i.e. containing about 20% of moist; Moist packaged or frozen pasta; Pasta fried or pre-fried in a non-aqueous frying medium, e.g. oil; Packaged pasta to be cooked directly in the package
Abstract
ABSTRACT OF THE DISCLOSURE
Pasta containing products are formulated and produced under conditions which enable the product, when packed in sealed containers, to be thermally processed under conditions which render the product commercially sterile, but do not adversely affect the texture, taste or appearance of the product. The pasta and each of the other components of the product, such as meat and sauce, are formulated and/or processed to have an equilibrium pH of less than 4.6, and are hot filled into containers, which after sealing do not require retorting, but are heat proces-sed under conditions to provide a sterilizing value equiva-lent to about 10 minutes at 200°F. to render the product commercially sterile. Pasta containing products such as spaghetti with meat sauce, beef ravioli with meat sauce, and the like, produced in accordance with the present invention, have a firmness and texture superior to conven-tionally retorted pasta products.
Pasta containing products are formulated and produced under conditions which enable the product, when packed in sealed containers, to be thermally processed under conditions which render the product commercially sterile, but do not adversely affect the texture, taste or appearance of the product. The pasta and each of the other components of the product, such as meat and sauce, are formulated and/or processed to have an equilibrium pH of less than 4.6, and are hot filled into containers, which after sealing do not require retorting, but are heat proces-sed under conditions to provide a sterilizing value equiva-lent to about 10 minutes at 200°F. to render the product commercially sterile. Pasta containing products such as spaghetti with meat sauce, beef ravioli with meat sauce, and the like, produced in accordance with the present invention, have a firmness and texture superior to conven-tionally retorted pasta products.
Description
~23~3~L
BACKGROUND OF THE INVENTION
This invention relates to the production of pro-cooked, shelf stable, pasta-containing products, such as, for example spaghetti with meat sauce, spaghetti with meatballs, beef or cheese ravioli in sauce, lasagna, cannelloni, and the like. More particularly, the invention relates to the production of novel hydrated pasta-containiny products, which are thermally processed under relatively mild conditions to render the products commercially sterile without adversely effecting the texture, taste, color or appearance of the pasta or other components of the products.
As used herein, the term "commercially sterile"
means (a) the absence of microorganisms capable of rowing in and spoiling the food under normal non-refrigerated storage conditions, and (b) the absence of pathogenic micro-organisms capable of proliferating in the food.
Conventional pasta products, such as macaroni, spaghetti, noodles and the like, consist basically of dough made with one or more of semolina, farina, or flour, and water, which is formed under pressure into a variety of sizes and shapes, are dried to a moisture content of 12% or less to obtain a hard product. At such moisture levels, the product will not support the growth of mold, yeast or other spoilage microorganisms, so that the products, if kept dry, can be stored without refrigeration for long periods of time. Dried pasta products are prepared for consumption by cooking in boiling water for about 8 to 15 I ., ' 38~3~
1 minutes to dehydrate and soften the pasta and provide it with a desirable firm, slightly chewy texture.
In order to facilitate the use of pasta products by consumers in the home, many pasta products are pro-cooked and provided in canned form, -together with tomato sauce, meat sauce, gravy, meatballs, and the like. The production of such canned pasta-containing products typic gaily includes the steps of blanching dried pasta in boil-in water to hydrate and soften the pasta, with the hydrated pasta containing about 70%-75~ by weight of water, filling the precooked pasta into cans together with sauce, meat, and the like, sealing the cans and retorting the sealed cans under time-temperature conditions sufficient to pro-vise a commercially sterile product. Since the pasta, upon hydration, has a moisture content which will support the growth of spoilage organisms, the canned pasta-containing products must be subjected to relatively severe heat processing conditions in order to produce a commercial-; lye sterile product. For example, canned spaghetti in 300 x 407 cans typically is heat processed at 240F. for 55 minutes. However, subjecting the canned pasta to such high temperature-long time heat processing reduces the desired firm texture of the pasta, causing it to become soft and mushy. The taste and texture of the resulting retorted product is undesirable to many consumers and has limited to acceptability of canned pasta-containing pro-ducts.
; - 2 -~3~3~31 SUM Y OF THE INVENTION
The present invention provides for the production of hydrated pasta-containing products, which are formulated in such a manner so as to allow the product, when packed in sealed containers, to be heat processed under relatively mild atmospheric conditions, rather-than by retorting, in order to produce a commercially sterile product which may be stored under non-refrigerated conditions. Since the product isn't subjected to the severe time-temperature conditions required in retorting, the pasta component of the product retains a firm texture and appearance kirk-touristic of freshly cooked pasta products, without becoming soft and mushy.
Typically, the product of this invention contains three components, namely, a pasta component, a meat combo-j next, and a sauce component Each of these components is ; formulated and/or processed to have an equilibrium pi of less than 4.6 so that the growth of microorganisms and . C. bo-tulinum spores is prevented and the product may be processed at the temperature of boiling water or less, such as by using a hot fill-hold procedure, to render it come Marshall sterile. Thus, in preparing the pasta component,.
a food grade acid is included in the ingredient mixture used to form the pasta dough which is formed under pressure into the desired size and shape The meat component is prepared by blanching ground-meat particles in a hot acid solution with the acidified meat being used as a separate : _ 3 _ :
3~323~
l component of the product or being included in the sauce component of the product. The sauce component is prepared by either the use of a food grade acid and/or through the use of high acid foods. The sauce component must be forum-fated so that it not only has a pi of less than 4.6, but also has a viscosity such that, when filled into containers, it completely surrounds the other components of the product In producing the product of the present invention, the components are heated to a temperature of at least about 185F. and, while at such an elevated temperature, filled into suitable containers, such as glass jars, cans, and the like, which are then sealed. Since each of the components has a pi of less than 4.6, the sealed product containers require only relatively mild thermal processing in order to render the product commercially sterile, such as heating the sealed containers in hot water or steam at about 190F.
for 13 minutes.
