PROCESS AND SYSTEM FOR SMOKING SEAFOOD AND MEAT WITH REDUCED GAS ODORS AND IMPROVED FLAVOR

Abstract

The present invention relates to an improved process and system for cold smoking of seafood and meat. The process is directed towards the reduction of distasteful gas compounds in aerosol smoke that cause unwanted gas odors and flavors in subsequently smoked foods. The method is further effective in preserving the freshness, wholesomeness, and appearance of smoked seafood and meat by retaining the desirable preservative aerosol components of the smoke. A superior smoke aroma and flavor can be imparted to seafood and meat, without the interference of distasteful gases odors. The process is further highly efficient, by incorporation of condensation filtering to regulate water, collect, and recycle smoke flavoring liquid condensates, thereby maximizing the value recovery from the smoking system.

Claims

1. A process for smoking food comprising: a) heating an organic material to produce aerosol smoke; b) prefiltering the aerosol smoke to reduce liquids and solids; c) reducing distasteful gas compounds, which are volatile organic compounds, in said aerosol smoke; d) retaining preservative components in said aerosol smoke; e) exposing food to said aerosol smoke; and f) the food having a traditional smoke aroma and flavor with reduced distasteful gas odors.

2. A process according to claim 1, wherein the organic material is hardwood traditionally used for smoke flavoring food.

3. A process according to claim 1, wherein water in the smoke is reduced.

4. A process according to claim 1, wherein supplemental traditional smoke flavor compounds are added to said aerosol smoke.

5. A process according to claim 1, wherein supplemental traditional smoke flavor compounds are added to said food.

6. A process according to claim 1, wherein a microporous material is used to reduce gas compounds having distasteful or objectionable odors.

7. A system for smoking food, the improvement comprising a water reduction subsystem and a gas odor reduction subsystem configured to control water condensation and adsorb gas distasteful compounds through the use of different filtering materials, resulting in a smoke flavored food with reduced objectionable gas odors.

8. The system for smoking food of claim 7 comprising: a) a smoke generator comprising: i) a hopper to feed organic smoking material, ii) a cooking oven configured for heating organic smoking material to generate smoke, iii) a control box coupled to a thermocouple and a cooking tube, iv) a motor configured to turn a screw auger, wherein said screw auger is configured to convey said hopper, and v) an ash collector; b) the water reduction subsystem coupled to the smoke generator, comprising a plurality of internal chambers separated by baffles; c) a smoke storage chamber coupled to said water reduction subsystem comprising: i) an accordion bladder, and ii) a pump configured to evacuate air from said bladder; d) the gas odor reduction subsystem coupled to said water reduction subsystem comprising: i) a plurality of filter housings comprising filtering material configured to adsorb gas distasteful compounds, ii) a plurality of heaters configured to control water condensation, wherein at least one of said heaters is controlled by a thermostat located in said control box, iii) a backpressure device coupled with a smoke pressure controller, wherein said backpressure device is configured to allow the flow of smoke when the pressure reaches 1 bar, and iv) a blower configured to force high volumes of air or dry inert gases in the opposite direction of the flow of the smoke; e) a smoking chamber coupled to the gas odor reduction subsystem comprising: i) a housing configured to received aerosol smoke from the gas odor reduction subsystem, wherein said aerosol smoke is substantially reduced of gas distasteful compounds, comprising internal racks to place food, ii) an exhaust pipe configured to discharge smoke, iii) a plurality of circulating fans, iv) a thermostatic controller configured to control the temperature of food, v) a humidity control device, vi) a pressure control device; and f) a plurality of valves configured to automatically and/or manually open and close during a smoking cycle, wherein the gas compounds having distasteful odors from said smoke aerosol are substantially reduced in the food after a smoking cycle.

9. The system of claim 7, wherein the filtering material comprises 6 millimeter beads of molecular sieves having a pore size of 7 angstroms.

10. The system of claim 7, wherein the filtering material comprises 4 millimeter beads with a pore size of 6 angstroms.

11. The system of claim 7, wherein the filtering material comprises 2.5 millimeter beads having a pore size of 5 angstroms.

