Process for producing refrigerated produce
The present invention includes a process for producing substantially stable produce, typically vegetables and fruit that can be stored in a refrigerated environment for at least about five weeks without preservatives and at least about three months with preservatives. The process involves holding the produce in an aqueous immersion solution that includes a cellular stabilizing agent for a time sufficient to convert the produce into a heat durable piece and thermally processing the heat durable produce in the immersion solution. The use of additional ingredients as components of the immersion solution such as sweeteners, acids, salt, and preservatives are optional.
1. A process for producing stable produce comprising the steps of:
providing at least one fresh or fresh frozen produce piece and an aqueous immersion solution comprising at least one cellular stabilizing agent selected from the group consisting of polyhydric alcohols and water bulking agents;
immersing the produce piece in the aqueous immersion solution which is at about ambient temperature;
holding the produce piece in the immersion solution at about ambient temperature for about one hour;
subsequently thermally processing by heating the immersion solution with the produce piece in the immersion solution to a temperature of from about 180° F. to about 195° F. and then holding the immersion solution at said temperature for about five minutes or less, and optionally agitating the produce piece in the immersion solution;
cooling the thermally processed produce piece in the immersion solution to about ambient temperature or less after thermally processing the produce piece to yield a processed produce piece;
separating the processed produce piece from the immersion solution; and
packaging the processed produce piece, at a moisture content of from about 39% to about 55%; and
wherein the packaged, processed produce piece remain substantially stable at least five weeks in a refrigerated environment without utilizing a preservative.
2. The process for producing stable produce of claim 1 , wherein the produce piece comprises a vegetable piece and the ratio of the produce piece to immersion solution is from about 1:1.5 to about 1:2.5.
3. The process for producing stable produce of claim 2 , wherein the vegetable piece comprises a vegetable piece chosen from the group consisting of whole, frozen vegetable pieces; whole, fresh vegetable pieces; sectioned, frozen vegetable pieces; and sectioned, fresh vegetable pieces.
4. The process for producing stable produce of claim 3 , wherein the at least one cellular stabilizing agent comprises a cellular stabilizing agent chosen from the group consisting of glycerin, polydextrose, sorbitol and propylene glycol.
5. The process for producing stable produce of claim 4 , wherein the immersion solution further comprises from about 0.1% to about 0.5% by weight of at least one preservative; and wherein the processed vegetable remains substantially stable for at least about three months in a refrigerated environment.
6. The process for producing stable produce of claim 5 , wherein the at least one preservative comprises a preservative chosen from the group consisting of potassium sorbate, sodium benzoate, sodium lactate, and sulfites.
7. The process for producing stable produce of claim 5 , wherein the immersion solution further comprises an acid chosen from the group consisting of citric acid and ascorbic acid, or a mixture thereof.
8. The process for producing stable produce of claim 7 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
9. The process for producing stable produce of claim 7 , wherein the immersion solution further comprises at least one sweetener, in an amount from about 0% to about 35% by weight, with said sweetener comprising a sweetener chosen from the group consisting of corn syrup, maltodextrin, and high maltose corn syrup.
10. The process for producing stable produce of claim 9 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
11. The process for producing stable produce of claim 5 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
12. The process for producing stable produce of claim 5 , wherein the immersion solution further comprises at least one sweetener, in an amount from about 0% to about 35% by weight, with said sweetener comprising a sweetener chosen from the group consisting of corn syrup, maltodextrin, and high maltose corn syrup.
13. The process for producing stable produce of claim 12 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
14. The process for producing stable produce of claim 4 , wherein the immersion solution further comprises an acid chosen from the group consisting of citric acid and ascorbic acid, or a mixture thereof when the vegetable piece comprises a vegetable piece chosen from the group consisting of a potato and a mushroom.
15. The process for producing stable produce of claim 14 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
16. The process for producing stable produce of claim 14 , wherein the immersion solution further comprises from about 0.1% to about 35% of at least one sweetener comprising a sweetener chosen from the group consisting of corn syrup, maltodextrin, and high maltose corn syrup.
17. The process for producing stable produce of claim 16 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
18. The process for producing stable produce of claim 4 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
19. The process for producing stable produce of claim 4 , wherein the immersion solution further comprises from about 0.1% to about 35% of at least one sweetener comprising sweetener chosen from the group consisting of corn syrup, maltodextrin, and high maltose corn syrup.
20. The process for producing stable produce of claim 19 , wherein the immersion solution further comprises salt, and the amount of salt is from about 0% to about 2% by weight.
21. The process for stable produce of claim 3 , wherein the immersion solution comprises from about 10% to about 20% by weight cellular stabilizing agent and the cellular stabilizing agent comprises glycerin.
22. The process for producing stable produce of claim 3 wherein the immersion solution comprises from about 5% to 10% by weight cellular stabilizing agent and the cellular stabilizing agent comprises polydextrose.