The reduced heat processing necessary -to achieve commercial sterility results in substantially less loss of texture in the pasta component than is usually found in canned pasta products which have been retorted, with the texture and appearance of the pasta component of the present product closely resembling that of freshly prepared cooked pasta.
DISCRETION' OF PREFERRED EMBOD'I'ME NUTS
us discussed hereinabove, each of the components of the product of this invention is formulated and/or I
1 processed to have an equilibrium pi of less than 4.6.
The acidified pasta component of the product is prepared by mixing a food grade acid, preferably in dry form, with a furnaces ingredient and water, with or without one or more additives, to form a dough, and forming the dough under pressure into a variety of sizes and shapes such as spaghetti, macaroni, noodles and the like. The furnaces ingredient may be one or more of semolina, drum flour, farina or flour, depending on the type of pasta product desired. Generally, semolina and drum flour are preferred for extruded pasta such as spaghetti, macaroni, etc., while drum or wheat flour are preferred for sheeted pasta, such as noodles. The furnaces ingredient is usually present in an amount of from 70 to 95% of the dry ingredient mix-lure, with amounts of between 80%-90% by wt. of the dry mix being preferred.
Wheat gluten is typically included in the dry ingredient mix at a level of about 2 to 20% by weight of Jo the dry mix, with amounts between 5% and 10% being preferred, to increase the protein content of the pasta thereby in-creasing its strength and firmness. Dehydrated egg material such as dried egg white, dried eggs and dried yolks and/or whole eggs, may if desired, be included in the ingredient mix at levels up to about 22% by weight of the dry ingredient I; 25 mix. Dried eggs and dried yolks generally are used in the production of noodles, while dried egg whites are generally used in the production ox extruded pasta In addition, ~;~3~3~
1 glycerol menstruate may, if desired, also be included in the ingredient mix, particularly in the production of extruded pasta, to improve firmness, reduce stickiness and minimize absorption of water from the sauce component by the pasta. If used, the glycerol menstruate preferably is present in amounts of from 0.5 to 5% by weight of the dry ingredient mix. It is to be understood that wheat gluten, eggs, and glycerol menstruate are optional inure-dints in the dry mix and are not essential in the product lion of the pasta component.
Sufficient food grade edible acid is included in the ingredient mix to provide the formed pasta with a pi of less than 4.6, preferably between 4.0 and 4.4. Any acid, organic or inorganic, which is suitable for use in foods and which is soluble in water may be used, such as citric, fumaric, lactic, mafia, tartaric, sulfuric, hydrochloric and phosphoric acids. The acid used must not impart to the pasta a taste which is incompatible with the other combo-newts of the product at the desired pi level. Mafia acid ; 20 and citric acid have been found to be particularly well suited for use in acidification of the pasta component.
The pasta component is formed by blending the dry ingredients, typically the furnaces ingredient, dehydrated egg material, wheat gluten, and food grade acid, with or without glycerol menstruate, and adding sufficient water to form a suitable dough. Generally, water is added to the dry mix in such quantity as to produce a dough containing .
~L23~3~L
1 from about 25% to 38% moisture. The resulting dough is kneaded and formed under pressure, using conventional pro-seeders, to form a pasta component having the desired size and shape. For example, in the production of acidified spaghetti, the dry ingredients are mixed, formed into a dough containing 30%-32~ moisture, kneaded and extruded through a die in a conventional continuous auger extrude to form a continuous cord-shaped extradite about 0.06 inch to 0.11 inch in diameter. The extradite, which has a moisture content of about 30%-32%, may either be cut into desired lengths and used directly in the production of the product of the present invention, or initially dried to a moisture content of about 12% by conventional procedures and cut into desired lengths for subsequent use in producing the product. Similarly, in the production of ravioli, an acidified dough having a moisture content of 30%-36% is prepared by mixing the dry ingredients and water and the dough is formed into sheets about 0.10 to 0.20 inch in thickness, in a standard macaroni press. The sheeted dough is then loaded into a conventional ravioli machine, together with acidified ravioli meat filling prepared as described hereinbelow and formed into individual meat fillet ravioli pieces.
The acidified meat component may be incorporated into the product of the present invention in a variety of forms, such as formed meatballs, as a meat filling in ravioli and/or as an addition to the sauce component.
_ 7 _ .. .
,:
'~3~3~L
1 Generally it is preferred to prepare the acidified meat component by grinding cooked meat pieces through a 1/8 inch - 1/4 inch grid and blanching the ground meat particles in a hot aqueous acid solution having a pi of below about 3.5 for a period of time sufficient to reduce the pi of the meat particles to less than 4.6, typically 4.3-4~4. Any of the food grade acids discussed above may be used in preparing the acid solution. The time required to reduce the pi of the meat to the desired level will vary depending upon the size of the meat particles, the pi of the acid solution and the temperature of the acid solution.
The acidified ground meat particles typically are used as a meat filling for ravioli and/or as a component of the sauce, as described more fully hereinbelow. Thus, in the production of beef ravioli, acidified ground beef is mixed with other ingredients, such as cheese, crackers, bread crumbs, seasonings, spices and water to provide an acidified meat filling having a pi below 4.6, which is loaded into a conventional ravioli machine, together with acidified sheeted dough, and formed into individual meat filled ravioli pieces comprising abut 60%;70% by weight pasta and 30~-4G% by weight meat filling, with the ravioli pieces preferably having a pi of no more than about 4.4.
