USRE41885E1 - Method for producing a dehydrated whole food product - Google Patents
Method for producing a dehydrated whole food product Download PDFInfo
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- USRE41885E1 USRE41885E1 US12/148,108 US14810808A USRE41885E US RE41885 E1 USRE41885 E1 US RE41885E1 US 14810808 A US14810808 A US 14810808A US RE41885 E USRE41885 E US RE41885E
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- beans
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- hydrated
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- 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
- A23L11/00—Pulses, i.e. fruits of leguminous plants, for production of food; Products from legumes; Preparation or treatment thereof
- A23L11/05—Mashed or comminuted pulses or legumes; Products made therefrom
- A23L11/07—Soya beans, e.g. oil-extracted soya bean flakes
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- 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
- A23L11/00—Pulses, i.e. fruits of leguminous plants, for production of food; Products from legumes; Preparation or treatment thereof
- A23L11/05—Mashed or comminuted pulses or legumes; Products made therefrom
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- 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
- A23L5/00—Preparation or treatment of foods or foodstuffs, in general; Food or foodstuffs obtained thereby; Materials therefor
- A23L5/10—General methods of cooking foods, e.g. by roasting or frying
- A23L5/13—General methods of cooking foods, e.g. by roasting or frying using water or steam
Definitions
- This invention is in the field of food products and, more particularly, directed to a method and system for producing a dehydrated food product, including whole cooked bean (and other such similar) products in such a way as to preserve the structural integrity of the bean which, in turn, helps provide a food product having significantly enhanced texture and quality.
- the second, more-frequently encountered type of “hard” bean is one in which the “hardness” is due to hardshell, i.e., an impermeable seed wall.
- hardshell i.e., an impermeable seed wall.
- the hard-shell bean portion of the initial raw materials will generally remain hard through the soaking and cooking processes. As such, when the hard-shell beans are left untreated, the final (cooked) product will have an inconsistent quality.
- over-soaking and/or over-cooking of the entire bean batch in order to render the untreated hard-shell beans palatable may cause the remaining (non-hard shell) beans to disintegrate, resulting in a final product that has a mushy consistency.
- U.S. Pat. No. 4,871,567 suggests “tempering”, whereby, once the beans have been washed and drained, they are permitted to simply sit for a period of “equilibrium” which lasts four or more hours. This procedure, however, introduces a relatively long period of downtime, thus making the overall process of producing a dehydrated reconstitutable food product very time consuming.
- sitting food products often lend themselves to deleterious effects, such as souring or other undesirable flavor changes. Such deleterious effects may only be dealt with by introducing additional processing steps, which makes the overall process even more complex and time consuming and, as a result, reduces overall processing efficiency.
- Flakes due to their method of manufacture, have a harder outer surface and are generally treated with oil on their surface, which is a water repellent, so that water take-up upon reconstitution is actually slower than it may be otherwise. Therefore, in both cases, water absorption rates are not optimal.
- Bird mouthing also referred to as “butterflying” is a phenomenon wherein the whole bean splits along its two halves and opens during the dehydration process. It is believed that bird mouthing is caused by a differential rate of drying between the bean skin and cotyledon, such that, during the dehydration process, the bean skin dries more rapidly than the cotyledon, and thus, contracts (a condition which is referred to as “case hardening”). As dehydration continues, the slower-drying cotyledon develops internal vapor pressure to an extent where the pressure ruptures the skin and causes bird mouthing.
- U.S. Pat. Nos. 3,290,159 and 4,871,567 as examples of the prior art's attempts to reduce the amount of bird mouthing in dehydration of whole beans.
- the '159 patent discloses a two-stage dehydration process, wherein the first stage involves a slower moisture-removal process, and the second stage involves a more rapid dehydration process. Both stages of the disclosed methodology are directed to drying using conventional air dryers.
- the '567 patent discloses a dehydration process comprising two or more “stages”.
- the '567 patent teaches a method involving incremental decreases, rather than increases, in the amount of heat supplied during the dehydration process. Nevertheless, neither methodology seems to have resolved, to an appreciable degree, the problem of bird mouthing.
- An additional drawback associated with the process disclosed in the '159 patent is that, in order to be effective, the process calls for slow drying rates. Such slow drying rates translate into relatively long drying times (e.g., on the order of 4-6 hours) which, in turn, result in low levels of throughput per unit time.
- the process disclosed in the '567 patent calls for an initial period of high-humidity drying which, again, results in longer drying times. This is especially true when convective heating is utilized to dry the beans since convective dehydration efficiency drops off drastically during the latter stages of drying particulate material when moisture diffusion from the center of the particle controls the drying rate.
- the '952 patent discloses a method of making dehydrated potatoes, wherein the method includes drying pieces of potato by exposing them simultaneously to microwave energy and to hot air.
- the hot air is enriched with moisture to maintain an average humidity of at least 83% in the oven during most of the drying period.
- about 10-50% of the energy used for drying is provided by moisture-enriched air that is heated to between 75 and 255° F. and, typically, to 100-150° F.
