WO2018122869A1

WO2018122869A1 - Instant legume-based pre-comestible

Info

Publication number: WO2018122869A1
Application number: PCT/IN2017/050618
Authority: WO
Inventors: Ganesh AHUJA; Kirti LADDHA
Original assignee: Ahuja Ganesh
Priority date: 2016-12-27
Filing date: 2017-12-27
Publication date: 2018-07-05

Abstract

The present invention discloses a novel process for preparing an instant legume-based pre-comestibleby using different combinations of techniques and processes to alter the structure and thus convert legumes into a pre- comestible The process as disclosed herein essentially avoids any usage of pressure or conventional cooking which makes the process more economical, efficient. The invention further discloses the instant legume-based pre- comestible product obtained by the process of the invention. The legume-based pre-comestible as disclosed herein can be consumed as a comestible without a vehicle as a snack or converted into a comestible with a liquid vehicle in 30 seconds – 10 minutes by using a liquid vehicle.

Description

INSTANT LEGUME-BASED PRE-COMESTIBLE

Field of Invention:

The current invention relates to process for preparing an instant legume-based pre- comestible for human consumption. More particularly, the present invention relates to a process for preparation of legume-based pre-comestible which is intended for instant preparation and the comestible prepared therefrom.

Background of Invention:

Legumes are multipurpose crops and are consumed either directly as food or in various processed forms or as feed in many farming systems. Legumes are an essential source of protein and carbohydrates, especially in country, like India, where the diet of choice for a third of the population is a pure vegetarian diet. A large variety of legumes are consumed in different forms throughout India. Different varieties of legumes contain varying amounts of the nutrients. Certain beans, nuts, peas and lentils also exhibit unique nutritional profiles. Legumes are typically low in fat, contain no cholesterol, and are high in folate, potassium, iron and magnesium as against meat. Therefore, legumes, more than sufficiently, cover the daily protein requirements of a vegan or a vegetarian diet.

A normal Indian staple diet usually includes at least one legume-product, particularly dais. The process usually followed for home consumption or large scale or industrial use is to soak the legumes in water for 2 - 3 hours and pressure cooked for 10 - 15 minutes at pressure of 15 - 20 psi. The cooked legumes are then given tadka and water and spices added to taste and served or consumed along with cooked rice or chapatti. While in industry the cooked legumes are then dried and used for ready to serve eatable products. The traditional process for preparation of dal, as can be seen from above, is a lengthy process. This process, though, acceptable in common household, is particularly unsuitable for certain situation, for instance in a military camp or in a rescue camp where one may not be able to gather all the pre-requi sites.

To attenuate this situation ready -to-eat meals have been developed, majorly by Defence Food Research Laboratory (DFRL) backed by Defence Research and Development Organisation (DRDO), in India. These ready-to-eat meals are, generally, pre-cooked meals product and require re-hydration, re-heating and require special equipments for storage or consumption such as a microwave to heat or a refrigerator for storing. However, standard ready-to-eat meals have a shorter- shelf life and in some the shelf-life is enhanced with the use of preservatives.

Further, these meals are not designed to be consumed in 'as is' form. This again is disadvantageous in situations arising out of natural calamities. Various methods for making shelf-stable ready-to-eat legumes are disclosed in US202975, US1088741, US1859279, IN189173 and IN189175.The prior art processes known vide the listed prior arts essentially comprise of pressure-cooking, either in a commercial pressure cooker or an autoclave. The prior art methods also involve salt treatment with salts like carbonates, bicarbonates, citrates and phosphates.

The major disadvantage exhibited by these processes is that the salt treatment may lead to adverse effect on taste, colour and flavour. Further, the obligatory pressure cooking or autoclaving leads to substantially increased cost input, thereby increasing the overall cost.

Therefore, there is a need to develop an economical process which retains the natural shape and taste of the legumes; while being fast cooking. Hence, the current inventors propose a novel process for manufacturing ready-to- eat instant legume-based pre-comestibles for human consumption and the comestible produced thereof. The novel process is economical and less time consuming than the prior art preparations. Further, the novel process retains the inherent nutritional value of the legumes and also preserves the taste.

Summary of Invention:

In the main aspect, the invention provides a process for preparation of an instant legume-based pre-comestible, which can be consumed with or without any further processing or liquid vehicle.

