WO2006095351A1 - Procede permettant de produire des compositions de pommes de terre ou d'autres legumes et produits resultants - Google Patents

Procede permettant de produire des compositions de pommes de terre ou d'autres legumes et produits resultants Download PDF

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Publication number
WO2006095351A1
WO2006095351A1 PCT/IL2006/000316 IL2006000316W WO2006095351A1 WO 2006095351 A1 WO2006095351 A1 WO 2006095351A1 IL 2006000316 W IL2006000316 W IL 2006000316W WO 2006095351 A1 WO2006095351 A1 WO 2006095351A1
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WO
WIPO (PCT)
Prior art keywords
potato
raw
composition
product
extrudable
Prior art date
Application number
PCT/IL2006/000316
Other languages
English (en)
Inventor
Yakov Porat
Rani Peles
Israel Adler
Original Assignee
Tapugan Industries Ltd.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Tapugan Industries Ltd. filed Critical Tapugan Industries Ltd.
Publication of WO2006095351A1 publication Critical patent/WO2006095351A1/fr
Priority to IL185787A priority Critical patent/IL185787A0/en

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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
    • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
    • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
    • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
    • A23L19/18—Roasted or fried products, e.g. snacks or chips
    • A23L19/19—Roasted or fried products, e.g. snacks or chips from powdered or mashed potato products
    • 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
    • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
    • A23L19/09—Mashed or comminuted products, e.g. pulp, purée, sauce, or products made therefrom, e.g. snacks
    • 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
    • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
    • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
    • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
    • A23L19/13—Mashed potato products
    • 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
    • A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
    • A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
    • A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
    • A23L19/14—Original non-roasted or non-fried potato pieces
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/20—Extruding
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/20—Extruding
    • A23P30/25—Co-extrusion of different foodstuffs