- the '952 patent does not address bird mouthing at all. Rather, it teaches a combination microwave/hot air drying process in order to minimize discoloration and loss of flavor for potato pieces.
- the '358 patent is related to a process in which microwave energy may be used during the production of dehydrated potato products, but not during the drying step.
- FIG. 1 shows an illustration of a hydration/cooking vessel and rotatable member of an apparatus that may be used in the practice of an embodiment of the invention.
- FIG. 2 shows a cross-sectional view of the vessel and rotating member of FIG. 1 , taken along line II—II.
- FIG. 3 shows an illustration of a shaft and rotatable member of an embodiment of the cooking vessel shown in FIG. 1 .
- FIG. 4 shows an illustration of a channel and forming conduit of an apparatus that may be used in the practice of an embodiment of the invention.
- FIG. 5 shows a cross-sectional view of the channel and forming conduit of FIG. 4 , taken along line V—V.
- FIG. 6 shows a condensed flow-chart format of an embodiment of the invention.
- FIG. 7 shows a condensed flow-chart format of an alternative embodiment of the invention.
- FIGS. 8A-8C show various cross-sections of a sheet of textured material according to an embodiment of the invention.
- FIG. 9 shows an illustration of a hydration vessel that may be used in the practice of an embodiment of the invention.
- An embodiment of the present invention is related to a method or process for producing a reconstitutable, dehydrated food product, which may be practiced by the use of apparatus comprising a stationary hydration vessel, a stationary cooking vessel, a chopping system, a forming mechanism, and a drying system.
- embodiments of the present invention are directed towards stationary processes that minimize (or completely eliminate) movement of the beans.
- raw beans In order to cook raw beans (with an initial moisture content in the range 6%-14%, e.g.), they have to be uniformly hydrated either prior to, or simultaneously with, cooking. Unfortunately, uniform hydration is difficult due to the variable presence of “hard” beans that are difficult to hydrate.
- a stationary hydration vessel In order to hydrate variable-quality (i.e., with respect to “hardness”) beans in as gentle a way as possible, a stationary hydration vessel is used that may be generally vertically elongated and includes means for maintaining the beans below a water/air interface, as well as means (e.g., standard pump, tubing, and inlet valve) for introducing and circulating a wetting liquid through the vessel and the beans.
- means e.g., standard pump, tubing, and inlet valve
- raw cleaned beans are placed within the vessel; the beans are maintained below the water/air interface (i.e., below the water, or wetting liquid, level) throughout a predetermined hydration period.
- beans that have been adequately hydrated generally sink to the bottom of the vessel and are removed.
- “Harder” beans, however, that tend to buoy up towards the upper portion of the hydration vessel are captured (e.g., by means of a mesh screen) during hydration, and if still “hard”, removed at the end of the hydration period and optionally returned to the vessel for additional hydration with a subsequent batch of raw beans.
- a “broth”, comprising the unabsorbed portion of the wetting liquid and a proportion of bean solids is removed from the vessel.
- the broth may be further processed to separate the bean solids therefrom, and some or all of these bean solids may be returned to the beans at a later stage in the process.
- the stationary cooking vessel is equipped with a perforated, rotatable internal baffle which may be rotated periodically to ensure contacting, if necessary, of all beans or other foods with a small and continuous diminishing quantity of water; the baffle holes ensure that fluids within the vessel are exchanged freely between the two chambers of the vessel as defined by the baffle.
- the beans are transferred to the chopping system, wherein they are urged through a channel, comprising a rotating blade that chops, and a perforated plate that re-sizes, the beans into a texturized composition.
- the blade speed and the size of the holes in the perforated plate can be changed in order to achieve different textures within the composition.
- the composition is then treated in a forming mechanism, comprising a shaped conduit, wherein the composition is formed into a generally flat sheet, which is then treated so as to produce an improved reconstitutable dehydrated bean product.
- the generally flat sheet may be ribbed, or ridged, on either, or both, of its top and bottom surfaces.
- the stationary cooking vessel of the present invention has significant processing advantages. First, since the vessel is stationary, it is relatively simple to construct large units which result in substantial economies of scale. Second, by using a horizontal cooking vessel with a perforated internal baffle having a length and width that are substantially the same as the vessel, it is easy to assure that, when needed during processing, all of the beans are gently and continuously contacted with a small, and diminishing quantity of liquid.
- the perforated internal baffle can be completely eliminated provided that the beans have been adequately hydrated prior to cooking. In this manner, movement of the beans during cooking is essentially eliminated.
- Embodiments of the present invention are directed to a method of preparing a reconstitutable, dehydrated food product by means of hydrating and cooking raw beans, so that all of the cooked beans achieve a similar moisture content, chopping the cooked beans and forming the chopped beans into a flat sheet of texturized composition, drying the sheet, and breaking the sheet into smaller pieces.