In another aspect, the invention provides a legume-based pre-comestible product prepared by the process of invention which is an instant, nutritious comestible that is ready for consumption and/or drastically reduces cook time.

Also, the invention provides a process by which its products can be used as an input/ingredient for other products such as bhujia, pooran poll, or re-hydratable bhajia. In accordance, with this aspect the instant pre-comestible of the invention could be extruded to form the input or ingredient for further processing.

The legume-based pre-comestible prepared by the process of invention can be stored and consumed without any special equipment to store or cook thus proving to be very cost effective.

Detailed Description of Invention:

The invention describes a process for preparation of instant legume-based pre- comestible in whole, flaked, powdered, cube or extrude form, which can instantly be converted in to a soft, chewy semi-liquid or liquid comestible, directly or by stirring or heating with a liquid vehicle, in 30 seconds to 10 minutes. For the purpose of this invention terms, 'legumes', 'legume grains' and 'grains' signify such grams, beans, pulses and lentils which are generally used in Indian diet as 'dais . Said pulses and lentils may be selected from, but not limited to, split, broken or whole arhar dal (pigeon pea; Cajanus cajan), split, broken or whole chana (bengal gram; Cicer arietinum), split, broken or whole moong (green gram; Vigna radiata), split, broken or whole urad (black gram; Vigna mungo), split, broken or whole masoor (red lentil; Lens culinaris ); split, broken or whole chole (white chick peas; Cicer arietinum), split, broken or whole mooth (moth beans; Vigna acotinifolia); split, broken or whole chowli (cow peas; Vigna unguiculata), split, broken or whole raj ma (kidney beans; Phaseolus vulgaris), split, broken or whole matar(Green peas; Pisum sativum) or white peas, split, broken or whole val (field beans; Vicia faba), split, broken or whole Kulthi (Horsegram; Macrotyloma uniflorum), split, broken or whole Khesari (Chickling vetch; Lathyrus sativus) . These terms are used interchangeably.

The process is designed in a manner to alter the structure of the grains at cellular level without compromising the nutritional value or the taste.

For the purpose of this invention, term "pre-comestible" encompasses a legume- based food product that is ready-to-use, ready-to-cook or instant consumption legumes-based product. The pre-comestible in accordance with this invention may be converted to an edible form, namely, a comestible, by mixing the pre-comestible form with a liquid vehicle, preferably in less than 10 minutes, or consume the said pre-comestible "as is".

In an embodiment, the process for preparation of legume-based pre-comestible product in accordance with this invention comprises of pre-soaking the legume grains in a water-based solution followed by draining, light drying the pre-soaked legume and/or treating the pre-soaked legume grains with Microwaves and/or Infra- red waves and/or super-heated air and/or roasting. In an embodiment, various stages in the process can be adjusted or re-adjusted to achieve the desired rehydration time or form of the end product such as, whole, flaked, shaped, cut, bits, embossed, pitted, pressed, powdered or extrude form. Finally a mix of spices and dried vegetables may be mixed with vegetable or palm oil and packed.

In accordance with the process of the invention, the nutrients are preserved by avoiding the use of water for cooking the legumes. The legumes may be blanched or steamed to further loosen or soften the structure of the grains if required. The water, used for processing the grains, may also be used as medium to infuse additional nutrients into the grains, for fortification.

In an embodiment, the process for preparation of the pre-comestible consists of cleaning, de-husking and dusting of the commercially available legumes. The cleaning of legumes is followed by sorting. The legumes, after sorting, are washed with clean water to remove any extraneous impurities. The washed legumes are than soaked in water solution for upto 30mins to 10 hours. Soaking is terminated by addition of acidulants. The legumes may, optionally, be blanched or steamed. The soaked or blanched or steamed legumes are then drained off of excess water and are cooled to ambient temperature. The legumes can then be lightly dried, for draining the excess moisture, at a temperature ranging from 15 - 32°C at 45 - 60% relative humidity. Optionally, the blanched or soaked legumes may then be partially dried at temperature of about 30 - 80°C till the moisture level of legumes is in range of 40 - 60% for a time period of 2 - 50 minutes. The blanched or steamed legumes are roasted and/or treated with super-heated air at 120° to 400°C for 2 - 50 minutes, till the final moisture content of the legumes is below 15%, the legumes are than cooled or de-humidified at a temperature between 15 - 32°C.In the case, the grains are subjected to high heat for a short duration to avoid charring or de-humidification can be carried out for further removal of moisture. In an alternative embodiment, the legumes can also be frozen/chilled at or below +5°C and processed. The legumes can be frozen/chilled at any stage during the inventive process as long as the moisture content is above 20% before subjecting to super-heated air and/or roasting and/or Dielectric waves and/or Radio frequency waves.