Definitions

  • This invention relates to the field of food products. More specifically, the invention- p relates to potato products that can be prepared on industrial scale and are suitable for storage and/or use upon reheating.
  • the products comprise a large number of additives and sometimes comprise flour additives.
  • a variety of available potato starting materials have been used for making commercial potato products for consumption. These starting materials include diced potatoes, sliced potatoes, potato granules and potato nubbins. The starting materials may be in a number of different forms including fresh, individually quick frozen, blanched or dehydrated.
  • a potato dough is made from the potato starting materials. -Typically, the dough comprises additives and sometimes requires a cooking process prior to forming the dough. The resultant dough may be extruded or sheeted and cut into a desired shape.
  • the potato products made in this manner contain a smooth, mashed potato consistency with few or no particulates.
  • Extrusion processes for the formation of food products offer an efficient and cost effective approach. Extrusion processes, however, necessarily have certain characteristics that suggest the types of products that can be effectively produced. In particular, significant pressure is exerted on the ingredients during extrusion when the food product is moved through a gap. Extrusion processes, thus, are particularly suitable for processing doughy products. Because of the pressures involved, extrusion is generally considered to be unsuitable for production of products that need to retain the piece integrity of the fragile starting materials.
  • raw (i.e. fresh, uncooked) potatoes shredded into small particles and combined with drying agent (i.e. water absorbing agent), e.g. potato flakes, give rise to a potato composition that can be shaped by extrusion into a relatively firm potato casing, with the particles that constitute it being firmly attached to one another, and can consequently accommodate a filling, to yield a filled potato product.
  • drying agent i.e. water absorbing agent
  • the potato composition may include also additives such as flavoring and/or sweetener and/or color enhancing agents.
  • the ingredients contained in the potato composition of the invention are sufficient for yielding said potato casing. Additives, such as gelling agents (e.g. methyl cellulose, cellulose gum, etc.), eggs, flour or the like, usually used in industrially manufactured potato products are not necessary for producing a casing according to the present invention.
  • This invention is directed to methods for producing an extrudable raw potato composition comprising:
  • the size reducing step comprises at least one unit operation selected from shredding, grating, comminuting, crushing, dicing, chopping and blending.
  • the size reducing step comprises shredding.
  • the average particle size is less than about 6 mm in at least two dimensions.
  • the raw potatoes are peeled. In other embodiments, the raw potatoes are unpeeled.
  • the extrudable raw potato composition is 100% natural.
  • the at least one drying agent is selected from potato flakes, potato granules, and mixtures thereof.
  • the method further comprises kneading the extrudable raw potato composition into a dough.
  • a method of making a filled raw potato food product containing an external potato casing and a filling comprising
  • the method further comprises cooking or partially cooking the product obtained in step (iv) by baking, boiling, frying or microwave cooking to form a filled cooked potato food product.
  • the method further comprises refrigerating or freezing the potato product obtained in step (iv) prior to cooking or partial cooking.
  • the method further comprises packaging the filled raw potato food product.
  • the method further comprises packaging the filled cooked potato food product.
  • the extrudable raw potato composition comprises 60-100% by weight raw potatoes shredded to a average particle size of less than about 10 mm in at least one dimension, and 0-40% by weight of the drying agent,.
  • the extrudable raw potato composition comprises 80- 99% by weight raw potatoes shredded to a particle size between about 1 to about 6 mm in at least one dimension and 1-20% by weight of the drying agent.
  • the method further comprises adding to the extrudable raw potato composition at least one additive selected from a flavor agent, a sweetening agent a color enhancer agent, an emulsifying agent; a stabilizing agent and a glazing agent.
  • an extrudable raw potato composition comprising an at least partially dried particulate of raw potatoes having a average particle size of less than about 10 mm in at least one dimension and at least one additive, wherein the composition comprises carbohydrates derived substantially only from potatoes.
  • a food product comprising an external raw potato casing and a filling, wherein the external casing is manufactured from an extrudable raw potato composition from raw potatoes shredded to an average particle size smaller than about 10 mm in at least one dimension, and a drying agent.
  • the drying agent is selected from potato flakes, potato granules and mixtures thereof.
  • the product is in a form selected from frozen, refrigerated, uncooked, cooked or partially cooked.
  • the extrudable raw potato composition comprises 60-100% by weight raw potatoes shredded to a particle size smaller than about 10 mm in at least one dimension and 0-40% by weight of the drying agent.
  • the external casing is manufactured by extruding or encrusting an extrudable raw potato composition from 80-99% by weight of the raw potatoes shredded to a particle size between about 1 to about 6 mm in at least one dimension, 1-20% by weight of the drying agent and optionally from 0.1-5% by weight of at least one of flavoring agent, sweetener and coloring agent.
  • the flavoring agent is selected from sodium chloride, potassium chloride, spices, vanilla and mixtures thereof.