12. The system of claim 7, wherein hot air is forced into the smoking system through a valve to regenerate said filtering material.

13. The system of claim 7 further comprising a distasteful gas compounds reduction subsystem comprising: a) a smoke receiving chamber, b) a filter housing coupled to the smoke receiving chamber comprising at least three filters and having a first adsorbent material having 1 to 3 millimeter granules of microporous activated carbon, a second adsorbent configured in 1.2 millimeter beads of molecular sieves with a pore size 7 to 8 angstroms, and a third adsorbent configured in 1.6 millimeter beads of molecular sieves with a pore size opening of 5 angstroms; and c) a passage way configured to run through said filters, comprising a smoke intensity regulator, wherein the smoke intensity regulator comprises: i) a cap, ii) a locking notch, iii) a steel washer placed inside the cap, configured to control the dosage of aerosol smoke that by-passes the filters, and iv) a gasket comprising a pin configured to lock the notch, wherein the gas compounds having distasteful odors from said smoke aerosol are substantially reduced in the food after a smoking cycle.

14. The system of claim 7, further comprising a liquid smoke system used for smoking food, wherein compounds having distasteful odors are substantially reduced in the food after a smoking cycle.

15. A process for smoking food comprising: a) heating an organic material to produce aerosol smoke having gas compounds with distasteful odors; b) reducing water from said smoke aerosol by condensing said aerosol smoke, wherein said condensed aerosol smoke passes through at least one microporous filter to reduce distasteful gas odors; and c) exposing food to said aerosol smoke with reduced distasteful odors, wherein the food has a traditional smoke aroma and flavor with reduced distasteful gas odors.

16. The process for smoking food of claim 15 further comprising steps d) and e) after step b), but before step c): d) reducing traditional smoke flavor compounds; and e) supplementing traditional smoke flavor compounds.

17. A process according to claim 15, wherein water in the smoke is reduced by condensation.

18. A process according to claim 16, wherein supplemental traditional smoke flavor compounds are added to said smoke.

19. A process according to claim 16, wherein supplemental traditional smoke flavor compounds are added to said food.

20. A process according to claim 16, wherein microporous material is configured and used to reduce gas compounds having distasteful gas odors.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0096] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

[0097] FIG. 1 shows a cutaway view of the smoke generator and water reduction subsystem.

[0098] FIG. 2 represents a cutaway diagram of the temporary smoke storage chamber, distasteful gas compound reduction subsystem, and a smoking chamber.

[0099] FIG. 3 illustrates an alternative distasteful gas compound reduction subsystem with smoke flavor regulator and liquid smoke enhancement provision.

DETAILED DESCRIPTION

[0100] According to embodiments, and referring now to FIG. 1, there is provided a smoke generator (100) and cooking oven (190) that provides a heating source preferably electrical or gas. The cooking oven (190) is preheated to a predetermined temperature set in a control box (180), preferably between 250 and 600° C. The control box (180) communicates with the thermocouple (162) receiving the temperature inside the cooking tube (160). When the desired temperature inside the cooking tube (160) measured by the thermocouple (162) is reached, the motor (150) is activated which turns the screw auger (164). Sawdust or other organic smoking material (110) in the hopper (140) is conveyed by the screw auger (164) through the cooking tube (160) and cooking oven (190) discharging smoke inside an ash collector (130). The ash collector is sealed at the bottom with water (132) serving as a multi-function device to collect tar and ash and reduce smoke temperature.

[0101] According to an embodiment, the smoke generator (100) may comprise at least one valve (122, 124) that are closed as the smoke fills the ash collector purging out air through the pipe and open valve (120). When the ash collector is flooded with smoke the valve (120) closes and the valve (122) opens. Smoke fills the condensing filter (200) that acts as a water reduction means to cool and condense water from the aerosol smoke while the air inside flows out the pipe with open valve (122).

[0102] According to an embodiment, the water reduction subsystem in the present embodiment is a metal condensing filter (200) having approximately 75 centimeters wide and 120 centimeters high, comprising a plurality of internal chambers separated by baffles (210) and condensing surfaces. The condensing filter (200) can be either air cooled or water cooled to condense water from the aerosol smoke. Liquid smoke condensates accumulate at the bottom of the condensing filter (220) and are collected through the pipe with valve (126).