In an alternative embodiment, the legumes may also be directly subjected to heat waves such as Microwaves or Infrared or any other such form to treat/dry/roast with or without introducing any additional water to the grains.

The legumes and pulses require to be processed at temperatures between 45°-400°C for a time span ranging from just a few seconds to 30 minutes. Different heating techniques may be used under different atmospheric pressures, relative humidities, temperatures for best results. For instance, vacuumized Microwave can be used for low temperature processing in cold climates.

In an embodiment, a combination of heating techniques may also be followed to achieve the best results such as Infra-red heating followed by convectional heating or lightly tempering the legumes to reduce costs. Combination drying enables rapid elimination of initial moisture and gradual phasing out of residual moisture thus increasing rate of dehydration, preventing any damage to the structure of product as well as reducing the cost.

In a preferred embodiment, the process for preparation of the pre-comestible consists of cleaning, de-husking and dusting of the commercially available legumes. The cleaning of legumes is followed by sorting of legumes. The legumes, after sorting, are washed with clean water to remove any extraneous impurities. The washed legumes are than soaked in water solution for upto 30 mins to 10 hours. Soaking is terminated by addition of acidulants. The legumes may, optionally, be blanched or steamed. The soaked or blanched or steamed legumes are then drained off of excess water and are cooled to ambient temperature. The legumes may then be subjected to IR waves at temperatures ranging from 60-400°C for 2-50 minutes till the moisture content in the legumes is around 20%. The legumes may then be subjected to microwave for 1-20 minutes at 50-200°C. The legumes are then cooled to ambient temperatures.

In an optional embodiment, the water solution used for soaking of legumes, contains at least one salt selected from ammonium chloride ( H4CI; E510), ammonium bicarbonate ( H4HCO3;E503(ii)), sodium bicarbonate (NaHCO- 3;E500(ii)) and sodium chloride (NaCl), along with a leavening agents if desired selected from Calcium Hydrogen Phosphate (CaHP04;E341(ii)), sodium aluminium sulphate (NaAl(S04)2- 12H₂0;E521), disodium pyrophosphate (Na₂H₂P2O7;E450(i)), sodium aluminium phosphates (NaHi4Al3(P04)8 4H₂0 and Na3Hi5Al₂(P04)8;E541) or any other leavening agent. The salt and/or leavening agent are added to the water solution in the range of 0.1% to 4%. The step of soaking in water solution brings the moisture content of the legumes in range of 40 - 80%.

Further in accordance with above embodiment, the acidulant used in the process of invention is an organic acid, selected from, but not limited to, citric acid, tartaric acids or acetic acid or malic acid. Said acidulant is taken in concentration ranging from 0.1% to 4% of the water solution.

In an optional embodiment, the legumes may be steamed or blanched, after acidulation. In accordance with above optional embodiment, in case of steaming, the steam must be dispensed over the legumes or the legumes must be passed over a steam until the colour or texture of the said grains changes to desired proportions.

Further in accordance with above optional embodiment, in case of blanching, the blanching may be carried out at a temperature in range of 75 - 101°C for 2 - 50 minutes or until the colour and texture of the said grains changes to desired proportion depending upon the initial moisture of the grain. For instance, if the initial moisture is around 5% then it may be blanched upto 50 minutes. If legumes are blanched for a short time, they may be allowed to remain in the heated water for another couple of minutes and not cool rapidly, thus also saving energy while allowing the water to imbibe thoroughly. However, if the grains are steamed or blanched for undesirably long time, then rapid cooling should be followed to prevent the grain from cooking, breaking or loosing nutrients in the water.

Natural colouring agents may, optionally, be added to the steamed/blanched legumes. Said natural colours may be added such as turmeric powder and the like.

