Search

EP-4740740-A1 - PROCESS AND APPARATUS TO MAKE PROCESSED FOOD PRODUCTS

EP4740740A1EP 4740740 A1EP4740740 A1EP 4740740A1EP-4740740-A1

Abstract

The present invention discloses a process to make processed food products (1) in a superheated steam environment and without the addition of oil in superheated steam, wherein, one or more elements (5) to direct a steam flow are placed to direct the superheated steam from below the basket (2) with the food products (1) to be processed, wherein the speed of the gas circulation unit (6) is adjusted to allow the food products (1) being processed to float at least partially in the superheated steam flow. Claimed is also an apparatus (3*) for applying the process, the use of the process of the invention and/or of the apparatus (3*) of the invention to process food products (1). Furthermore, claimed is also use of said process and/or of the apparatus (3*) to obtain the processed food products (1).

Inventors

  • Zehnder, Josef

Assignees

  • ZEEN Holding AG

Dates

Publication Date
20260513
Application Date
20241108

Claims (15)

  1. Process to make processed food products (1) without the addition of oil, wherein the food products (1) to be processed are added to a basket (2) which is or is placed into an apparatus (3) comprising one or more elements (5) to direct a steam flow, a gas circulating unit (6), an inlet (7) to feed water and/or steam into the apparatus (3), and a gas/liquid outlet (8), wherein - water and/or steam is fed through the inlet (7) into the apparatus (3), wherein, when water is added, the water is evaporated with a heating element (4), and the gas temperature in the apparatus (3) is or is adjusted to be 130°C to 330°C, - the pressure in the apparatus (3) is allowed to be at least 2.5 bar below the boiling pressure of water at the gas temperature in the apparatus (3) to allow steam to be superheated steam, and - the gas circulating unit (6) is adjusted to allow a gas circulation speed of at least 5 m/sec, when measured between the elements (5) and the basket (2), characterized in that the one or more elements (5) are placed to direct the superheated steam from below the basket (2) to the food products (1) to be processed, wherein the speed of the gas circulation unit (6) is adjusted to allow the food products (1) being processed to float at least partially in the superheated steam flow.
  2. Process according to claim 1, characterized in that the basket (2) is a closable basket, and the apparatus (3) comprises an engine capable of rotating the basket (2) inside the apparatus (3).
  3. Process according to claim 1 or claim 2, characterized in that the oxygen content in the apparatus (3) is reduced in a first step to 3 vol.% or lower, preferably by evacuation or displacement by a gas free of oxygen (O 2 ), preferably steam.
  4. Process according to any one of claims 1 to 3, characterized in that the amount of food products (1) to be processed in the basket (2) is 20 vol.% or lower, preferably 10 vol.% or lower, based on the volume of the basket (2).
  5. Process according to any one of claims 1 to 4, characterized in that the - the process is a batch process, - the gas temperature in the apparatus (3) is between 140°C and 330°C, preferably between 150°C and 300°C, - the gas pressure in the apparatus (3) is about room pressure, i.e., there is free gas transfer from the apparatus (3) to the outside environment, - the processing time of the food products (1) is between 0.1 to 10 minutes, preferably between 0.1 and 7 minutes, and/or - the oxygen content in the apparatus (3) is adjusted to be 2 vol.% or lower, preferably 1 vol.% or lower.
  6. Process according to any one of claims 1 to 5, characterized in that the apparatus (3) comprises one or more sensors (9) to measure temperature, gas circulation speed, humidity, and/or pressure, and a control unit (10) to adjust the temperature, gas circulation speed, humidity, pressure, oxygen content and/or the amount of water and/or gas inlet.
  7. Process according to any one of claims 1 to 6, characterized in that the food products (1) to be processed include i) raw food products, such as potato slices, nuts or corn; ii) processed dry food products, i.e., pellets for expandable snacks; iii) frozen products, such as potato fries, chicken wings or fish bites; iv) food products to be sterilized, such as fruits, meats, seafood, or ready meals; v) reheat food products, such as ready meals; and/or vi) set products, such as apply a coating onto a food product.