- the above-described process results in a dehydrated bean product that absorbs water faster and more uniformly upon reconstitution. Also, after the raw beans have been hydrated, the broth can be partially, if desired, removed from the hydration vessel, thus eliminating some flatulent sugars from, and improving the digestibility of, the final bean product. Moreover, salt, oil, colorant, and other flavoring may be added during the chopping, or other steps, of the above-described process.
- a portion of hydrated and cooked whole beans may be removed before the chopping step, and then added to the beans in a subsequent step, or after drying to the final product upon reconstitution.
- whole beans may be independently hydrated, cooked, flavored, and dried, and then mixed with dehydrated small pieces of chopped beans produced separately.
- a portion of hydrated whole beans may be separately cooked, flavored, and dried, and then mixed with dehydrated small pieces of chopped beans produced separately from the remainder of the hydrated beans.
- the hydrated whole beans may be cooked, flavored and dried. Such product can then be used where quickly reconstitutable whole beans are desired as needed.
- FIGS. 1 and 4 show one embodiment of the apparati which may be used to practice the invention.
- a stationary vessel 10 comprises a vessel shell 12 , and a central shaft 30 .
- the vessel 10 has a substantially circular cross-section, this is done for purposes of demonstration only, and it is intended that the invention encompass other vessel configurations as well.
- the vessel 10 is also equipped with a solid-blade baffle 20 , which is attached to, and is rotatable around, shaft 30 .
- baffle 20 has a length and width that are substantially as long as the length and width, respectively, of the vessel 10 . Therefore, in the embodiment of FIGS. 1 and 2 , the width of the baffle 20 is substantially commensurate with the diameter of a cross-section of the vessel 10 . To ensure proper operation, a clearance of less than 3/16 inch is maintained between the inner surface 18 of the shell 12 and an edge 24 of the baffle 20 , as well as between an end 28 of the baffle 20 and an end 11 of the vessel 10 .
- the baffle 20 divides the inner space of the vessel 10 into two chambers, 14 and 16 , where each chamber is defined substantially by the space between the inner surface 18 of the vessel shell 12 , and a wall 26 of the baffle 20 .
- the solid-blade baffle 20 has transverse holes 22 (shown in FIG. 1 , and by dashed lines in FIG. 2 ) which, while large enough to allow fluids within the vessel 10 to travel between the chambers 14 and 16 , are small enough to keep the vessel contents 100 separated on each side of the baffle 20 .
- the vessel 10 may be employed both to hydrate raw beans and to cook the hydrated beans.
- the vessel 10 when used in the latter capacity, the vessel 10 is transformed into a pressure cooker, using steam to cook the beans.
- steam is forced through the shaft 30 , and enters each chamber 14 , 16 through steam outlets 32 which are arranged along the length of the shaft 30 (FIG. 3 ).
- steam can also be injected into the vessel through other suitably placed entrances to the vessel.
- a separate, stationary hydration vessel 200 is used to hydrate the beans, which are then transferred to vessel 10 in order to be cooked (see FIG. 9 ).
- Hydration vessel 200 is generally vertically elongated, with a top end 210 and a bottom end 220 , and includes means (such as an inlet valve or similar structure, e.g., at its bottom end 220 ) for introducing a wetting liquid into the vessel to establish a liquid level 240 such that all of the beans are immersed into the liquid.
- the wetting liquid may be pumped into the hydration vessel 200 such that the liquid is circulated through the beans within the vessel 200 for a predetermined hydration period which, typically, may last between 40 and 150 minutes.
- the hydration vessel 200 is equipped with means for capturing harder beans that may not hydrate adequately during the allotted hydration period and, as such, buoy up towards the upper end 212 of the vessel 200 (i.e., “floater” beans).
- the capturing means may include, for example, a mesh screen 230 , or similar structure.
- the hydration vessel 200 includes means, such as a release valve 250 , for removing the floater beans from the vessel 200 upon termination of the hydration period.
- beans that have been adequately hydrated and, as such, have generally sunk towards a lower portion 222 of the vessel 200 may be removed through outlet means (e.g., an outlet valve or similar structure) which may be placed at the bottom 220 of the vessel 200 .
- outlet means e.g., an outlet valve or similar structure
- a “broth”, comprising the unabsorbed portion of the wetting liquid and a proportion of bean solids may also be removed from the vessel 200 through the same, or an additional, outlet means (not shown), which may also be placed at the bottom 220 of the vessel 200 .
- the hydration vessel 200 may have a circular cylindrical configuration, with a height of about 10 feet, and a circular base having an inner diameter of about 3 feet.
- a circular cylindrical configuration with a height of about 10 feet, and a circular base having an inner diameter of about 3 feet.
- other configurations and dimensions may also be used in practicing the invention.
- raw beans typically have an initial moisture content in the range 6%-14%.
- prior-art methods cannot use a batch of raw materials that includes beans and legumes from this entire range because the disparity in initial moisture levels may exacerbate the variations in water absorption during hydration, so that the result would be a highly non-uniform final product.
- the prior art is limited to using raw beans that fall within a small range of initial moisture content, e.g., 6-8%, or 12-14%.