One of the parameter for judging the extent of blanching or steaming required is that it must be done only until the point legume grains are about to start disintegrating.

In the case of whole grains, the steaming or blanching must be continued till the extent the grains swell. Another technique in estimating the time or temperature for steaming or blanching is the change in skin colour or toughness or breakability of the whole grains.

In one more optional embodiment, the pre-soaked or blanched or steamed legumes processed in accordance with above process may be subjected to be freezing for upto 12 months and then subjected to Light drying and/or Super-heated air treatment and/or Roasting and/or. The freezing helps in maintaining just-in-time inventories.

In accordance with above embodiment, roasting can be carried out with help of infra-red irradiation, or sand roasting or any other direct dry heating method that ensures dry heating medium encompasses the entire grain from all the sides, for instance, heating metal or ceramic balls / pieces and then roasting the legumes between them. In case of use of super-heated air treatment, air is heated at high temperature and circulated at high speeds. The heating mediums could be selected from, but not limited to, dry heat oven, commercial roasters, indirect roasting using silica/sand, high velocity dryer, conveyor dryers, halogen ovens, Microwaves, Infra-Red dryers, rapid air dryers or combinations thereof. The heating medium used should ideally allow sufficient exit of moisture from the grains and circulation of fresh air based on the environment. For example, in cold regions where maintaining high temperature condition is difficult, vacuumized microwaves may be used. In an alternative embodiment, the partially dried grains are pressed and flattened or cut or shaped either after initial drying or in between the super-heated air/Infra- red/microwave/Roasting process. This is done for quickening the roasting process and saving costs so as to offer a cheaper variant. Pressed dried grains are faster and easier to cook, for instance within 3 minutes which is beneficial for end users in acutely cold climates.

In an advantageous embodiment, the cutting and/or shaping and/or flattening of the grains save rehydration time and/or fuel costs for calamity victims with limited means. These variants maybe offered 'as is' or with a mix of spices, seasonings, starch, enriched natural proteins, and the like.

In one embodiment, the legume-based pre-comestible of the invention may be made from a single variety of legumes or may involve use of plurality of legume varieties. In another embodiment, the legume-based pre-comestible prepared from whole grains, by process of the invention, may be marketed with or without any additives, selected from, but not limited to, spices, seasonings, colours, flavours, starch and/or permitted stabilizers, enriched natural proteins which could be prepared in 30 seconds - 10 minutes, depending on the form of the processed legume or its ingredients or the rehydration method followed. In further embodiment, the legume-based powdered pre-comestible prepared by the process of invention may be marketed as pre-mix containing spices or seasonings or flavours or starch or permitted stabilizers or enriched natural proteins which could be prepared in 30 seconds - 10 minutes, depending on the time required for cooking or rehydration method followed.