[0103] Referring now to FIG. 2, according to an embodiment, there is provided a temporary smoke storage chamber (300) is constructed of an outer housing (370) that is scaled in size to output volume of the smoke generator (100). In an embodiment the housing (370) is fabricated from the equivalent of a 209 liters steel drum. The temporary smoke storage chamber (300) comprises a collapsible accordion bladder (310) that is positioned inside outer housing (370) and at least two valves (320, 322). Preparation of the temporary smoke storage chamber (300) for a smoking cycle begins with valve (124) from the condensing filter (200), and valve (320) being closed, while valve (322) is opened. This enables pump (330) to evacuate air from the bladder (310). When the inner bladder (310) is shrunken valve (322) closes. In the starting position the inner bladder (310) is collapsed.

[0104] According to an embodiment, when the condensing filter (200) is flooded with smoke and the temporary smoke storage chamber (300) is in the starting position valve (122) closes. Then valve (124) opens to allow smoke to naturally flow from the condensing filter to the reduced pressure temporary smoke storage chamber (300) with its inner bladder (310) expanding.

[0105] According to an embodiment, the temporary smoke storage chamber (300) can be comprised of any means that regulates or synchronizes the output of the smoke generator and input to a gas odor reduction subsystem (400).

[0106] According to an embodiment, when the accordion bladder (310) is substantially filled with smoke, sensor (340) opens valves (320, 410, 412), and closes valves (414, 416). When pump (350) is activated it pushes smoke through subsystem (400) purging the air out valve (412) into the atmosphere. When the smoke is evacuated from the temporary smoke storage chamber (300) and the accordion bladder (310) is collapsed, the sensor (380) turns off the pump (350). When subsystem (400) is substantially flooded with smoke the valve (412) closes.

[0107] According to an embodiment, the subsystem (400) is comprised of filtering material that reduces distasteful gas compounds that will contribute objectionable foul odors, unappetizing, or unsavory flavors to smoked seafood and meats, especially noticeable in lightly cold smoked seafood.

[0108] According to an embodiment, microporous adsorbents are applied, preferably, hydrophobic molecular sieves that give priority to adsorption of risk odor gas compounds and exclude water containing phenols. In an embodiment the subsystem (400) comprises at least three filter housings (420, 422, 424) comprising a filter (430, 432, 434), each housing having at least 15 centimeter in inner diameter and 180 centimeters long. Each one of the three filter housings (420, 422, 424) comprises a different type of adsorbent.

[0109] In an embodiment, a first filter (430) is packed with 6 millimeter beads of molecular sieves having a pore size of 7 angstroms.

[0110] In an embodiment, a second filter (432) is loaded with 4 millimeter beads with a pore size of 6 angstroms.

[0111] In an embodiment, a third filter (434) is 2.5 millimeter beads having a pore size of 5 angstroms.

[0112] According to an embodiment, the reduced distasteful gas compound subsystem (400) is further equipped with an optional heater (440), thermostatic probe (450), and optional backpressure device (460) at the discharge port of the subsystem (400).

[0113] According to an embodiment, the temporary smoke storage chamber (300) has a thermocouple (360), configured to transmit the temperature to the control box (180). The control box (180) receiving the temperature from the thermocouple (360) and either manually or automatically sets the thermostatic controller for the heater (440) to be 1° C. to 4° C. higher than the smoke temperature from the thermocouple (360). The heater (440) is activated and controlled by a thermostat (182) located in the control box (180) to maintain the desired internal temperature of the subsystem (400).

[0114] According to an embodiment, the backpressure device (460) is optionally set to maintain a consistent backpressure inside the subsystem (400) and also acts as a closed valve for regeneration of molecular sieves using the air blower (470). In an embodiment the backpressure at the backpressure device (460) is set to 1 bar. Any pressure can be used, depending on the desired outcome. If the pressure is increased then water condensation in the subsystem (400) may increase as well. However, water condensation can be controlled by increasing the internal temperature through the heaters (440).