- the present invention is not so limited.
- the hydrated beans can then be cooked in a stationary cooking vessel 10 by simply placing them on the upper side of the baffle 20 when the latter is in the horizontal position. Since there is no need to have any further water in the vessel 10 while the beans are being cooked, it is not necessary to rotate baffle 20 during the cooking step.
- the hydrated beans are cooked using direct steam injection.
- the separately hydrated beans can be pressure cooked in a vessel with no rotatable baffle, provided the beans are sufficiently elevated off the bottom of the cooker to prevent the steam condensate from contacting the lower beans.
- An option is to add salt or other flavoring, colorant, oil and/or similar additives to the cooking vessel 10 . Also, either as a substitute for, or a supplement to, this option, oil, colorant, salt, and/or other flavoring may be added at various other steps within the process (e.g., after cooking or during the chopping step).
- the vessel 10 In order to cook the beans, steam is directly injected into the vessel 10 and chambers 14 and 16 , such that the vessel 10 is pressurized above atmospheric pressure, and the beans are cooked at a temperature in the range 228° F.-270° F. and pressure in the range 5 psig-25 psig for a predetermined cooking period.
- the cooking vessel 10 remains stationary, and the baffle 20 may either remain stationary, or rotate around the central shaft 30 for a minimal number of times. However, if the baffle 20 rotates, it is possible to drain any water condensate off the bottom of the cooker prior to rotation, so as to further minimize any contact of cooking beans with water.
- the beans are removed and transferred to a channel 40 having a proximal end 41 and a distal end 42 (see FIGS. 4 and 5 ).
- the cooked beans are urged towards the distal end 42 via a piston or other suitable mechanism, such as a rotating shaft with advancing frights.
- a rotating blade 50 As the beans are urged forward, they are chopped by a rotating blade 50 , which rotates at an angular velocity ⁇ .
- the beans are then pushed through the holes 62 of a perforated plate 60 , which is located distal to the rotating blade 50 and re-sizes the chopped beans as they travel past the plate.
- the present invention offers the capability of varying the texture of the final bean product to a desired consistency by changing the blade angular velocity ⁇ , the size of the plate holes 62 , or both.
- the chopped beans are next fed through a forming conduit 70 .
- the inlet 72 of the forming conduit 70 is connected to the distal end 42 of the channel 40 .
- the inlet 72 may comprise a hopper, or other inlet configuration, that is situated within close proximity of, but not necessarily connected to, the channel 40 . Regardless, once the chopped beans are in the conduit 70 , they are urged towards the conduit outlet 74 .
- the outlet 74 has a generally rectangular cross-section which may have ridges on its top and/or bottom surface(s), a thickness T, and a width that is considerably larger than T. Therefore, as the texturized composition exits the conduit outlet 74 , it is formed into a generally flat, continuous elongated sheet of rectangular cross-section that may have ridges 99 on its top and/or bottom surface(s). Additives, such as salt, oil, flavorings, and/or colorants may be added to the beans during the chopping and/or forming steps so as to result in a uniform dispersion of these additives.
- FIGS. 8A-8C show various cross-sections of the sheet of textured material.
- the outlet 74 of the forming conduit 70 has a rectangular cross-section of thickness T (see FIG. 4 )
- a generally flat sheet of textured composition is produced that also has a generally rectangular cross-section, with thickness T 1 (see FIG. 8 A), where the magnitude of T 1 may be slightly less than the magnitude of T.
- the outlet 74 may have ridges, or ribs, on its top and/or bottom surface(s). As shown in FIGS. 8B and 8C , this will result in a sheet of texturized composition that also has ridges (or ribs) 99 running longitudinally on its top and/or bottom surface(s).
- the cross-sectional configuration of the sheet of texturized composition is generally determined by striking a balance between throughput and drying efficiency. That is, on the one hand, the thicker the sheet of texturized composition, the higher the amount of beans that can be processed for a given speed through the forming conduit 70 . On the other hand, the thicker the sheet of texturized composition, the higher the required amount of time for exposure to heat (or other drying mechanism) which, in turn, translates into a slower processing speed—or, put another way, if the speed is kept constant, then a thicker sheet of composition may not be sufficiently dried. In this regard, experimental results indicate that, in a preferred embodiment, all sections of the sheet are typically less than about 1 ⁇ 4 inch thick.
- the elongated sheet of texturized composition is next dried and then broken up, or formed, into chunks, where each chunk may be approximately 0.25 to 0.50 inch in size.
- the drying step is accomplished by drying the elongated sheet of texturized composition in a combination microwave/convection dryer, where the sheet is dried to a final moisture content of less than about 9-10%.
- This drying arrangement provides for control over the characteristics (e.g., flavor) of the final product, as well as a higher level of efficiency and throughput by the overall process.
- the sheet of texturized composition may be toasted (to enhance flavor) by adjusting the convection air temperature.
- the microwave-energy mode allows drying of ribbed sheets of texturized composition of a thickness greater than 1 ⁇ 2-5 ⁇ 8 inch in relatively short time periods.