In one more embodiment, the pre-comestible hence prepared can be consumed by mixing desirable quantity of said pre-comestible with sufficient quantity of liquid vehicle, which may be hot or warm or cold water. Alternatively, the pre-comestible can be directly consumed without addition of any liquid vehicle, if probability of getting any kind of potable liquid vehicle is remote, such as in case of drought or famine triggered by natural calamity such as earthquakes/tremors, landslides or typhoons. In preferred embodiment, the process for preparation of the pre-comestible consists of cleaning, de-husking and dusting of the commercially available legumes. The cleaning of legumes is followed by sorting of legumes. The legumes, after sorting, are washed with clean water to remove any extraneous impurities. The washed legumes are than soaked in water solution for upto 30 mins to 10 hours. Soaking is terminated by addition of acidulants. The legumes may, optionally, be blanched or steamed. The soaked or blanched or steamed legumes are then drained off of excess water and are cooled to ambient temperature. The legumes can then be centrifuged for draining the excess moisture at a temperature ranging from 15 - 32°C at 45 - 60% relative humidity. Optionally, the blanched or soaked legumes may then be partially dried at temperature of about 30 - 80°C till the moisture level of legumes is in range of 40 - 60% for a time period of 2 - 25 minutes. The blanched or steamed legumes are treated with super-heated air at 120° to 400°C for 2 - 50 minutes, till the final moisture content of the legumes is below 15%, the legumes are than cooled or de-humidified at a temperature between 15° - 32°C. If the grains are subjected to high heat for a short duration to avoid charring; de-humidification can be carried out for further removal of moisture. The legumes may be frozen/chilled either after soaking or blanching or steaming at or below temperature +5°C and then treated with Super-heated air. The legumes can be frozen/chilled at any stage during the inventive process before subjecting to Super-heated air. In another preferred embodiment, the process for preparation of the pre-comestible consists of cleaning, de-husking and dusting of the commercially available legumes. The cleaning of legumes is followed by sorting of legumes. The legumes, after sorting, are washed with clean water to remove any extraneous impurities. The washed legumes are then soaked in water solution for upto 30 mins to 10 hours. Soaking is terminated by addition of acidulants. The legumes may, optionally, be blanched or steamed. The soaked or blanched or steamed legumes are then drained off of excess water and are cooled to ambient temperature. The legumes can then be centrifuged for draining the excess moisture at a temperature ranging from 15° - 32°C at 45 - 60% relative humidity. Optionally, the blanched or soaked legumes may then be partially dried at temperature of about 30° - 80°C till the moisture level of legumes is in range of 40 - 60% for a time period of 2 - 25 minutes. The blanched or steamed legumes are then roasted at upto 400°C for 2 - 50 minutes, till the final moisture content of the legumes is below 15%, the legumes are than cooled or dehumidified at a temperature between 15° - 32°C. In case the grains are subjected to high heat for a short duration to avoid charring; de-humidification can be carried out for further removal of moisture. The legumes may be frozen/chilled either after soaking or blanching or steaming at or below temperature +5°C and then roasted. The legumes can be frozen/chilled at any stage during the inventive process before roasting.

In yet another preferred embodiment, the process for preparation of the pre- comestible consists of cleaning, de-husking and dusting of the commercially available legumes. The cleaning of legumes is followed by sorting of legumes. The legumes, after sorting, are washed with clean water to remove any extraneous impurities. The washed legumes are than soaked in water solution for upto 30 mins to 10 hours. Soaking is terminated by addition of acidulants. The legumes may, optionally, be blanched or steamed. The soaked or blanched or steamed legumes are then drained off of excess water and are cooled to ambient temperature. The legumes can then be centrifuged for draining the excess moisture at a temperature ranging from 15° - 32°C at 45 - 60% relative humidity. Optionally, the blanched or soaked legumes may then be partially dried at temperature of about 30° - 80°C till the moisture level of legumes is in range of 40 - 60% for a time period of 2 - 25 minutes. The blanched or steamed legumes are then subjected to IR waves at upto400°C for 2 - 50 minutes, till the final moisture content of the legumes is below 15%), the legumes are than cooled or de-humidified at a temperature between 15 - 32°C. If the grains are subjected to high heat for a short duration to avoid charring; de-humidification can be carried out for further removal of moisture to avoid charring.

The legumes may be frozen/chilled either after soaking or blanching or steaming at or below temperature +5°C and then subjected to IR heating methods. The legumes can be subjected to IR heat treatment at any stage during the inventive process as long as the moisture content is above 5%.

In another embodiment, the instant legume-based pre-comestible product may by prepared in extrude form. Accordingly, the process for preparation of pre- comestible legume-based product of the invention comprises steps whereby, the legumes undergoes a pre-soak in a water-based solution or in a solution permissible by the food authorities and then the legume may be directly dried or blanched or steamed or frozen and then dried at a low temperature for a few minutes. The soaked or blanched or steamed or frozen legumes are than further drained of excess moisture, if required. The dried legumes are then treated with super-heated air or roasted at high temperature which helps it remain in its whole form to from a pre- comestible product. The pre-comestible product produced in accordance with above embodiment, is further dried till the moisture content of the legumes falls below 15%>. The dried legumes are then ground to a fine powder. Sufficient quantity of starch or wheat flour is added to the ground legume powder and other ingredients such as salts, nutrients, other pulses, spices, seasoning, dehydrated veggies, fat, colours, such as turmeric, sugar may be added to form a dry mix. The dry mix is than is passed through a pre-conditioner, whereby steam is used to hydrate the mix and bring moisture levels to 25 - 50%. The steam helps in hydrating the mix uniformly, moisten well, and to convert the dry mix to a paste form. The paste, hence formed, is than extruded and packed. In one of the optional embodiment, the roasted or steamed or blanched legumes may be shaped if required. Accordingly, the soaked or blanched or steam legumes with a high moisture content can be broken or chopped or scraped or pitted or cut into shapes like stars, half-moon and the like to give the legumes a different appearance. These shaped legumes are then processed as in accordance with one of the above embodiments. This will give the legumes a different or uniform appearance and may also facilitate faster roasting/drying/treatment with Infra-red waves and/or microwaves and/or super-heated air making the cooking easier at the consumer level as the outer structure has been broken - making it easier for the moisture or water to penetrate or escape.