The meat component may also be acidified by in-corporating in a-meat emulsion, an encapsulated acid, that is an edible acid coated with an edible fat having a melting ; point of above room temperature, but below about 150F., ' ' ' .
.
323~
1 generally between about 126 F~-135 F. This method of meat acidification is particularly well suited when it is desired to incorporate meat in the product in the form of relatively large pieces having a separate identity, such as meatballs, sausage, and the like. According to this procedure, an encapsulated acid, such as mafia acid coated with a 135F.
melting point fat, is added to a meat emulsion containing meat, fillers such as cracker meal or bread crumbs, and binders such as soy protein concentrate, at a level of from about 0.75~-2.5% of the emulsion, and the emulsion is heated at about 135F.-150F. for 90 minutes. The meat emulsion is then formed into the desired shape, such as meatballs, and cooked for about 10 minutes to set the emulsion and release the remainder of the acid into the meat emulsion, which has a final pi of less than 4.5.
The nature of the sauce component will depend upon the type of product desired and the condiments in-eluded therein, and-may contain ingredients such as spices, for example, oregano, parsley, basil; flavorings for example, garlic, pepper, onion; corn syrup; vegetable oil;
salt; and the like. Of course, the ingredients used and - the amounts of ingredients will be determined by the taste desired for the sauce component. The important character-is tics of the sauce component are that it has a pi of less than 4.6, has a taste which is compatible with an acid pi and with the other components of the product, and has a viscosity such that the sauce surrounds the other components _ g _ , ~3~3~L
1 of the product when packed in containers. The desired - acidity may be provided in the sauce component by the in-elusion therein of any of the food grade acids disclosed above, and/or an acid food, such as tomato paste, or tomato sauce. Since tomato products have both a taste which is compatible with many pasta products and a pi of less than 4.6, it is generally preferred to use tomato sauce or paste, with or without additional food grade acids, as an acid food in the preparation of the sauce component. Other ingredients of the sauce are determined by the taste desired and include corn syrup, vegetable oil, seasoning and spices, together with sufficient water to provide the sauce with the desired viscosity.
In accordance with one embodiment of the present invention the acidified meat component is included in the sauce. For example, an acidified meat sauce having a pi of less than 4.6, preferably between 4.3 and 4.4, is pro-pared by blanching particles of ground meat in a hot acid solution having a pi of about 3.5 or below, and then adding the remaining ingredients of the sauce to the hot acid solution to form the meat sauce.
The acidified pasta and meat components are combined in a suitable container with the acidic sauce so that the sauce surrounds the pasta and meat components in .
the container. While the procedure used in filling the components into the container may vary, it is necessary that each of the components be at a temperature of about .
.
~231323~
1 185F. or above when filled into containers.
The pasta component filled into containers may either be freshly prepared, undried pasta, or it may have been previously prepared and then dried or frozen for storage and subsequent use. If previously prepared, the pasta is hydrated and heated, preferably in two steps, such as by first heating in boiling water for 2-10 minutes, and then heating in a steam blencher at a temperature of 190F.
or above for about 5-15 minutes just prior to filling into the containers.
The components, each of which has a pi of less than 4.6 and is at a temperature of 185F. or higher, are filled into suitable containers, such as cans, glass jars, and the like, so that the pasta and meat components are surrounded by the sauce. The filled containers are then sealed and heat processed to render the product commercially sterile. In accordance with the present invention, the containers are heat processed under atmospheric conditions which provide a sterilizing value equivalent to 10 minutes at 200F~ For example, a commercially sterile product is produced by processing the sealed containers for 13 minutes in hot water or steam at 190F., when the components are filled into the containers at a temperature of 185-190F.
Upon completion of heat processing, the containers are rapidly cooled to a temperature of about 110F. or below in order to preserve the texture of the products.
;;
... .
or ~:38~
1 The pasta containing product of the present in-mention is commercially sterile and requires no roughage-ration, with the pasta having a desirable firm texture and appearance.
The following examples are given to illustrate, but not to limit, the present invention. In these examples, and elsewhere herein, proportions and percentages are expressed as parts by weight unless otherwise indicated.
- Example I
A spaghetti with meat sauce product is prepared in accordance with the present invention by the following procedure.
The pasta component is prepared by dry blending Ingredient% by weight drum flour 82.4 dehydrated egg White wheat gluten 7.4 mafia acid 1~1 glycerol menstruate 1.1 The dry mix is transferred to a conventional continuous macaroni press and water is added, with mixing, to form a dough having a moisture content of about 31%. The dough is kneaded and vacuumized to remove occluded air bubbles and extruded through a die having openings .072 inch in diameter to form continuous strands of spaghetti. The spaghetti strands thus formed are dried at 90F. fireboat 48 hours to reduce their moisture content to about 12%, and are cut into pieces about 10-12 inches in length.
.
":' '.
. . .
~2~3~3~3~
1 The acidified spaghetti thus wormed has a pi of about 4.3.
The meat sauce component is prepared by the following formulation.
Ingredient 'I my weight Water 54-9 Beef 19.2 Tomato paste, 31~17.5 Corn syrup 4.6 Cottonseed Oil -1.1 Salt owe Citric acid ' 0.2 Flavorings, spices 1.6 . The meat is ground two times through a 1/4 inch grid, and is then added to a boiling solution of the citric acid an water having a pi of below 3.5, with the resulting meat slurry being heated to boiling for 1 minute. The remainder of the sauce ingredients are then added to the hot acidified meat slurry, with the resulting meat sauce, which has a pi offbeat 4.3, being maintained at a tempera-lure of at least 195 F.