- aspects of embodiments of the present invention are directed to a method of preparing a reconstitutable, dehydrated whole bean product in such a way as to preserve the structural integrity of the whole beans which, in turn, would significantly enhance the texture and quality of the final bean product containing the whole beans.
- a method must address, and significantly decrease, the amount of bird mouthing that is prevalent in methods currently existing in the art, without adversely affecting productivity levels (i.e., throughput).
- the above-mentioned goals are achieved by a method of preparing dehydrated whole beans so as to preserve the beans' structural integrity, wherein the method comprises:
- the above-mentioned goals are achieved by a method of preparing dehydrated whole beans so as to preserve the beans' structural integrity, wherein the method comprises: cleaning, washing, hydrating, and cooking raw beans; arranging the cooked beans into multiple bean layers; and drying said layers of cooked beans using microwave energy, convective heating, or both microwave energy and convective heating energy.
- a method of preparing dehydrated whole beans so as to preserve the structural integrity of substantially all of the beans comprises: providing a heating chamber for drying of cooked beans, wherein said chamber includes means for continuously advancing the cooked beans through said chamber; arranging the cooked beans into multiple bean layers; and drying said layers of cooked beans in said chamber using either microwave energy, convective heating, or both microwave energy and convective heating energy.
- embodiments of the present invention utilize microwave energy and/or convective energy to efficiently dry cooked whole beans and minimize “bird mouthing”.
- use of the microwave mode will heat water from inside each bean, thus minimizing case hardening, and use of the convective mode will “blow” away evaporated water.
- embodiments of the present invention are also directed to a method for producing a reconstitutable dehydrated chunky bean product so as to substantially eliminate hard beans from the bean product, the method comprising:
- the method for producing a reconstitutable dehydrated chunky bean product so as to substantially eliminate hard beans from the bean product comprises arranging the second portion of unchopped cooked beans into a stack of multiple bean layers, and then drying the layers using microwave energy, convective heating, or both microwave energy and convective heating energy prior to adding the second portion of unchopped cooked beans to the chunks.
- each of the drying steps may by accomplished by using microwave energy, convective heating or a combination thereof.
- the beans destined to be chopped are processed as described previously, and the beans destined to remain whole are processed separately. More specifically, the beans destined to remain whole are washed, cleaned, hydrated, and cooked separately from, but in a similar fashion to, the beans destined to be chopped. Thus, for example, the beans destined to remain whole are hydrated and cooked in the apparati depicted in FIGS. 9 and 1 , respectively, using substantially the same steps, but a different temperature/pressure/time profile, than that used for the beans destined to be chopped.
- the whole beans are arranged into a stack having multiple bean layers, and then dried using microwave energy, convective heating, or a combination of microwave and convective energy.
- the stack of beans is at least 13 ⁇ 8 inches high (containing at least 4 layers) and is dried using a combination microwave/convection dryer.
- the microwave energy input allows the drying step to proceed at high throughput rates.
- adjustment of the convection air temperature allows a significant degree of control over the rate of incidence of bird mouthing in the whole beans.
- the vessel was then maintained at atmospheric pressure, and the baffle was alternately and continuously slowly rotated for one (1) minute each in the clockwise and counterclockwise directions. Steam was added through the baffle shaft to maintain the bean/water mixture temperature between approximately 180° F. and 190° F. The beans immediately started to absorb the hot water, and the rotating baffle served to mix and contact the beans with a continuously diminishing quantity of water. This hydration step was continued for 20 minutes, after which approximately 6700 ml of broth was drained from the now partially-hydrated beans. 75 grams of salt was then dissolved in 600 ml of the drained broth and this salt solution was returned to the cooking vessel.
- the hatch to the cooking vessel was now secured and the vessel pressurized with steam and held at a pressure of 10 psig for 40 minutes in order to cook the beans.
- the cooking vessel baffle continued to rotate alternatively and slowly for one (1) minute each in the clockwise and counterclockwise directions. In this manner, all the beans were contacted with the remaining and continuously reducing broth volume.
- the vessel was depressurized and the cooked beans with very little remaining liquid broth were discharged into a holding vessel.
- cooked beans were then chopped and texturized by a small electrically driven meat grinder, which had a front plate with 1 ⁇ 4 inch holes and knife cutters which rotated against the inner side of the front plate.
- the cooked beans were manually fed into the grinder and the textured bean mass collected as it exited through the grinder front plate.
- the textured bean mass was then placed in a cylindrical vessel, and was shaped into a sheet approximately 1 ⁇ 8 inch in thickness and 4 inches wide by applying pressure to the vessel so as to force the bean mass through a 1 ⁇ 8 inch by 4 inch slot situated at the base of the vessel.
- the bean sheet was initially dried for 3 minutes and 45 seconds using 400° F. hot air impinging on the top and bottom of the bean sheet.
- the partially-dried beans were then broken into smaller pieces, placed on the perforated metal supporting squares, and finally dried for 4 minutes in the same convective dryer using 350° F. hot air.