  • the sweetener is selected from sugar, a dietary sugar product and an artificial sweetener.
  • the filling is selected from meat or meat-derived products, soya products, sea food or sea food-derived products, vegetable or vegetable-derived products, dairy or dairy-derived products, egg or egg-derived products, sauces, cheese, dairy products, nuts, flavorings and mixtures thereof.
  • the product comprises a weight ratio of the potato casing to the filling of about 4:1 to about 1:4. In some cases, the ratio is about 1 :1.
  • the extrudable raw mixed vegetable composition is 100% natural.
  • the at least one drying agent is selected from potato flakes, potato granules, and mixtures thereof.
  • the method further comprises kneading the extrudable raw mixed vegetable composition into a dough.
  • a method of making a filled raw vegetable food product containing an external vegetable casing and a filling comprising
  • the method further comprises cooking or partially cooking the product obtained in step (iv) by baking, boiling, frying or microwave cooking to form a filled cooked mixed vegetable food product.
  • the extrudable raw mixed vegetable composition comprises 60-100% by weight of raw vegetables shredded to a average particle size of less than about 10 mm in at least one dimension, and 0-40% by weight of the drying agent.
  • an extrudable raw vegetable composition comprising an at least partially dried particulate of raw vegetables having an average particle size of less than about 10 mm in at least one dimension and at least one additive, wherein the composition comprises carbohydrates derived substantially only from vegetables.
  • a food product comprising an external raw vegetable casing and a filling, wherein the external casing is manufactured from an extrudable raw mixed vegetable composition from raw vegetables shredded to an average particle size smaller than about 10 mm in at least one dimension, and a drying agent.
  • drying agent is selected from potato flakes, potato granules and mixtures thereof.
  • the extrudable raw mixed vegetable composition comprises 60-100% by weight of the raw vegetables shredded to a particle size smaller than about 10 mm in at least one dimension and 0-40% by weight of the drying agent.
  • the particle size of the potato shreds is of critical importance for maintaining structural integrity of the potato composition during the extrusion process and further processing of the product.
  • structural integrity refers to a potato composition or product that can be handled and processed without breaking apart during the process. The potato products of the invention maintain structural integrity even upon reheating by the consumer.
  • the invention provides a potato product.
  • the product comprises an external potato casing and an edible filling, where the external casing, manufactured from a potato composition consisting essentially of raw potatoes shredded to a particle " size smaller than about 10 mm, preferably between about 6 mm to about 1 mm, in at least one dimension and a drying agent.
  • the potato product of the invention is typically, albeit not exclusively, manufactured by a co-extrusion process of the potato composition and the filling.
  • the potato composition may further contain additives, in relative small amounts, e.g. for impacting taste or color such as flavoring and/or sweetener and/or color enhancer agents.
  • raw potato in the context of the present invention refers to fresh, uncooked potato that was not exposed to any processing procedure such as cooking, partial cooking, blanching, hydration, dehydration and the like.
  • potato includes all the edible kinds of potatoes, including sweet potato.
  • potato products in frozen, refrigerated, uncooked, cooked or partially cooked forms are included in frozen, refrigerated, uncooked, cooked or partially cooked forms.
  • the invention provides a filled potato product comprising an external potato casing and an edible filling, where the external casing is manufactured from a potato composition consisting essentially of 60-100% (by weight) raw potatoes shredded to a particle size smaller than about 10.mm in at least one dimension and 0-40 % (by weight) drying agent, e.g. potato flakes.
  • the potato composition may optionally contain small amounts of additives such as flavoring and/or sweetener and/or color enhancer agents.
  • the present invention provides a filled potato product comprising an external potato casing and an edible filling, where the external casing is manufactured from a potato composition consisting essentially of 80-99% (by weight) raw potatoes shredded to a particle size smaller than about 10 mm in at least one dimension and 1-20% (by weight) potato flakes.
  • the composition may further contain at least one additive such as a flavoring agent, sweetener, coloring agent and others.
  • the invention provides a method of making a potato product containing an external casing and an edible filling, the method comprising
  • the filled potato product that exits the extruder can be cooked or partially cooked by baking, boiling, frying or microwave cooking, preferably, by frying. Rather than cooking the filled potato product immediately following the extrusion process, the potato product can be refrigerated or frozen prior to cooking.
  • Fig. 1 is a simplified flowchart of a process for producing an extrudable raw potato composition, in accordance with an embodiment of the present invention
  • Fig. 2 is a simplified flowchart of a process for preparing a filled potato product using an extrudable raw potato composition, in accordance with an embodiment of the present invention
  • Fig. 3 is a simplified flowchart of a process for producing an extrudable raw mixed vegetable composition, in accordance with an embodiment of the present invention
  • Fig. 4 is a simplified flowchart of a process for cooking and packaging a filled potato product following the process of Fig. 2, Fig. 3 or Fig. 5;