  8. Process according to any one of claims 1 to 7, characterized in that the processed food products (1) include chips from potatoes, fruits, vegetables or tortilla chips; expanded or extruded snacks; popcorn; nuts; dried products from fruits, vegetables, herbs; potato fries or croquettes; chicken nuggets or wings; coated products, such as schnitzel; fish bites; burger patties; and/or sterilized food, such as fruits, meats, seafood, ready meals; ready meals.
  9. Apparatus (3*) for applying the process of any one of claims 1 to 8, characterized in that the apparatus (3*) comprises the basket (2), the heating element (4), the one or more elements (5) to direct steam flow, the gas circulating unit (6), the inlet (7) to feed water into the apparatus (3*), the gas/liquid outlet (8), and a door (11) to enter into and exit food products (1) from the apparatus (3*), characterized in that - the one or more elements (5) are placed below the basked (2), and - the gas/liquid outlet (8) is placed iii) below the one or more elements (5) to direct the steam flow, and iv) in the lower 10% of the apparatus (3*).
  10. Apparatus (3*) according to claim 9, characterized in that the apparatus (3*) comprises an engine capable to rotate the basket (2) inside the apparatus (3*), wherein the rotation axis of the basket is horizontal and/or within a deflection of +/- 60° or lower, preferably +/- 45° or lower, relative to the horizontal axis.
  11. Apparatus (3*) according to claim 9 or 10, characterized in that the - water inlet (7) is placed to feed water to the heating element (4), - heating element (4) enables temperatures of 380°C or higher, thus, to allow the generation of superheated steam, - the gas circulating unit (6) is placed to vent the gas out of the basket (2), wherein the gas circulating unit (6) is preferably a fan, and/or - the gas/liquid outlet (8) is placed in the lower 5% of the apparatus (3*), preferably at the bottom of the apparatus (3*).
  12. Apparatus (3*) according to any one of claims 9 to 11, characterized in that the heating element (4) enables temperatures of 450°C or higher, preferably 550°C or higher.
  13. Apparatus (3*) according to any one of claims 9 to 12, characterized in that the apparatus (3*) further comprises - a water filter and/or deionization unit (71) being placed before or after the inlet (7) for the water for cleaning the water, - a valve (81) to regulate the gas/liquid outlet (8), and thus to allow inside the apparatus (3*) a pressure different the outside, - one or more sensors (9) to measure the temperature, pressure, humidity and/or oxygen content of the gas phase, and/or - a control unit (10) to control the ∘ water and/or steam flow to the heating element (4), ∘ the temperature of the heating element (4), ∘ the humidity of the gas phase within the apparatus (3*), ∘ the circulation speed of the circulation unit (6), and/or ∘ the valve (81) to regulate the amount of gas/liquid to exit the outlet (8).
  14. Use of the process according to any one of claims 1 to 8 and/or of the apparatus (3*) according to any one of claims 9 to 13 to process food products (1), preferably in restaurants, take-away shops, canteens, industrial food processing factories, food processing unit on a farm, and/or at home, wherein the food products (1) to be processed include i) raw food products, such as potato slices, nuts or corn; ii) processed, e.g., extruded, dry food products, such as pellets for expandable snacks; iii) frozen products, such as potato fries, chicken wings or fish bites; iv) food products to be sterilized, such as fruits, meats, seafood, or ready meals; v) reheat food products, such as ready meals; and/or vi) set products, such as apply a coating onto a food product, e.g., applying a breading on a product, such as chicken nuggets.
  15. Use of the process according to any one of claims 1 to 8 and/or of the apparatus (3*) according to any one of claims 9 to 13 to obtain processed food products (1), wherein the processed food products (1) include chips from potatoes, fruits, vegetables or tortilla chips; expanded or extruded snacks; popcorn; nuts; dried products from fruits, vegetables, herbs; potato fries or croquettes; chicken nuggets or wings; coated products, such as schnitzel; fish bites; burger patties; and/or sterilized food, such as fruits, meats, seafood, ready meals; ready meals.