In producing the product, the dried spaghetti is heated in boiling water for 5 minutes to hydrate and cook the spaghetti, after which the spaghetti is rinsed drained and heated in a steam blencher at a temperature of above 195F. for 5 minutes to heat the spaghetti to a temperature of at least 1~5F. The spaghetti, while at a temperature : of at least 185F., is filled into 16 oz. glass jars, and the meat sauce, which also has a temperature of at least 185F., is added to the jars in an amount sufficient to ; provide a ratio of about 16 parts of spaghetti per 100 parts ' - 13 -.
-"
, isle l of meat sauce, so that the meat sauce completely covers the spaghetti. The filled jars are then sealed, inverted and heated in hot water or steam at a temperature of at least 190F for 13 minutes. The jars ore then cooled to 110F.
or below by quenching in water.
-The resulting product it commercially sterile, with the product having a mass average pi of about 4.47 immediately after production, and about 4.45 after 24 hours.
The spaghetti has a firm, freshly cooked texture and lo appearance Example II
A meat ravioli with meat sauce product is prepared in accordance with the present invention by the following procedure.
The pasta component is prepared using the follow-in dry ingredients:
Ingredient % by weight drum flour 91.2%
wheat gluten 5.0 egg white solids 3.0 mafia acid 0.8 The dry ingredients are blended in a paddle mixer for lo minutes and water is added in an amount of about 36 parts by weight of water per lo parts by weight of dry ingredients, to form a dough having pi of about 4.3. The dough is formed into sheets about 0.16 inch thick on a conventional sheeter-kneader, and the pasta sheets are then formed into rolls.
~38~3~
1 An acidified meat filling for the ravioli is formed using the following ingredients:
Ingredient -by weight cooked meat dices 38.8%
whole eggs 19.4 water 20.5 cracker crumbs 10.7 cheese 6.8 salt 1.2 mafia acid Ox flavoring, spices 1.7 The cooked meat dices are ground through a 1/8 inch grid. To this is added a solution of the mafia acid in about 1/4 of the water of the formulation, and the resulting meat slurry mixed for about 10 minutes. The eggs and the remaining filling ingredients are then mixed into the meat slurry to provide an acidified meat slurry having a pi of about 4.35. The rolls of sheeted dough and the acidified meat filling are loaded into a conventional ravioli machine and formed into ravioli pieces, about 1"
square, containing about byway weight of the meat filling.
An acidified meat sauce having a pi of about 4.3 is prepared in accordance with the formulation and procedure used ion Example I, except that the sauce is formulated to have a meat content of about 7%-8%, and the meat sauce is heated to a temperature of at least 195F.
In producing the product, the ravioli pieces are blanched in boiling water for several minutes, and are then heated in a steam blencher at a temperature of at least 190F. for 5 minutes, so that the temperature of the ravioli Jo - 15 - -,,. ' . .
AL
1 pieces is at least 185 F. The ravioli pieces and meat sauce, both of which are at a temperature of 185 F. or above, are filled into glass jars in an amount sufficient to provide a ratio of about 30 parts of ravioli per 70 parts of meat sauce, so that the meat sauce completely covers and.sur-rounds the ravioli pieces. The filled jars are then sealed, inverted and heated in hot water or steam at a temperature of at least 190 F. for 13 minutes. The jars are then cooled to aloof. or below by quenching in water.
The ravioli product thus produced is commercially sterile, and has a mass average pi of about 4.45 immediately after production and 24 hours after production. The pasta portion of the product has a desirable firm texture.
While the invention has been particularly described and illustrated with reference to a three-component product, that is, acidified pasta, acidified meat and acidified sauce, it is to be understood that products of the present invention may be formulated and produced with only two components, namely acidified pasta and an acidified liquid phase such as sauce, gravy, dressing, and the like.
Such products include, for example, a cheese filling for various pasta products such as ravioli, manicotti, cannelloni, etc. with an acidified cheese sauce.
BACKGROUND OF THE INVENTION
This invention relates to the production of pro-cooked, shelf stable, pasta-containing products, such as, for example spaghetti with meat sauce, spaghetti with meatballs, beef or cheese ravioli in sauce, lasagna, cannelloni, and the like. More particularly, the invention relates to the production of novel hydrated pasta-containiny products, which are thermally processed under relatively mild conditions to render the products commercially sterile without adversely effecting the texture, taste, color or appearance of the pasta or other components of the products.
As used herein, the term "commercially sterile"
means (a) the absence of microorganisms capable of rowing in and spoiling the food under normal non-refrigerated storage conditions, and (b) the absence of pathogenic micro-organisms capable of proliferating in the food.
Conventional pasta products, such as macaroni, spaghetti, noodles and the like, consist basically of dough made with one or more of semolina, farina, or flour, and water, which is formed under pressure into a variety of sizes and shapes, are dried to a moisture content of 12% or less to obtain a hard product. At such moisture levels, the product will not support the growth of mold, yeast or other spoilage microorganisms, so that the products, if kept dry, can be stored without refrigeration for long periods of time. Dried pasta products are prepared for consumption by cooking in boiling water for about 8 to 15 I ., ' 38~3~
1 minutes to dehydrate and soften the pasta and provide it with a desirable firm, slightly chewy texture.