  • Fig. 5 a simplified flowchart of a process for preparing a filled potato product using an extrudable raw potato composition, accordance with an embodiment of the present invention
  • Fig. 6 is a simplified schematic diagram of an extrusion die and a filled potato product therefrom, in accordance with an embodiment of the present invention.
  • Fig. 7 is a simplified flowchart of a process for preparing a filled potato product using an extrudable raw potato composition employing the extrusion die of Fig. 6.
  • Fig. 1 shows a simplified flowchart 100 of a process for producing an extrudable raw potato composition, in accordance with an embodiment of the present invention.
  • the size reducing process step typically comprises at least one unit operation selected from shredding, grating, comminuting, crushing, dicing, chopping and blending.
  • step 110 comprises a shredding process. Examples of typical industrial shredders/grinders used in this process, such as Lan Elec Shredder, Model # PC14AHD in US 6,890,580, or Tummer's pulverizer (Tummers Methodic, Hoogerheide, The Netherlands).
  • Stream 102 comprises raw potatoes which have been washed and may be peeled or unpeeled.
  • the word "potato” is used broadly herein to describe any type or strain of the potato such as, but not limited to, Aurora, Saturna, Kinnebec, Idaho Russet, Mentor, Norchip, Norgold, Russet Burbank, Lady Russeta, Norkota, Sebago and, Bentgie.
  • the potato is replaced by a similar vegetable such as a sweet potato, parsnip, turnip or one or more similar vegetables.
  • a liquid removal step with liquid stream 116 may be performed during or after step 110 to remove excess liquids from the particulate. The liquid removed in this step is normally less than 10% of the potato weight of stream 102.
  • Size reduction step 110 yields a raw potato particulate in stream 112.
  • the average particle size is normally less than about 10 mm in at least one dimension. In some embodiments, the particles are less than 6 mm in at least two dimensions, and in some further embodiments the particles are less than 5 mm in at least two dimensions.
  • the raw potato particulate stream 112 is mixed with at least one drying agent 114 to form an extrudable raw potato composition 122.
  • the at least one drying agent is selected from potato flakes, potato granules and mixtures thereof.
  • excess liquid is removed in stream 126. In other embodiments, no liquid is removed in stream 126.
  • the extrudable raw potato composition 122 comprises only natural ingredients.
  • up to 3% by weight sodium chloride and/ or potassium chloride are added to the composition in step 120.
  • Excess liquid may be removed once or more in step 120 from the composition in stream 126 employing an industrial sieve or settling apparatus such as Barred grate -perforated bend - barred sieve (Tummers Methodic, Hoogerheide, The Netherlands).
  • excess liquid can be removed from the solids employing other filtration, centrifugation, settling- process equipment, known in the art, such as a drum sieve conveyor (Tummers Methodic, Hoogerheide, The Netherlands).
  • the resultant extrudable raw potato composition in stream 122 comprises carbohydrates derived substantially only from potatoes.
  • An example of the extrudable raw potato composition appears in Table IA hereinbelow.
  • the extrudable raw potato composition may optionally further processed to render a pre-specified consistency.
  • excess liquid may be filtered at step 110 and/or at step 120 after a settling step (not shown).
  • salt and the drying agent may be added to composition 122 to provide the pre-specified consistency.
  • the extrudable raw potato composition is in the form of a dough.
  • the potato dough can be extruded or sheeted and cut into a desired shape.
  • the potato products made in this manner contain a smooth, mashed potato consistency with few or no particulates.
  • the extrudable raw potato compositions described herein surprisingly maintain structural integrity even when the potato products are produced using protocols that expose the potato composition to significant pressure for example, during extrusion. Without being bound to theory it is assumed that the integrity is maintained due to suitable particle size distribution and amount of the potato shreds, combined together with a suitable amount of a drying agent.
  • the shredded potatoes in the potato compositions are obtained from raw potatoes that are peeled and typically shredded to a particle size smaller than about 10 IM, preferably between about 6 mm to about 1 mm in at least one dimension.
  • Shredded potatoes generally refer to a collection of potato pieces in which at least about 50 percent of the pieces have the desired particle size. Potato products with pieces that are too large may not form the desired network of shredded potatoes and product. According to the present invention, the shredded potatoes are not subjected to processing steps such as blanching, hydrating or the like but rather retained in a raw state and used as such to prepare said potato composition.
  • the potato composition includes between about 0% by weight to about 40% by weight of drying agent. In some embodiments, the drying agent is between about 1% by weight to about 20% by weight. In some embodiments the drying agent is between about 1% by weight to about 10% by weight of the composition.
  • the drying agent can typically absorb 2-4 times its own weight of liquid. Thus, in many cases, there is no need to filter or dry stream 122 as all the excess liquid is adsorbed by the drying agent.
  • Table IA A typical extrudable raw potato composition.
  • FIG. 2 is a simplified flowchart of a process 200 for preparing a filled potato product using an extrudable raw potato composition, in accordance with another embodiment of the present invention.