In accordance with above embodiment, the particle size may be varied in accordance with rehydration requirements. For instance, if fast rehydration is desired then the mix should be coarse and smaller particles to make a more compact extrude for slower rehydration or compressed to make soup cube.

Oils, spices and dried vegetables maybe added during or after the process. Fresh vegetables and/or flavourants/tadka maybe added after the process or before consumption to the pre-comestible of the invention. Tadka may also be packed separately and supplied without mixing with the end product of the invented process. In an advantageous embodiment, the process of the invention does not require pressure-cooking of the legumes.

In an additional advantageous embodiment, the time required for readying the pre- comestible in accordance with this invention in a comestible form is between 30 seconds to 10 minutes.

In another advantageous embodiment, the pre-comestible obtained from the invented process can be readied for consumption within 30 seconds to 10 minutes of introducing room temperature/warm/hot liquid vehicle. Alternatively, some forms of the products obtained from the process of the invention may also be consumed in dry form without even adding any liquid vehicle. Some spices, oils, dried vegetables or a mixture of all of these maybe added for consumption in dry form. Also, some variants of the product may be used as an ingredient/base for noodles, snacks etc. The concept of the invented process is to cut down cook time by 50% to 95%.

In yet another advantageous embodiment, some forms of the pre-comestible product produced the preparation of the invention can be converted in a comestible form by stirring the pre-comestible with hot liquid medium or even by heating in the microwave along with the liquid medium in less than 90 seconds.

In an alternate embodiment, the pre-soaked legumes can be allowed to sprout eliminating the process of blanching or steaming. The sprouted legumes can be directly subjected to heat treatment thus reducing energy input. Examples:

The invention will now be exemplified by below non-limiting examples. It may, however, be noted that the below examples in no way limit the scope of the invention. Further, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the appended claims should be studied to determine the true scope and content of this invention.

Example 1: Preparation of Black Urad Dal:

For preparation of Black Urad dal based pre comestible, Black Urad dal is first washed with water and then soaked in 1.2 - 2.3% of salt based water solution for 6- 10 hrs. The Black Urad dal used in the preparation is unpolished, whole and de- stoned with initial moisture content of about 5-8%. Soaking is terminated by addition of 0.8 - 1.7% acidulant. After soaking the moisture content goes upto 45- 60%. It is then frozen or chilled for 2 days. Blanching is carried out for different periods of time ranging from 5-25 minutes at 70-101°C after thawing. The grains become translucent in appearance and soft in texture whereas the moisture level increases to 60-80%. The grains are then subjected to light drying at 30-80 °C for less than 30 minutes. On light drying the moisture level is brought down to 40-70%). Further the grains are roasted in sand for about 1-10 minutes at temperatures ranging from 150-350 °C. The grains are then allowed to cool at ambient temperatures for less than 30 minutes. The end moisture is successfully brought to <8%. Example 2: Preparation of Arhar Dal:

For preparation of Arhar dal based pre comestible, Arhar dal is first washed with water and then soaked in 1.3-2.8%) of salt based water solution for 1-5 hrs. The Arhar dal used in the preparation is unpolished, split and de-stoned with initial moisture content of about 3-6%>. Soaking is terminated by addition of 1 - 1.9% of acidulant After soaking the moisture content goes upto 40-60%). Blanching is carried out for different periods of time ranging from 4-11 minutes at 70-101°C after soaking. The grains become translucent in appearance and soft in texture whereas the moisture level increases to 60-80%. The grains are then subjected to light drying at 30-80 °C for less than 30 minutes. On light drying the moisture level is brought down to 45-60%). Further, the grains are cut into pieces and then subjected to super-heated air for about 1-8 minutes at temperatures ranging from 60-150 °C. The grains are then allowed to cool at ambient temperatures for less than 30 minutes. The end moisture is successfully brought to <8%>.