In order to facilitate the use of pasta products by consumers in the home, many pasta products are pro-cooked and provided in canned form, -together with tomato sauce, meat sauce, gravy, meatballs, and the like. The production of such canned pasta-containing products typic gaily includes the steps of blanching dried pasta in boil-in water to hydrate and soften the pasta, with the hydrated pasta containing about 70%-75~ by weight of water, filling the precooked pasta into cans together with sauce, meat, and the like, sealing the cans and retorting the sealed cans under time-temperature conditions sufficient to pro-vise a commercially sterile product. Since the pasta, upon hydration, has a moisture content which will support the growth of spoilage organisms, the canned pasta-containing products must be subjected to relatively severe heat processing conditions in order to produce a commercial-; lye sterile product. For example, canned spaghetti in 300 x 407 cans typically is heat processed at 240F. for 55 minutes. However, subjecting the canned pasta to such high temperature-long time heat processing reduces the desired firm texture of the pasta, causing it to become soft and mushy. The taste and texture of the resulting retorted product is undesirable to many consumers and has limited to acceptability of canned pasta-containing pro-ducts.
; - 2 -~3~3~31 SUM Y OF THE INVENTION
The present invention provides for the production of hydrated pasta-containing products, which are formulated in such a manner so as to allow the product, when packed in sealed containers, to be heat processed under relatively mild atmospheric conditions, rather-than by retorting, in order to produce a commercially sterile product which may be stored under non-refrigerated conditions. Since the product isn't subjected to the severe time-temperature conditions required in retorting, the pasta component of the product retains a firm texture and appearance kirk-touristic of freshly cooked pasta products, without becoming soft and mushy.
Typically, the product of this invention contains three components, namely, a pasta component, a meat combo-j next, and a sauce component Each of these components is ; formulated and/or processed to have an equilibrium pi of less than 4.6 so that the growth of microorganisms and . C. bo-tulinum spores is prevented and the product may be processed at the temperature of boiling water or less, such as by using a hot fill-hold procedure, to render it come Marshall sterile. Thus, in preparing the pasta component,.
a food grade acid is included in the ingredient mixture used to form the pasta dough which is formed under pressure into the desired size and shape The meat component is prepared by blanching ground-meat particles in a hot acid solution with the acidified meat being used as a separate : _ 3 _ :
3~323~
l component of the product or being included in the sauce component of the product. The sauce component is prepared by either the use of a food grade acid and/or through the use of high acid foods. The sauce component must be forum-fated so that it not only has a pi of less than 4.6, but also has a viscosity such that, when filled into containers, it completely surrounds the other components of the product In producing the product of the present invention, the components are heated to a temperature of at least about 185F. and, while at such an elevated temperature, filled into suitable containers, such as glass jars, cans, and the like, which are then sealed. Since each of the components has a pi of less than 4.6, the sealed product containers require only relatively mild thermal processing in order to render the product commercially sterile, such as heating the sealed containers in hot water or steam at about 190F.
for 13 minutes.
The reduced heat processing necessary -to achieve commercial sterility results in substantially less loss of texture in the pasta component than is usually found in canned pasta products which have been retorted, with the texture and appearance of the pasta component of the present product closely resembling that of freshly prepared cooked pasta.
DISCRETION' OF PREFERRED EMBOD'I'ME NUTS
us discussed hereinabove, each of the components of the product of this invention is formulated and/or I
1 processed to have an equilibrium pi of less than 4.6.
The acidified pasta component of the product is prepared by mixing a food grade acid, preferably in dry form, with a furnaces ingredient and water, with or without one or more additives, to form a dough, and forming the dough under pressure into a variety of sizes and shapes such as spaghetti, macaroni, noodles and the like. The furnaces ingredient may be one or more of semolina, drum flour, farina or flour, depending on the type of pasta product desired. Generally, semolina and drum flour are preferred for extruded pasta such as spaghetti, macaroni, etc., while drum or wheat flour are preferred for sheeted pasta, such as noodles. The furnaces ingredient is usually present in an amount of from 70 to 95% of the dry ingredient mix-lure, with amounts of between 80%-90% by wt. of the dry mix being preferred.
Wheat gluten is typically included in the dry ingredient mix at a level of about 2 to 20% by weight of Jo the dry mix, with amounts between 5% and 10% being preferred, to increase the protein content of the pasta thereby in-creasing its strength and firmness. Dehydrated egg material such as dried egg white, dried eggs and dried yolks and/or whole eggs, may if desired, be included in the ingredient mix at levels up to about 22% by weight of the dry ingredient I; 25 mix. Dried eggs and dried yolks generally are used in the production of noodles, while dried egg whites are generally used in the production ox extruded pasta In addition, ~;~3~3~
1 glycerol menstruate may, if desired, also be included in the ingredient mix, particularly in the production of extruded pasta, to improve firmness, reduce stickiness and minimize absorption of water from the sauce component by the pasta. If used, the glycerol menstruate preferably is present in amounts of from 0.5 to 5% by weight of the dry ingredient mix. It is to be understood that wheat gluten, eggs, and glycerol menstruate are optional inure-dints in the dry mix and are not essential in the product lion of the pasta component.
Sufficient food grade edible acid is included in the ingredient mix to provide the formed pasta with a pi of less than 4.6, preferably between 4.0 and 4.4. Any acid, organic or inorganic, which is suitable for use in foods and which is soluble in water may be used, such as citric, fumaric, lactic, mafia, tartaric, sulfuric, hydrochloric and phosphoric acids. The acid used must not impart to the pasta a taste which is incompatible with the other combo-newts of the product at the desired pi level. Mafia acid ; 20 and citric acid have been found to be particularly well suited for use in acidification of the pasta component.
The pasta component is formed by blending the dry ingredients, typically the furnaces ingredient, dehydrated egg material, wheat gluten, and food grade acid, with or without glycerol menstruate, and adding sufficient water to form a suitable dough. Generally, water is added to the dry mix in such quantity as to produce a dough containing .