  • a size reduction step 210 raw potatoes 202 undergo a size reduction step, substantially similar to step 110 of Fig. 1. Excess liquid may optionally be removed during step 210 in stream 206 and/or in step 220 in stream 216 by filtration, centrifugation, settling or by another unit operation known in the art. Furthermore a settling process (not shown) may be performed to the raw potato particulate 212.
  • the raw potato particulate, produced in step 210 is mixed with at least one drying agent 214 in mixing step 220.
  • the at least one drying agent is selected from potato flakes, potato granules and mixtures thereof. In some embodiments, corn starch or other drying agents may be added.
  • At least one additive is added in a mixing step 220.
  • the at least one additive typically comprises less than 5 % and more preferably, less than 3% by weight of the resultant extrudable raw potato composition 222.
  • the at least one additive is selected from at least one of flavoring agent, at least one antioxidant, at least one sweetener, at least one emulsifier, at least one stabilizer and at least one coloring agent or a mixture thereof.
  • up to 5% salt and/or potassium chloride may be added to the composition.
  • the at least one additive is at least one natural additive.
  • flavoring agents include sodium chloride and potassium chloride, spices and vanilla.
  • a flavoring agent may be included in said potato composition in a concentration between about 0.1% by weight and about 5% by weight.
  • the potato composition may also include color enhancers. Suitable color enhancers to yield a golden brown color of the finished product include dextrose, maltose, lactose, galactose and the like. The use of dextrose as the color enhancer is preferred.
  • the potato composition generally includes minor amounts of color enhancer.
  • the extrudable raw potato composition 222 comprises only natural ingredients.
  • At least 95% of the carbohydrates of the composition 222 are from at least one potato source. In some cases at least 98% of thecarbohydrates of the composition are from potatoes. In some other cases, at least 99% of the carbohydratesare from at least one potato source. In some further embodiments all of the carbohydrates of the composition 222 are from potatoes. In the context of this invention "substantially all" means at least 99%.
  • the extrudable raw potato composition of step 220 is co-extruded with a filling 234 in extrusion and filling step 230 to form an extruded raw potato filled food product 232.
  • a variety of fillings 234 may be used to make the filled raw potato food products 232.
  • the filling may include raw and/or cooked foods.
  • the filling 234 is relatively thick and viscous, such that it will not readily flow through any imperfection in the casing formed by the potato composition or out from the ends or seams of the potato product during or prior to cutting and crimping of the filled potato material after exiting step 230. Extrudable fillings are particularly useful in this invention.
  • the filling can be made from a variety of different food ingredients, including, but not limited to, meat or meat-derived products, sea food or sea food-derived products, soya products, vegetable or vegetable-derived products, dairy or dairy-derived products, egg or egg- derived products, fruit or fruit-derived products, jams and spreads, chocolate and condiments, nuts, spices, flavoring agents, fats, and the like. It should be clear to the artisan that the invention is not limited to any specific type of filling.
  • the filled raw potato products described herein may be made using any extrusion or encrusting process, known in the.
  • the extrusion step 230 process involves the application of pressure against the potato composition 222 to force the potato composition through a die.
  • the extrusion can be performed using a variety of extruders or pumping systems. Suitable extruders include conventional food extruders that operate at low to moderate pressures. Suitable extruders include any type of commercial extruders designed to encase a filling automatically in a desired form, e.g. spherical, cylindrical,- etc. An example of such commercial type extruder is the Rheon type encrusting machine.
  • a bi-annular die 600 as shown in Fig. 6, and described in further detail hereinbelow, is used for producing the filled raw potato product 232.
  • FIG. 3 is a simplified flowchart o 300 of a process for producing an extrudable raw mixed vegetable composition, in accordance with an embodiment of the present invention.
  • a potato preparing step 310 potatoes are washed and optionally peeled to form prepared potatoes 302. Thereafter prepared potatoes are fed into a size reduction apparatus.
  • a vegetable preparing step 320 one or more other vegetables are washed and optionally peeled.
  • one or more fruits may be prepared in step 320.
  • the one or more other vegetables are selected from sweet potato, carrot, parsnip, corn and turnip.
  • any one or more other vegetables are employed.
  • one or more fruits are employed.
  • the fruits have a relatively high starch content, such as cassava.
  • one or more types of nut or grain may be added in this step.
  • the prepared vegetable(s) and/of fruits(s) 304 are fed into a size reduction apparatus.
  • the weight ratio of potato 302 to other vegetables 304 is at least 80:20. In some further embodiments, the ratio is at least 90:10. In some further embodiments, the ratio is at least 95:5.
  • a size reduction step 330 the prepared potatoes 302 and other vegetables and/or fruit 304 are size reduced.
  • the size reducing process step typically comprises at least one unit operation selected from shredding, grating, comminuting, crushing, dicing, chopping and blending. This step is typically similar to step 110 of Fig. 1 and may be performed using the same equipment. Excess liquid may optionally be removed during step 330 in stream 336 and/or in step 340 in stream 346 by filtration, centrifugation, settling or by another unit operation known in the art. Furthermore a settling process (not shown) may be performed to the raw particulate 332.