- a dehydrated refried bean product mix was prepared according to FIG. 7 .
- the “texturized composition” portion of the mix was made by placing 200 lbs. of dry raw, cleaned pinto beans in a vertical hydration vessel.
- the hydration vessel was equipped with a screen and liquid outlet so that the beans would be immersed in hydrating liquid throughout the hydration step. 600 lbs. of hot water were then continuously circulated through a heat exchanger and the bed of hydrating beans. For the first 30 minutes of the hydration, the recirculating hot water was maintained at approximately 190° F., and then the hot water was heated to approximately 203° F. and maintained at this temperature for an additional 85 minutes.
- the hydration vessel was then first drained of broth.
- the beans were very uniformly hydrated (moisture of 61.3%) maintaining their whole-bean integrity and thus easily flowed out of the vessel through a 4-inch tube into a holding container.
- the hydrated beans were transferred to a cooking vessel having a 4-ft. diameter and equipped with a central rotating baffle that extended to within 3 1/16 inch of the cooking vessel's walls.
- the cooking vessel's baffle was placed in a horizontal position and the hydrated beans were placed on the baffle within the cooking vessel.
- the beans were then pressure cooked by direct steam injection for about 60 minutes, the first 10 minutes at 10 psig and the remaining time at 13 psig.
- the central rotating baffle was stationary during the entire cooking step so as to maintain the whole bean integrity.
- the cooked whole beans were continuously fed by conveyor into a convection/microwave dryer.
- the beans were stacked in a layer 18 inches wide by 13 ⁇ 8 inches high on the feed conveyor and fed through the dryer at about 8 inches per minute.
- a batch convection/microwave oven was used in Examples 3-22.
- the oven When operating in the convection/microwave mode, the oven is set up to provide intermittent microwave power (of approximately 0.6 kilowatts for approximately 40% of the time).
- the convection system circulates hot air at a defined temperature, and is on “continuously”, in the sense that, when the microwave mode is “off” (and the convection mode in “on”), energy is supplied to the heating elements of the convection oven, and fans (or blowers) blow the hot air through and around the mass of beans inside the chamber.
- the microwave mode in “on” energy is no longer supplied to the heating elements, but the fans continue to operate, so that hot air inside the chamber is still forced through (and around) the mass of beans.
- convective heating is supplied in such a way as to generate and circulate hot air when microwave heating is not applied, and to circulate existing hot air, without generation of further convective heat, when microwave heating is applied.
- the hot air at a defined temperature is simply recirculated around and through the product, and no microwave energy is applied.
- a square microwave dish (6 in. on each side, and 11 ⁇ 2 in. deep) was used to place about 244 grams of cooked whole beans inside a combination microwave-convection heating oven. With this setup, the beans arranged themselves in about 2-21 ⁇ 2 layers within the dish.
- the cooked beans had a moisture level of about 70%.
- the beans were first exposed to full microwave energy for a period of 31 ⁇ 2 minutes (to heat them from room temperature to 212° F.).
- the beans were dried using both microwave and convective energy for a period of approximately 12 minutes with the convective air temperature set at 250° F.
- microwave heating was supplied intermittently, for a total of approximately 40% of the time.
- the convection mode was fully “on” when the microwave mode was “off”, and only partially “on” (i.e., fans continued to operate, so that hot air inside the oven was forced through and around the mass of beans) when the microwave mode was “on”.
- the cooked whole bean material remaining in the dish weighed about 120 grams.
- Example 3 The experiment of Example 3 was repeated, with the difference that the drying process was carried out using convective air set at 350° F., rather than at 250° F.
- the beans were first heated solely with microwave energy for 31 ⁇ 2 minutes, and then for successive 12-minute and 8-minute periods using both microwave and convective heating as described in Example 3. This resulted in 76 grams of dried whole bean material, of which 14 grams, or about 18.4%, were identified as being bird mouthed.
- Example 3 The experiment of Example 3 was repeated, with the difference that only about one-half as much starting material was used, such that the beans arranged themselves in a single layer. This resulted in a shorter heating time, as well as about double the amount of microwave energy per unit mass of beans. Using the same dish as in Example 3, this resulted in only one layer of beans.
- Example 3 The experiment of Example 3 was repeated, with the difference that only microwave energy was used to dry the beans.
- 254 grams of cooked beans were exposed to full microwave power for 31 ⁇ 2 minutes, followed by a 12-minute exposure to microwave energy with the power set at 40%.
- the beans were then mixed and dried for an additional 12 minutes using only microwave energy with the power similarly set at 40%.
- the 84 grams of dried bean material remaining at the end of this period contained about 13 grams, or about 15.5%, of visually-identified bird-mouthed beans.
- Example 8 The experiment of Example 8 was repeated, except that a large bowl having a base diameter of 6 inches, a top diameter of 7 inches, and a depth of 41 ⁇ 2 inches was used, which resulted in 2 21 ⁇ 2 bean layers. After the 231 ⁇ 2-minute dehydration period, about 32% of the dried beans were bird-mouthed.