~L23~3~L
1 from about 25% to 38% moisture. The resulting dough is kneaded and formed under pressure, using conventional pro-seeders, to form a pasta component having the desired size and shape. For example, in the production of acidified spaghetti, the dry ingredients are mixed, formed into a dough containing 30%-32~ moisture, kneaded and extruded through a die in a conventional continuous auger extrude to form a continuous cord-shaped extradite about 0.06 inch to 0.11 inch in diameter. The extradite, which has a moisture content of about 30%-32%, may either be cut into desired lengths and used directly in the production of the product of the present invention, or initially dried to a moisture content of about 12% by conventional procedures and cut into desired lengths for subsequent use in producing the product. Similarly, in the production of ravioli, an acidified dough having a moisture content of 30%-36% is prepared by mixing the dry ingredients and water and the dough is formed into sheets about 0.10 to 0.20 inch in thickness, in a standard macaroni press. The sheeted dough is then loaded into a conventional ravioli machine, together with acidified ravioli meat filling prepared as described hereinbelow and formed into individual meat fillet ravioli pieces.
The acidified meat component may be incorporated into the product of the present invention in a variety of forms, such as formed meatballs, as a meat filling in ravioli and/or as an addition to the sauce component.
_ 7 _ .. .
,:
'~3~3~L
1 Generally it is preferred to prepare the acidified meat component by grinding cooked meat pieces through a 1/8 inch - 1/4 inch grid and blanching the ground meat particles in a hot aqueous acid solution having a pi of below about 3.5 for a period of time sufficient to reduce the pi of the meat particles to less than 4.6, typically 4.3-4~4. Any of the food grade acids discussed above may be used in preparing the acid solution. The time required to reduce the pi of the meat to the desired level will vary depending upon the size of the meat particles, the pi of the acid solution and the temperature of the acid solution.
The acidified ground meat particles typically are used as a meat filling for ravioli and/or as a component of the sauce, as described more fully hereinbelow. Thus, in the production of beef ravioli, acidified ground beef is mixed with other ingredients, such as cheese, crackers, bread crumbs, seasonings, spices and water to provide an acidified meat filling having a pi below 4.6, which is loaded into a conventional ravioli machine, together with acidified sheeted dough, and formed into individual meat filled ravioli pieces comprising abut 60%;70% by weight pasta and 30~-4G% by weight meat filling, with the ravioli pieces preferably having a pi of no more than about 4.4.
The meat component may also be acidified by in-corporating in a-meat emulsion, an encapsulated acid, that is an edible acid coated with an edible fat having a melting ; point of above room temperature, but below about 150F., ' ' ' .
.
323~
1 generally between about 126 F~-135 F. This method of meat acidification is particularly well suited when it is desired to incorporate meat in the product in the form of relatively large pieces having a separate identity, such as meatballs, sausage, and the like. According to this procedure, an encapsulated acid, such as mafia acid coated with a 135F.
melting point fat, is added to a meat emulsion containing meat, fillers such as cracker meal or bread crumbs, and binders such as soy protein concentrate, at a level of from about 0.75~-2.5% of the emulsion, and the emulsion is heated at about 135F.-150F. for 90 minutes. The meat emulsion is then formed into the desired shape, such as meatballs, and cooked for about 10 minutes to set the emulsion and release the remainder of the acid into the meat emulsion, which has a final pi of less than 4.5.
The nature of the sauce component will depend upon the type of product desired and the condiments in-eluded therein, and-may contain ingredients such as spices, for example, oregano, parsley, basil; flavorings for example, garlic, pepper, onion; corn syrup; vegetable oil;
salt; and the like. Of course, the ingredients used and - the amounts of ingredients will be determined by the taste desired for the sauce component. The important character-is tics of the sauce component are that it has a pi of less than 4.6, has a taste which is compatible with an acid pi and with the other components of the product, and has a viscosity such that the sauce surrounds the other components _ g _ , ~3~3~L
1 of the product when packed in containers. The desired - acidity may be provided in the sauce component by the in-elusion therein of any of the food grade acids disclosed above, and/or an acid food, such as tomato paste, or tomato sauce. Since tomato products have both a taste which is compatible with many pasta products and a pi of less than 4.6, it is generally preferred to use tomato sauce or paste, with or without additional food grade acids, as an acid food in the preparation of the sauce component. Other ingredients of the sauce are determined by the taste desired and include corn syrup, vegetable oil, seasoning and spices, together with sufficient water to provide the sauce with the desired viscosity.
In accordance with one embodiment of the present invention the acidified meat component is included in the sauce. For example, an acidified meat sauce having a pi of less than 4.6, preferably between 4.3 and 4.4, is pro-pared by blanching particles of ground meat in a hot acid solution having a pi of about 3.5 or below, and then adding the remaining ingredients of the sauce to the hot acid solution to form the meat sauce.
The acidified pasta and meat components are combined in a suitable container with the acidic sauce so that the sauce surrounds the pasta and meat components in .
the container. While the procedure used in filling the components into the container may vary, it is necessary that each of the components be at a temperature of about .
.
~231323~
1 185F. or above when filled into containers.
The pasta component filled into containers may either be freshly prepared, undried pasta, or it may have been previously prepared and then dried or frozen for storage and subsequent use. If previously prepared, the pasta is hydrated and heated, preferably in two steps, such as by first heating in boiling water for 2-10 minutes, and then heating in a steam blencher at a temperature of 190F.
or above for about 5-15 minutes just prior to filling into the containers.