Example 3: Whole Mix dal:

Firstly, the pre-comestible masoor dal in whole/split form is brought below 7%> of moisture.

To this, around 10-30 %> of Chana split is added along with other ingredients such as salts, nutrients, spices, 5%> seasoning, 5%> dehydrated veggies, fat, colours such as turmeric and sugar to form a dry mix.

The final product can be consumed within 7 minutes of introducing liquid medium

Example 4: 70:30 ArharrChana Pre - comestible powder mix:

Firstly, Raw material, that is, the pre-comestible legume in either whole, flaked, shaped, cut, bits, embossed, pitted, or pressed form is dried down to 7%> moisture. 6Kg of pre - comestible mix is ground to form powder of 30 mesh size.2 Kg of course Chana powder(20 mesh) is added to form a 3 : 1 powder mix. 1.2Kg or 15%> of potato starch is added to the pre-comestible legumes mix. To this 400g or 15%> salt is added. The mixture is blended well followed by addition of 400g seasoning and oil

The powder mix hence formed is rehydrated before consumption. Example 5: Soup:

Firstly, Raw material, that is, the pre-comestible legume in either whole, flaked, shaped, cut, bits, embossed, pitted, or pressed form is dried down to 7% moisture It is then ground to obtain an appropriate particle size, usually in the range of 10- 60 mesh. The particle size may vary depending upon the required duration of rehydration.

On obtaining the desired particle size, 30 to 50 % corn starch is added to it along with other ingredients such as seasoning and oil. For consumption, the final product requires a rehydration time of 30 seconds to 1 minute using hot/warm water.

Example 6: Preparation of extrude:

Firstly, Raw material, that is, the pre-comestible legume in either whole, flaked, shaped, cut, bits, embossed, pitted, or pressed form is dried down to 7% moisture and then ground to the correct particle size, usually to consistent size in range of 10-30 mesh. The particle size may be varied subject to rehydration requirements. For instance, if fast rehydration is desired then the mix should be coarse or and smaller particles to make a more compact extrude for slower rehydration. Secondly, 7 - 34% starch or wheat flour is added to the pre-comestible powder and other ingredients such as salts, soya, nutrients, other pulses, spices, seasoning, dehydrated veggies, fat, colours, such as turmeric, sugar are added to form a dry mix. Thirdly, the dry mix, hence formed, is put through a pre-conditioner, whereby steam is used to hydrate the mix and bring moisture levels to 25 - 50%. Steam Helps in hydrating the mix consistently, moisten well, and to convert the dry mix to a paste form. Fourthly, the paste, hence formed, is then passed through an extruder (some drying maybe required, if moisture is high) and packed.

Optionally, seasoning and spices may be sprinkled or given separately in a sachet and packed together.

Parameters of the extrudate of Example 6:

Output moisture should be below 10%.

Claims

We Claim,

1. A process for preparing a legume-based pre-comestible product that could be prepared within 30 seconds - 10 minutes and can be instantly consumed in various forms, said process comprises of:

a. cleaning, de-husking and dusting of commercially available legumes; b. sorting of the cleaned legumes of step (a) ;

c. washing of the sorted legumes of step (b) with a water jet to remove extraneous matters;

d. pre-soaking of the washed legumes of step (c) in 0.1% to 4% in a salt and/or leavening agent solution for 30min to 10 hours, till the moisture content of the legumes is in range of 40 - 80%;

e. adding acidulants to the legumes pre-soaked in salt-water solution as in step (d);

f. draining the excess moisture form the pre-soaked acidulated legumes of step (e);

g. drying of the legumes till the moisture content of the legumes is in range of 40 - 60%;

h. treating or roasting the dried legumes of step (g) at 120 - 400°C for 2 - 50 minutes

i. drying the roasted legumes of step (h) till the moisture content of the legumes is below 15%;

j . cooling or de-humidification of the dried legumes of step (i) till 15-32°C, and

k. packing the cooled dried legumes in suitable packs with or without flavourings or dehydrated vegetables, seasonings,

wherein, the process does not require any pressure cooking step.