  • Fluid stream 336 typically comprises less than 20% of the total vegetable/fruit weight of streams 302, 304. In some cases, stream 336 is less than 10% of the weight of streams 302, 304. In some cases, stream 336 is 0-1 % of the weight of streams 302, 304.
  • a resultant raw mixed vegetable/fruit particulate 332 results from the size reduction process.
  • the raw mixed vegetable/fruit particulate, produced in step 330 is mixed with at least one drying agent 344 in mixing step 340.
  • the at least one drying agent is selected from potato flakes, potato granules, and mixtures thereof. This step is similar to step 120 and may be performed using the same equipment.
  • the resultant extrudable raw mixed vegetable/fruit composition 342 is of a similar consistency to extrudable raw potato composition 122 and 222, described hereinabove.
  • At least one additive is added in a mixing step 340.
  • the at least one additive typically comprises less than 5 % and more preferably, less than 3% by weight of the extrudable raw mixed vegetable/fruit composition 342.
  • the at least one additive is selected from at least one of flavoring agent, at least one sweetener, at least one emulsifier, at least one stabilizer and at least one coloring agent or a mixture thereof.
  • up to 5% salt and/or potassium chloride may be added to the composition.
  • the at least one additive is at least one natural additive.
  • the extrudable raw mixed vegetable/fruit composition 342 comprises only natural ingredients.
  • the extrudable raw mixed vegetable/fruit composition 342 and/or raw potato composition 222 can be used in a large number of food products.
  • the composition 222 and/or 342 can be made into a dough.
  • the dough can be used in the bakery and confectionary industry in the place of any other dough.
  • the composition(s) can be used as a pie base, as a buiscuit/cookie dough, as a filled food product dough, as a pasty dough, as a cake dough, as a snack dough, as a cracker dough.
  • composition(s) 222 and/or 342 may be combined with a raising agent, such as baking powder or yeast to provide a more fluffy dough.
  • a raising agent such as baking powder or yeast
  • the composition 222 and/or 342 may be used in/as confectionery.
  • Some of the products produced with composition 222 and/or 342 may be natural, meaning that they have no unnatural chemicals or additives.
  • flavoring agents include sodium chloride and potassium chloride, spices and vanilla.
  • a flavoring agent may be included in said potato composition in a concentration between about 0.1% by weight and about 5% by weight.
  • the potato composition may also include color enhancers. Suitable color enhancers to yield a golden brown color of the finished product include dextrose, maltose, lactose, galactose and the like. The use of dextrose as the color enhancer is preferred.
  • the potato composition s generally includes minor amounts of color enhancer.
  • At least 80% of the carbohydrates of the composition 332 are from raw vegetables and fruits. In some cases, at least 90% carbohydrates of the composition are from mixtures of raw vegetables and fruits and dried potato products. In some further cases, at least 99% carbohydrates are from raw vegetables and fruits and dried potato products. In some further embodiments, all of the carbohydrates of the composition 332 are from raw vegetables and fruits and pure dried potato products, such that composition 332 is 100% natural.
  • extrudable raw mixed vegetable/fruit composition of step 342 is co- extruded with a filling 354, similar or identical to filling 234 described hereinabove, in extrusion and filling step 350 to form an extruded raw mixed vegetable/fruit filled food product 352.
  • This step is typically similar to step 230 of Fig. 2 and may be performed using the same equipment.
  • waste stream 356 comprises extraneous pieces of composition 342 and/or of filling 354.
  • Fig. 4 is a simplified flowchart 400 of a process for cooking and packaging a filled raw potato product 402 following the process of Fig. 2.
  • the product may be further processed and packaged by any sequence of processes' known in the art. For example, by cooking or partially cooking, by baking, boiling, frying or microwave cooking after it exits the extruder. A preferred process is by frying.
  • the product 402 is at least partially immersed in an oil or molten fat, 404.
  • the oil or molten fat is selected from one or more of a vegetable oil, a fish oil, an animal fat, margarine and butter.
  • the oil 404 is selected from one or more vegetable oils such as soy bean oil, safflower oil, corn oil, cottonseed oil, canola oil and mixtures thereof.
  • Step 410 may be performed to partially cook or to fully cook the product 402, typically, but not limited to, at 170-200 0 C for up to several minutes to product a fried filled potato product 412.
  • the product 412 may be basted prior and/or after step 410 with, for exampled an egg layer or with another glazing agent known in the art.
  • the product may be covered in a layer of breadcrumbs, spices, sesame seed, poppy seed or other external covering known in the art, or with mixtures thereof.
  • the Fried product 412 may then be baked in a baking step 420.
  • the baking step typically comprises passing product 412, for example, through a belt oven, such as Lincoln Electric Impinger II Digital Conveyor Oven Model 113*-000A, for a number of minutes, typically 2-10 minutes, at temperatures of 150-250 0 C so as to produce a baked filled product 422.
  • the fried product 412 may be baked in a microwave oven or batch oven.
  • the product 412 may be cooked in a cooking step (not shown).
  • the baked filled product 422 may be frozen in a freezing step 430.
  • the product may be frozen on an industrial belt freezer, such as a spiral freezer (available from IQF FREEZER, Walnut, CA 5 USA) or in a blast type freezer, such as Rinox Blast Chiller and Freezer available from Servolift Eastern Co., Boston, MA, USA).