The components, each of which has a pi of less than 4.6 and is at a temperature of 185F. or higher, are filled into suitable containers, such as cans, glass jars, and the like, so that the pasta and meat components are surrounded by the sauce. The filled containers are then sealed and heat processed to render the product commercially sterile. In accordance with the present invention, the containers are heat processed under atmospheric conditions which provide a sterilizing value equivalent to 10 minutes at 200F~ For example, a commercially sterile product is produced by processing the sealed containers for 13 minutes in hot water or steam at 190F., when the components are filled into the containers at a temperature of 185-190F.
Upon completion of heat processing, the containers are rapidly cooled to a temperature of about 110F. or below in order to preserve the texture of the products.
;;
... .
or ~:38~
1 The pasta containing product of the present in-mention is commercially sterile and requires no roughage-ration, with the pasta having a desirable firm texture and appearance.
The following examples are given to illustrate, but not to limit, the present invention. In these examples, and elsewhere herein, proportions and percentages are expressed as parts by weight unless otherwise indicated.
- Example I
A spaghetti with meat sauce product is prepared in accordance with the present invention by the following procedure.
The pasta component is prepared by dry blending Ingredient% by weight drum flour 82.4 dehydrated egg White wheat gluten 7.4 mafia acid 1~1 glycerol menstruate 1.1 The dry mix is transferred to a conventional continuous macaroni press and water is added, with mixing, to form a dough having a moisture content of about 31%. The dough is kneaded and vacuumized to remove occluded air bubbles and extruded through a die having openings .072 inch in diameter to form continuous strands of spaghetti. The spaghetti strands thus formed are dried at 90F. fireboat 48 hours to reduce their moisture content to about 12%, and are cut into pieces about 10-12 inches in length.
.
":' '.
. . .
~2~3~3~3~
1 The acidified spaghetti thus wormed has a pi of about 4.3.
The meat sauce component is prepared by the following formulation.
Ingredient 'I my weight Water 54-9 Beef 19.2 Tomato paste, 31~17.5 Corn syrup 4.6 Cottonseed Oil -1.1 Salt owe Citric acid ' 0.2 Flavorings, spices 1.6 . The meat is ground two times through a 1/4 inch grid, and is then added to a boiling solution of the citric acid an water having a pi of below 3.5, with the resulting meat slurry being heated to boiling for 1 minute. The remainder of the sauce ingredients are then added to the hot acidified meat slurry, with the resulting meat sauce, which has a pi offbeat 4.3, being maintained at a tempera-lure of at least 195 F.
In producing the product, the dried spaghetti is heated in boiling water for 5 minutes to hydrate and cook the spaghetti, after which the spaghetti is rinsed drained and heated in a steam blencher at a temperature of above 195F. for 5 minutes to heat the spaghetti to a temperature of at least 1~5F. The spaghetti, while at a temperature : of at least 185F., is filled into 16 oz. glass jars, and the meat sauce, which also has a temperature of at least 185F., is added to the jars in an amount sufficient to ; provide a ratio of about 16 parts of spaghetti per 100 parts ' - 13 -.
-"
, isle l of meat sauce, so that the meat sauce completely covers the spaghetti. The filled jars are then sealed, inverted and heated in hot water or steam at a temperature of at least 190F for 13 minutes. The jars ore then cooled to 110F.
or below by quenching in water.
-The resulting product it commercially sterile, with the product having a mass average pi of about 4.47 immediately after production, and about 4.45 after 24 hours.
The spaghetti has a firm, freshly cooked texture and lo appearance Example II
A meat ravioli with meat sauce product is prepared in accordance with the present invention by the following procedure.
The pasta component is prepared using the follow-in dry ingredients:
Ingredient % by weight drum flour 91.2%
wheat gluten 5.0 egg white solids 3.0 mafia acid 0.8 The dry ingredients are blended in a paddle mixer for lo minutes and water is added in an amount of about 36 parts by weight of water per lo parts by weight of dry ingredients, to form a dough having pi of about 4.3. The dough is formed into sheets about 0.16 inch thick on a conventional sheeter-kneader, and the pasta sheets are then formed into rolls.
~38~3~
1 An acidified meat filling for the ravioli is formed using the following ingredients:
Ingredient -by weight cooked meat dices 38.8%
whole eggs 19.4 water 20.5 cracker crumbs 10.7 cheese 6.8 salt 1.2 mafia acid Ox flavoring, spices 1.7 The cooked meat dices are ground through a 1/8 inch grid. To this is added a solution of the mafia acid in about 1/4 of the water of the formulation, and the resulting meat slurry mixed for about 10 minutes. The eggs and the remaining filling ingredients are then mixed into the meat slurry to provide an acidified meat slurry having a pi of about 4.35. The rolls of sheeted dough and the acidified meat filling are loaded into a conventional ravioli machine and formed into ravioli pieces, about 1"
square, containing about byway weight of the meat filling.
An acidified meat sauce having a pi of about 4.3 is prepared in accordance with the formulation and procedure used ion Example I, except that the sauce is formulated to have a meat content of about 7%-8%, and the meat sauce is heated to a temperature of at least 195F.
In producing the product, the ravioli pieces are blanched in boiling water for several minutes, and are then heated in a steam blencher at a temperature of at least 190F. for 5 minutes, so that the temperature of the ravioli Jo - 15 - -,,. ' . .
AL
1 pieces is at least 185 F. The ravioli pieces and meat sauce, both of which are at a temperature of 185 F. or above, are filled into glass jars in an amount sufficient to provide a ratio of about 30 parts of ravioli per 70 parts of meat sauce, so that the meat sauce completely covers and.sur-rounds the ravioli pieces. The filled jars are then sealed, inverted and heated in hot water or steam at a temperature of at least 190 F. for 13 minutes. The jars are then cooled to aloof. or below by quenching in water.