23. The process for producing stable produce of claim 2 , wherein the processed vegetable pieces comprise a water activity of from about 0.82 to about 0.98.
24. The process for producing stable produce of claim 1 , wherein the produce piece comprises a fruit piece and the ratio of the produce piece to immersion solution is from about 1:1.5 to about 1:2.5.
25. The process for producing stable produce of claim 24 , wherein the immersion solution comprises from about 10% to about 20% by weight cellular stabilizing agent and the cellular stabilizing agent comprises glycerin; and also includes
at least one preservative chosen from the group consisting of potassium sorbate, sodium benzoate, sodium lactate, and sulfites; and
wherein the immersion solution further comprises an acid chosen from the group consisting of citric acid, ascorbic acid, and a mixture thereof; and
wherein the immersion solution further comprises at least one sweetener, in an amount from about 0% to about 35% by weight, and said sweetener comprising a sweetener chosen from the group consisting of corn syrup, maltodextrin, and high maltose corn syrup; and
wherein the fruit piece comprises pineapple.
26. The process of claim 1 in which said produce comprises a vegetable.
27. The process of claim 26 in which said vegetable is broccoli or carrot.
28. A process for producing stable vegetables comprising the steps of:
providing at least one fresh or fresh frozen vegetable piece and an aqueous immersion solution comprising at least one cellular stabilizing agent selected from the group consisting of polyhydric alcohols and water bulking agents;
immersing the vegetable piece in an aqueous immersion solution at about ambient temperature and holding the vegetable piece in the immersion solution at ambient temperature for about one hour to convert the vegetable piece into a heat durable vegetable piece;
subsequently thermally processing by heating the immersion solution with the vegetable piece in the immersion solution to a temperature of from about 180° F. to about 195° F. and then holding the immersion solution at said temperature for about five minutes or less, and optionally agitating the vegetable in the immersion solution;
cooling the thermally processed vegetable in the immersion solution to about ambient temperature or less after thermally processing the vegetable piece to yield a processed vegetable piece;
separating the processed vegetable piece from the immersion solution;
packaging the processed vegetable piece; and
wherein the processed vegetable piece comprises a water activity of from about 0.82 to about 0.98 and a percent moisture content of from about 39% to about 55% and remains stable for at least about five weeks in a refrigerated environment when the immersion solution is substantially free of a preservative and at least about three months in a refrigerated environment when the immersion solution further comprises a preservative.
29. The process for producing stable vegetables of claim 28 , wherein the vegetable pieces comprises a vegetable piece chosen from the group consisting of whole, frozen vegetable pieces; whole, fresh vegetable pieces; sectioned, frozen vegetable pieces; and sectioned, fresh vegetable pieces.
30. The process for producing stable vegetables of claim 29 , wherein the cellular stabilizing agent comprises a cellular stabilizing agent chosen from the group consisting of glycerin, polydextrose, sorbitol, and propylene glycol; and wherein the at least one cellular stabilizing agent is present in the immersion solution in an amount up to about 60% by weight.
31. The process for producing stable vegetables of claim 30 , wherein the immersion solution further comprises a sweetener chosen from the group consisting of corn syrup, maltodextrin, high maltose corn syrup, and mixtures thereof, and the at least one sweetener comprises up to about 35% by weight of the immersion solution.
32. The process for producing stable vegetables of claim 31 , wherein the immersion solution further comprises salt and, wherein salt is present in an amount up to about 2% by weight.
33. The process for producing stable vegetables of claim 32 , wherein the immersion solution further comprises a preservative chosen from the group consisting of potassium sorbate, sodium benzoate, sodium lactate, sulfites, and mixtures thereof; and wherein the at least one preservative comprises up to about 0.5% by weight of the immersion solution.
34. The process for producing stable vegetables of claim 33 , further comprising an acid chosen from the group consisting of ascorbic acid, citric acid, and mixtures thereof; and wherein the acid is present in the immersion solution in an amount of up to about 0.5% by weight.
35. The process for producing stable vegetables of claim 34 , wherein the at least one vegetable piece comprises cucumber, and wherein the cellular stabilizing agent comprises polydextrose.
36. The process for producing stable vegetables of claim 34 , wherein the immersion solution comprises at least one acid and the at least one vegetable piece comprises a vegetable piece chosen from the group consisting of a mushroom and a potato.
37. The process for producing stable vegetables of claim 34 , wherein the at least one vegetable piece comprises a vegetable piece chosen from the group consisting of broccoli, cut beans, zucchini, sweet corn, tomato, and green peas.
38. The process for producing stable vegetables of claim 28 , wherein the step of immersing the vegetable piece in an aqueous immersion solution includes holding the vegetable piece in the immersion solution for about an hour at about ambient temperature.
39. The process of claim 28 in which said vegetable is broccoli or carrot.