  • the product is typically frozen to a temperature colder than -8°C, and more preferably to colder than -10°C to produce a frozen baked filled product 432.
  • the frozen product may be stored under standard freezing conditions -18°C to -25 0 C.
  • Alternative freezing processes may additionally or alternatively be employed.
  • the frozen product 432 may then be packaged in a packaging step 440 to form packaged product 442.
  • the product 432 may be packed individually or packed by weight as is known in the art. Typically the product is sold in packages for retail and/or for wholesale distribution.
  • a packaging machine such as but not limited to a ROVEMA completely automated packaging system (ROVEMA, Fernwald, Germany) may be employed in step 440.
  • the frozen product 432 is typically packaged in polypropylene and/or aluminum foil and/or cardboard packages as is known in the art.
  • Refrigerated or frozen dough products can be stored for periods of time based on the storage temperatures.
  • the refrigerated or frozen product can be reheated prior to consumption, if desired, e.g. by baking, frying, toasting or microwave heating.
  • the potato products of the invention are particularly amenable to microwave heating and/or oven/toaster oven heating.
  • FIG. 5 is a simplified flowchart 500 of a process for preparing a filled potato product 542 using an extrudable raw potato composition, accordance with an embodiment of the present invention.
  • Peeled washed raw potatoes 502 are shredded in a shredding step 510 as described in further detail hereinabove (Fig. 1) to produce a wet particulate 512.
  • an adding step 520 at least one drying agent are added in stream 514 to the particulate 512.
  • salt and further additives may be added in this step, either substantially as described in Fig. 2 hereinabove or as is known in the art.
  • a resultant mixture 522 may be mixed and/homogenized/size reduced in a mixing step 530 to form a homogeneous raw potato mixture 532.
  • the mixture 532 may be in a viscous slurry form, in highly viscous liquid phase or of a doughy consistency.
  • excess liquid may be removed in one or more of steps 510, 520 and 530 using methods known in the art.
  • the homogeneous raw potato mixture 532 may be molded or shaped as is known in the art in a pressing molding step 540. For example, if in a doughy consistency, the mixture may be pressed into a hollow form, a shell form, a container form, a cup-cake form or any other form known in the art. Simultaneously or thereafter, a filling 544 may be added to the fo'rm. Filling 544 may be identical, similar or different from filling 314 described hereinabove with regard to Fig. 3.
  • a second layer of mixture 532 may optionally be added to cover and/or enclose the filling.
  • the resultant filled raw potato product 542 may then be frozen and/or processed as in the process 400 of Fig. 4. Additionally or alternatively, further processing (not shown) of the product 542, such as coloring may be performed as is known in art.
  • Fig. 6 is a simplified schematic diagram of an extrusion die 600 and a filled potato product 650 therefrom, in accordance with an embodiment of the present invention.
  • a typical industrial die that may be used in this process is a Wenger extruder die (Wenger X-20 or the like, Wenger Kansas City, MO, USA). Die 600 is typically constructed from stainless steel 316.
  • Die 600 typically comprises a thick metallic outer pipe 610 and a concentric inner metallic pipe 630, both pipes of length H 1 .
  • Outer pipe 610 comprises a wall of thickness ti -
  • Inner pipe 630 typically is of thickness t 2 , wherein t 2 is much thinner than ti.
  • Outer pipe 610 and inner pipe 630 form an outer annulus 620.
  • Inner pipe 630 forms an internal concentric cylindrical section 640.
  • a filled product 650 may be formed employing die 600 in accordance with the process of Fig. 7.
  • FIG. 7 is a simplified flowchart of a process 700 for preparing a filled potato product 742 using an extrudable raw potato composition 702 employing the extrusion die of Fig. 6.
  • composition 702 may be substantially identical to any one of extrudable raw potato composition 122 of Fig. 1, extrudable raw potato composition 222 of Fig. 2, homogeneous raw potato mixture 532 of Fig. 5, or any variation thereof.
  • a filling 704 may be substantially identical to any one of filling 314 of Fig. 3, filling 544 of Fig. 5 or a variant thereof.
  • Filling 704 is passed through the internal concentric cylindrical section. Normally, the composition 702 and filling 704 are passed through die 600 in parallel under a positive pressure such that the potato composition, pushed " through the outer annulus 620 which surrounds the internal concentric cylindrical section 640, forms around the filling as the filling flows from the inner section.
  • the filling is coextruded with the potato composition.
  • the relative amounts of filling and potato composition can be adjusted by the relative speed of the extruder screw and the flow rate of the filling.
  • the ratio (by weight) between the potato composition 702 forming the casing and the filling 704 inside is from about 4:1 to about 1 :4, preferably about 1:1.
  • the resultant long cylindrical filled product 712 or extmdate may then be cut perpendicularly thereto in a cutting step 720.
  • the filled extrudate 712 may be cut to a desired length L 1 .
  • Li may be substantially identical to H 2 of product 650 (Fig. 6) to form a cut uncooked product 722.
  • Uncooked product 722 may then be processed in one or more processing steps 730 to form a finished product 732.
  • uncooked product 722 is fried in oil 734, substantially as described in step 410 of Fig. 4 hereinabove. Additionally or alternatively steps 420-440 may be applied to uncooked product 722. In some embodiments, one or more of steps 420-440 may be omitted.
  • Finished product 732 is then packaged in packaging step 740 to form packaged finished product 742.
  • the packaging step 740 may be substantially similar or different from packaging step 440 of Fig. 4.