The ravioli product thus produced is commercially sterile, and has a mass average pi of about 4.45 immediately after production and 24 hours after production. The pasta portion of the product has a desirable firm texture.
While the invention has been particularly described and illustrated with reference to a three-component product, that is, acidified pasta, acidified meat and acidified sauce, it is to be understood that products of the present invention may be formulated and produced with only two components, namely acidified pasta and an acidified liquid phase such as sauce, gravy, dressing, and the like.
Such products include, for example, a cheese filling for various pasta products such as ravioli, manicotti, cannelloni, etc. with an acidified cheese sauce.
Claims (9)
- Claim 1 continued...
without adversely affecting the texture or appearance of the pasta. - 2. The process defined in claim 1 in which the sauce component contains acidified meat which is prepared by blanching ground meat particles in a hot aqueous solu-tion of an edible acid to reduce the pH of the meat parti-cles to below 4.6, and adding flavouring, spices and other desired ingredients of the sauce to the hot acid solution to thereby provide a meat containing sauce having a pH of below 4.6.
- 3. The process defined in claim 1 in which the acidified pasta dough is formed under pressure into sheets which are combined with acidified ground meat having a pH
of below 4.6 to form ravioli pieces having a pH of less than 4.6. - 4. The process defined in claim 2 in which an aqueous solution of an edible acid having a pH of 3.5 or below is contacted with ground cooked meat and mixed for a period of time sufficient to reduce the pH of the meat particles to below 4.6, thereby providing said acidified meat.
- 5. The process defined in claim 1 in which the acidified pasta dough is extruded through a die to form spaghetti strands having a pH of less than 4.6 which are dried to a moisture content of about 12%.
- 6. The process defined in claim 5 in which the acidified dried spaghetti is heated in hot water to rehyd-rate and cook the spaghetti, and the rehydrated spaghetti is heated to a temperature of at least 185°F. prior to combining with the sauce component.
- 7. The process defined in claim 1 in which an acidified meat component, having a pH of below 4.6, is combined with the acidified pasta and sauce components in the container.
- 8. The process defined in claim 7 in which the acidified meat component is in the form of meatballs which are prepared by adding to a meat emulsion an edible acid encapsulated with an edible fat having a melting point of between about room temperature and 150°F., in an amount of about 0.75%-2.5% by weight of the emulsion, heating the emulsion to a temperature above the melting point of said edible fat, forming the meat emulsion into a desired shape and heating the emulsion at a temperature and for a period of time sufficient to set the emulsion and release all of the acid into the emulsion.
- 9. The process defined in claim 1 in which an edible acid and a high acid food are included in the sauce phase to provide the sauce with a pH of below 4.6
1. A process for producing commercially sterile, hydrated pasta-containing product having a desirable firm texture, which comprises forming an acidified pasta dough by mixing a farinaceous material selected from the group consisting of semolina, durum flour, farina, flour, and mixtures thereof, sufficient edible acid to provide the pasta dough with a pH of less than 4.6, from 2-20% by weight of gluten, from 0-25% by weight of an egg material, from 0-25% of glyceryl monostearate, and water, forming the acidified dough under pressure into a pasta component having a desired size and shape, preparing a liquid sauce component having a pH
of below 4.6, heating the pasta component and the sauce compo-nent to a temperature of at least 185°F. and combining said components, while at a temperature of at least 185°F., in a container so that the sauce component surrounds the pasta component, sealing the container, and heat processing the sealed container under atmospheric conditions to provide a sterilizing value equivalent to about 10 minutes at 200°F., whereby the contents of the container are rendered commercially sterile
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US558,907 | 1983-12-07 | ||
| US06/558,907 US4597976A (en) | 1983-12-07 | 1983-12-07 | Process for producing shelf stable pasta containing product |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1238231A true CA1238231A (en) | 1988-06-21 |
Family
ID=24231485
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000467819A Expired CA1238231A (en) | 1983-12-07 | 1984-11-14 | Shelf stable pasta product and process for producing same |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU584413B2 (en) |
| CA (1) | CA1238231A (en) |
| GB (1) | GB2188530B (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2182461B (en) * | 1985-11-05 | 1989-10-04 | Nestle Sa | Steam injection process |
| US7189423B2 (en) * | 2000-04-26 | 2007-03-13 | Kraft Foods Holdings, Inc. | pH control of sauces used on acidified pasta or rice |
| DE102009003039A1 (en) | 2009-05-12 | 2010-12-30 | Freiberger Lebensmittel Gmbh & Co. Produktions- Und Vertriebs Kg | Deep-cooled or cooled pasta dish useful in a packaging unit, comprises a piece of pasta, and a fatty cream sauce, where a piece-suitable quantity of the fatty cream sauce transportably adheres on one side of the piece of pasta |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3886296A (en) * | 1973-03-22 | 1975-05-27 | Carnation Co | Canning process |
-
1984
- 1984-11-14 CA CA000467819A patent/CA1238231A/en not_active Expired
-
1986
- 1986-04-03 GB GB8608199A patent/GB2188530B/en not_active Expired - Fee Related
- 1986-04-15 AU AU56141/86A patent/AU584413B2/en not_active Ceased
Also Published As
| Publication number | Publication date |
|---|---|
| GB2188530A (en) | 1987-10-07 |
| AU5614186A (en) | 1987-10-22 |
| GB2188530B (en) | 1990-03-28 |
| GB8608199D0 (en) | 1986-05-08 |
| AU584413B2 (en) | 1989-05-25 |
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