2. The process of Claim 1, wherein treating or roasting of legumes comprises of treating the legumes with super-heated air, infra-red rays, microwaves, metal balls, sand and combinations thereof.

3. The process according to Claim 1, wherein the legumes may be blanched after step (e).

4. The process according to Claim 3, wherein the blanching is carried out at a temperature of about 70 - 101°C until the colour, texture of the said grains changes to desired proportion.

5. The process according to Claim 4, wherein the legumes may be frozen at any stage during the inventive process as long as the moisture content is above 20%.

6. The process according to Claims 1, wherein blanching is followed by step (f).

7. The process according to Claim 1, wherein the legumes may be steamed after step (e).

8. The process according to Claim 7, wherein steaming is carried out at a temperature of about 70 - 101°C until the colour, texture of the said grains changes to desired proportion.

9. The process according to Claim 7, wherein steaming is followed by step (f).

10. The process according to Claim 1, wherein salt-water solution contains from 0.1 - 4% of mixture of a salt and/or a leavening agent.

11. The process according to Claim 10, wherein the salt is selected from ammonium chloride, ammonium bicarbonate, sodium bicarbonate and sodium chloride.

12. The process according to Claim 10, wherein the leavening agent is selected from calcium hydrogen phosphate (CaHP04) [E341], yeast, sodium aluminium sulphate (NaAl(S04)r 12H₂0) [E521], disodium pyrophosphate (Na₂H₂P₂07), [E450] and sodium aluminium phosphates (NaHi4Ab(P04)8 4H₂0 [E541] and Na3Hi5Ai₂(P04» [E541].

13. The process according to Claim 1, wherein the acidulant is an organic acid.

14. The process according to Claim 13, wherein the organic acid is selected from acetic acid, citric acid, tartaric acid, malic acid.

15. The process according to Claim 1, wherein roasting and/or infra-red heating and/or micro waves and/or super-heated air treatment and/or heating via metallic and/or ceramic balls/pieces comprises of heating the legumes at a temperature of 120 - 400°C until the colour, texture of the said grains changes to desired proportion.

16. The process according to Claim 1, wherein the legumes are drained at temperature ranging from 15- 32°C, at relative humidity of 45 - 60% for 3 - 30 minutes for drying or draining excessive moisture in step (g).

17. The process according to Claim 1, wherein the legumes are subjected to partial drying or tempering at temperature ranging from 30 - 80°C for 2 - 50 minutes.

18. The process according to Claim 1, wherein a mix of spices and dried vegetables is mixed along with vegetable oil and packed.

19. The process according to Claim 1, wherein the legume is pre-treated in a solution permissible by the food authorities and additives are added and then dried into whole or flake or shaped or powdered or pitted or embossed or cut or concentrate or mash or extrusion.

20. The process according to any of the above claims, wherein the legumes are pressed and flattened either after Step (g) or in during Step (h).

21. A legume-based pre-comestible prepared by the process as claimed in Claim 1 - 20, wherein the legumes based pre-comestible product could be prepared within 30 seconds - 10 minutes.

22. The legume-based pre-comestible of Claim 21, wherein the legume-based pre- comestible product comprises of a single variety of legumes or plurality of legume varieties.

23. The legume-based pre-comestible product of Claim 21, wherein the legume- based pre-comestible product can be formulated as whole product, pressed, shaped, flaked product, powdered product or mixture thereof.

24. The legume-based pre-comestible of Claim 21, wherein the legume-based pre- comestible product is offered as "as is" for customisation at the time of consumption by the consumer or with spices seasoning, flavours, starch, permitted stabilizers, enriched natural proteins, nutrients or combinations thereof.

25. The legume-based pre-comestible claimed in Claim 21 can be consumed without adding a liquid vehicle.

26. The legume-based pre-comestible of Claim 21, can be consumed with a liquid medium, wherein the liquid vehicle is selected from hot water or warm water or cold water.

27. The legume-based pre-comestible of Claim 21, wherein the legume-based pre- comestible product is offered as a pre-mixed comprising the legume-based pre- comestible mixed with spices, seasoning, flavours, starch, permitted stabilizers, enriched natural proteins or combinations thereof.