- Example 9 The experiment of Example 9 was repeated (i.e., deep bowl 2-21 ⁇ 2 bean layers), except that a combination of both microwave energy and convection heating with the air temperature set at 250° F. was used to dry the beans. After 231 ⁇ 2 minutes (31 ⁇ 2+12+8 minutes), the dried beans exhibited a bird-mouthed rate of about 25%.
- Example 8 The experiment of Example 8 was repeated (i.e., open dish, 1-2 layers), except that the beans were dried using a combination of convection heating (with the air set at 250° F.) and microwave energy. With the beans again arranging themselves in about 1-2 layers, after 231 ⁇ 2 minutes (31 ⁇ 2+12+8 minutes) and drying at about 250° F., the dried beans exhibited a bird-mouthed rate of about 33%.
- Beans were placed in a small bowl (about 41 ⁇ 2 inches in diameter and 31 ⁇ 2 inches deep), where they arranged themselves in 4-5 layers.
- the beans were dried using a combination of both convection heating (with the air set at 250° F.) and microwave energy. After 231 ⁇ 2 minutes (31 ⁇ 2+12+8 minutes), the dried beans exhibited a bird-mouthed rate of about 11%. This experiment was repeated a second time, with a bird-mouthed rate of about 8%.
- Example 12 The experiment of example 12 was repeated, except that only microwave energy (at 40% power level) was applied. After 231 ⁇ 2 minutes (31 ⁇ 2+12+8 minutes), the dried beans exhibited a bird-mouthed rate of about 10%.
- a large container having a diameter of 81 ⁇ 2 inches, a depth of 11 ⁇ 2 inches, and a lid having 8 transverse 1 ⁇ 8-inch holes was used to dry beans with microwave energy only. Beans were placed in the container and the lid used to cover the container. The beans, which arranged themselves in only 1 layer, were first dried for 31 ⁇ 2 minutes at full power, followed by a 12-minute period with the microwave at about 40%. The beans were then mixed and dried for an additional 11 minutes using the microwave at about 40%. The dried beans exhibited about 14% bird mouthing.
- Example 14 The experiment of Example 14 was repeated with the lid removed. At the end of 261 ⁇ 2 minutes, the dried beans exhibited about 30% bird mouthing.
- a flat bowl (6 inches on each side, and 13 ⁇ 4 inches deep) was used to place about 230 grams of cooked whole beans inside a combination microwave-convection heating oven. With this setup, the beans arranged themselves in about 2-21 ⁇ 2 layers within the bowl.
- the beans were first exposed to full microwave power for a period of 31 ⁇ 2 minutes. Next, the beans were dried for a period of approximately 12 minutes using both microwave energy (with power set at 40%) and convective heating (with the air temperature set at 250° F.). The beans were then mixed and dried for an additional 8-minute period. Of the remaining 63 grams of bean material about 9 grams, or about 14.3%, of the beans exhibited bird mouthing.
- Example 16 The experiment of Example 16 was repeated, with the difference that only microwave energy was used to dry the beans. After 231 ⁇ 2 minutes (31 ⁇ 2+12+8 minutes), the dried beans exhibited a bird-mouthed rate of about 27%.
- Examples 12 and 13 indicate that, with multiple layers, especially in the range of 4-5 layers, a bird-mouthed rate of 8%-11% may be achieved.
- Example 16 resulted in a bird-mouth rate (14.3%) that was about half as much as that achieved in the experiment of Example 17 (i.e., about 27%).
- a flat dish (6 in. on each side, and having no walls) was used to place about 188 grams of cooked whole beans inside a combination microwave-convection heating oven. With this setup, the beans arranged themselves in about 1-2 layers within the dish.
- the beans were first exposed to full microwave energy for a period of 31 ⁇ 2 minutes. Next, the beans were dried for a period of approximately 12 minutes using both microwave and convective heating with the circulating air temperature set at 250° F. During this time interval, microwave heating was supplied intermittently, for a total of approximately 40% of the time. In addition, the convection mode was fully “on” when the microwave mode was “off”, and only partially “on” (i.e., fans continued to operate, so that hot air inside the oven was forced through and around the mass of beans) when the microwave mode was “on”. At the end of this 12-minute time interval, the cooked whole bean material remaining in the dish weighed about 82 grams.
- Example 18 The experiment of Example 18 was repeated, with the difference that the successive 12- and 3-minute drying stages were carried out using circulating air temperature set at 225° F. rather than at 250° F.
- the dried beans exhibited a bird-mouthed rate of about 9%.
- Example 22 With multiple bean layers, and in particular, with 4-5 bean layers, bird mouthing of the beans can be essentially eliminated. See, e.g., Example 22.
- dehydration of the beans can be achieved in a shorter amount of time than would be possible with either pure convection heating or drying with 1-2 bean layers.
- the experiment of Example 20 for instance, in which the beans arranged themselves in 1-2 layers, required 191 ⁇ 2 minutes to dry the beans using microwave energy.