Abstract

L'invention concerne des procédés permettant de produire une composition extrudable à base de pommes de terre crues ou de légumes crus, présentant des propriétés mécaniques permettant de préserver l'intégrité structurale de la composition après sa transformation, cette composition contenant des glucides dérivés quasi exclusivement de pommes de terre. Ce procédé consiste à fragmenter les pommes de terre crues ou les légumes crus en particules présentant une taille moyenne inférieure à 10 millimètres dans au moins une dimension, afin de produire une matière particulaire à base de pommes de terre crues ou de légume crus, et à mélanger au moins un agent desséchant à ces particules de pommes de terre crues ou de légume crus afin de former une composition extrudable de pommes de terre crues ou de légume crus. L'invention concerne également des produit obtenus avec cette composition de pommes de terre crues ou de légume crus, ainsi que les utilisations de cette composition.
PCT/IL2006/000316 2005-03-09 2006-03-09 Procede permettant de produire des compositions de pommes de terre ou d'autres legumes et produits resultants WO2006095351A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
IL185787A IL185787A0 (en) 2005-03-09 2007-09-06 Methods for producing potato or other vegetable compositions and products thereof

Applications Claiming Priority (2)

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US65943305P 2005-03-09 2005-03-09
US60/659,433 2005-03-09

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WO2006095351A1 true WO2006095351A1 (fr) 2006-09-14

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011075847A1 (fr) * 2009-12-23 2011-06-30 Mccain Foods Limited Feuille de pâte alimentaire pliable à base de légume-racine
WO2014082884A1 (fr) * 2012-11-27 2014-06-05 Unilever N.V. Procédé de fabrication de produits à base de pomme de terre séchée

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE20011725U1 (de) * 2000-07-05 2000-11-30 Graefe Christian Hohlkörperförmige Speise
EP1133927A2 (fr) * 2000-03-16 2001-09-19 Bestfoods Snack tubulaire à base de filaments de pomme de terre et son procédé de fabrication
US6692782B1 (en) * 1999-10-19 2004-02-17 The Pillsbury Company Filled potato product

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6692782B1 (en) * 1999-10-19 2004-02-17 The Pillsbury Company Filled potato product
EP1133927A2 (fr) * 2000-03-16 2001-09-19 Bestfoods Snack tubulaire à base de filaments de pomme de terre et son procédé de fabrication
DE20011725U1 (de) * 2000-07-05 2000-11-30 Graefe Christian Hohlkörperförmige Speise

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011075847A1 (fr) * 2009-12-23 2011-06-30 Mccain Foods Limited Feuille de pâte alimentaire pliable à base de légume-racine
WO2014082884A1 (fr) * 2012-11-27 2014-06-05 Unilever N.V. Procédé de fabrication de produits à base de pomme de terre séchée

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