Description

The present invention relates to a process to make processed food products in a superheated steam environment and without the addition of oil, an apparatus for use in said process, as well as the uses of said process and said apparatus. Processed food products, such as potato chips or fries, chicken wings or fried fruit or vegetable slices became beloved snacks and finger food. They are all processed using oil. As a matter of fact, the presence of oil is an essential element in today's processing techniques in order to give processed food products a unique taste and crisp. However, the presence of oil during processing such food products has also a number of disadvantages. Besides being unhealthy due to the presence of oil, the latter may also lead to the formation of acrylamide, which is assumed to be a carcinogenic compound. In addition, processing food containing oil needs to be packed under a protective atmosphere, such as nitrogen, which contributes to an additional packaging step, thus increasing cost of the product. Hence, it is the objective of the present invention to overcome said problems. Although various attempts were made in past, no disclosed process technology is good enough to bring such food processed without oil to a breakthrough. Surprisingly, this highly demanding object is solved by a process to make processed food products (1) in a superheated steam environment and without the addition of oil according to claim 1. Claimed also is an apparatus (3*) according to claim 9 for applying the inventive process. In addition, claimed is also the use of the inventive process and/or the inventive apparatus (3*) according to claim 14 to process food products (1). Furthermore, claimed also is the use of the processed food products (1) according to claim 15, obtained from the inventive process and/or with the inventive apparatus (3*). The process, apparatus and the uses of the present invention provide surprisingly a number of different advantages. The process is fast, straightforward, and no complex installation is required. Pressure may be applied but is not required. In addition, it is not required - although possible - to evacuate the apparatus (3, 3*). Hence the equipment may only be designed to work under standard pressure and elevated temperatures. Most importantly, the food products (1) can be processed without addition of oil, while the final product taste - having comparable types and amounts of artificial flavor - is very similar to today's processed food products comprising oil. Hence, the food products (1) may only comprise oil added before or after the process of the invention. Therefore, the processed food products (1) are healthier due to the absence of oil and toxic acrylamide. In addition, the packaging of the processed food products may occur in the presence of oxygen, and thus air. No specific protective atmosphere is required. Furthermore, it was surprisingly found that the process of the invention reduces significantly, or omits completely, the Maillard-reaction, i.e. the embrowning of the starch-based food products (1), which has a negative impact of the taste of the processed food products (1). It is believed that this is due to the presence of superheated steam, and the absence of oxygen as well as of oil. The apparatus (3*) of the present invention is safe and easy to handle. Most surprisingly, oxygen gas present in the initial air environment can be displaced readily, e.g., within a fraction of a minute, and without evacuation step, just by introducing sufficient amount of water being evaporated in the apparatus (3*). Additionally, since no oil is added to the food products (1) to be processed, no or only minor soiling of the inside of the apparatus (3*) occurs, thus the cleaning effort is significantly reduced. Hence, a wide variety of different food products (1) can be processed, thus obtaining many different types of processed food products (1). And surprisingly, it was found that food processing using the present invention and /or apparatus may be 30-50% faster, depending on the food products, e.g., pellets and their composition, used. And the energy consumption may be reduced by about 80%, compared to conventional frying. The process The process according to the invention allows to make processed food products (1) without the addition of oil, wherein the food products (1) to be processed are added to a basket (2) which is or is placed into an apparatus (3) comprising one or more elements (5) to direct a steam flow, a gas circulating unit (6), an inlet (7) to feed water and/or steam into the apparatus (3), and a gas/liquid outlet (8), wherein water and/or steam is fed through the inlet (7) into the apparatus (3), wherein, when water is added, the water is evaporated with a heating element (4), and the gas temperature in the apparatus (3) is or is adjusted to be 130°C to 330°C,the pressure in the apparatus (3) is allowed to be at least 2.5 bar below the boiling pressure