- the experiment of Example 22 required only about 151 ⁇ 2 minutes to accomplish the same task.
- Example 21 results in only about 5% of the beans exhibiting bird mouthing, as opposed to about 16% in the experiment of Example 20.
- this reduction in bird mouthing can be achieved in a shorter amount of time (i.e., in this case, 191 ⁇ 2 minutes) than would be possible with pure convection heating.
- the higher-humidity dehydration process summarized in Example 21 is still slower than the larger-bean-layer dehydration process summarized in Example 22.
- the dehydration process is faster when multiple bean layers are used.
- Example 18 took about 181 ⁇ 2 minutes to complete and resulted in a bird-mouthing rate of about 10%.
- beans from both moisture categories i.e., those having an initial moisture content of about 58% (that were cooked using the apparatus depicted in FIGS. 1-3 herein) and those having an initial moisture content of about 70% were separately dried in a continuous impingement convection oven (e.g., Lincoln impingement oven) using convection only.
- a continuous impingement convection oven e.g., Lincoln impingement oven
- the beans were placed on a teflonized perforated plate (12 in. ⁇ 12 in.), where they arranged themselves in about 1-11 ⁇ 2 layers.
- the beans were then dried for just over 10 minutes at 235° F., followed by 81 ⁇ 2 minutes at 265° F., and 91 ⁇ 4 minutes at 300° F drying time was about 28 minutes.
- embodiments of the invention may employ a heating chamber allowing continuous product passage therethrough, rather than a traditional convection/microwave oven.
- a heating chamber capable of providing convective heating and/or microwave energy may be equipped with a conveyor or other similar means for continuously advancing the beans through the chamber.
- the speed of the conveyor will be determined by the number of bean layers, the exposure temperature, the required duration of exposure, the level of humidity within the chamber, etc.
- Embodiments of the present invention are also directed to a method of producing a reconstitutable dehydrated chunky bean product so as to substantially eliminate hard beans from the bean product, wherein dried whole beans produced by the methods described immediately above so as to be substantially free of bird-mouthing effects can be added at various points within the process outlined in FIG. 6 .
- a reconstitutable dehydrated bean product may be produced that has an improved amount of chunkiness and home-made feel due to the existence of actual, structurally intact, whole beans in the final, reconstituted product.
- additives such as salt, colorant, flavor ingredients, and/or oil may be added to either portion of beans at various points (e.g., prior to cooking, prior to chopping, etc.).
- embodiments of the present invention are not limited in their design or application to specific embodiments disclosed herein.
- injection of steam into the stationary pressure vessel may be accomplished through ports in the vessel walls.
- steps of embodiments of the methodology lend themselves to dried legumes, other food-stuffs (e.g., carrots, celery, meats, chicken, fish and the like) are also within the scope of the present invention.
- the present invention is intended to encompass all of the embodiments disclosed and suggested herein as defined by the claims appended hereto and any equivalents thereof.
Abstract
Description
-
- cleaning, washing, hydrating, and cooking raw beans; and
- drying the cooked beans in a combination microwave-convection heating process, wherein the beans are dried by exposure to both microwave energy and convective heating energy.
-
- providing a heating chamber for drying of cooked beans, wherein said chamber includes means for continuously advancing the cooked beans through said chamber; and
- drying the cooked beans in said chamber by exposing said beans to both microwave energy and convective heating energy.
-
- separately hydrating first and second portions of raw beans by maintaining the entirety of said first and second portions submerged in a wetting liquid for respective hydration periods so as to obtain respective first and second portions of unchopped hydrated beans;
- separately cooking each of said first and second portions of hydrated beans to obtain respective first and second portions of unchopped cooked beans;
- chopping said first portion of the cooked beans to form a composition of a desired texture;
- forming the texturized composition into a generally flat sheet;
- drying the flat sheet of texturized composition;
- forming the sheet into chunks;
- drying the second portion of unchopped cooked beans using microwave energy, convective heating, or both microwave energy and convective heating energy; and
- adding the dried second portion of unchopped cooked beans to said chunks.
Claims (114)
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US09/640,297 US6482457B1 (en) | 2000-08-16 | 2000-08-16 | Method for producing a reconstitutable dehydrated food product |
US10/300,197 US7074444B2 (en) | 2000-08-16 | 2002-11-19 | Method for producing a dehydrated whole food product |
US10/745,365 US7029716B2 (en) | 2000-08-16 | 2003-12-23 | Method and system for producing a dehydrated whole food product |
US12/148,108 USRE41885E1 (en) | 2000-08-16 | 2008-04-16 | Method for producing a dehydrated whole food product |
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US20100255176A1 (en) * | 2007-05-07 | 2010-10-07 | Nonpareil Corporation | Baked potato products and process for preparing same |
US20170208825A1 (en) * | 2016-01-21 | 2017-07-27 | Alan Backus | Gaseous transfer device |
US20180042277A1 (en) * | 2015-01-29 | 2018-02-15 | Geirmund Vik | Soybean Processing Method |
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