[0115] According to an embodiment, when pressure in subsystem (400) exceeds 1 bar smoke will flow out of the backpressure device into a smoke temperature controller (480) that regulates the smoke to its desired temperature for smoking food.

[0116] According to an embodiment, the smoke temperature can be adjusted by cooling or heating provisions applied to the smoking chamber (500). The aerosol smoke with reduced distasteful gas odors can now be used to smoke seafood and meat by flooding a smoking chamber (500), while needle injection can be supplemental applied to thicker cuts of food.

[0117] According to an embodiment, the smoking chamber (500) comprises an insulated housing (510) that receives aerosol smoke from the temperature controller (480), which is circulated around the food on racks (520). The smoke discharges through the exhaust pipe (530). The smoking chamber can be further equipped with circulation fans, thermostatic controllers, food temperature and/or humidity control devices, pressure features, as desired. Any type of smoking receptacle or temperature control means can be used.

[0118] According to an embodiment, the adsorbent materials of filters (430, 432, 434) are regenerated by heat to remove distasteful gas compounds. After smoking operations are finished valve (410) closes and (460) acts as a closed valve, while valves (414) and (416) open for regeneration of filtering material.

[0119] According to an embodiment, the internal temperature of the subsystem (400) is raised by the optional heaters (440) to a temperature of 150° C. High volumes of air or dry inert gas such as nitrogen is forced by the blower (470) in the reverse direction of smoke flow through the subsystem (400). The hot air exits through valve (414) into the atmosphere. The internal temperature established by the probe (450) and control box (180) is gradually increased from 150° C. to as high as 315° C., depending on the adsorbent type of material.

[0120] According to an embodiment, in the absence of the optional heater (440) hot air or hot dry gas can be heated to 150° to 315° C. and forced into the pipe through valve (416) and out of the pipe with valve (414). Hot air flow continues until regeneration of the filtering material is complete, at which time valves (414) and (416) close.

[0121] According to an embodiment, and now referring to FIG. 3, an alternative distasteful gas compound reduction subsystem (600) is shown with and optional smoke intensity regulator (610) that controls the amount of traditional smoke aroma and flavors applied to seafood or meat.

[0122] According to an embodiment, the gas compounds reduction subsystem (600) comprises a filter housing (620) configured in the form of a cylinder with an inside diameter of approximately 25 centimeters and 200 centimeters long. The filter housing (620) comprises at least three types of adsorbents; a first adsorbent having 1 to 3 millimeter granules of microporous activated carbon (622); a second adsorbent configured in 1.2 millimeter beads of molecular sieves with a pore size 7 to 8 angstroms (624); and a third adsorbent configured in 1.6 millimeter beads of molecular sieves with a pore size opening of 5 angstroms (626).

[0123] According to an embodiment, the gas compounds reduction subsystem (600) comprises a passage way (630) constructed of a hollow stainless steel tube with an inside diameter approximately 5 centimeter and a length that runs through the center of the adsorbents (622, 624, 626) from one end and out of the other. The hollow passage way (630) is coupled with the smoke intensity regulator (610) transports a minority percentage of smoke from the condensing filter, bypassing the adsorbent filters, and increasing the traditional smoke flavor intensity.

[0124] According to an embodiment, the smoke intensity regulator (610) is attached to the entryway of the hollow passage way (630) and comprises of a cap (612) with a 4 cm hole (614) and a locking notch (616). Nested inside the cap (612) there is a stainless steel washer (618) with a 2 centimeter hole (640) providing an orifice that controls a precise dosage of aerosol smoke bypassing the adsorbent filters (622, 624, 626). An O-ring or gasket (642) seals the assembly comprises a pin (644) on the outside tube entryway (646) locking the assembly in the notch (616) of the cap (612).

[0125] According to an embodiment, the size, type and quantities of filter material (622, 624, 626) can be adjusted. At least one microporous material may be used to substantially reduce distasteful gas compounds from the smoke. The orifice (640) is sized to control a measured volume of smoke from the condensing filter (200) circumventing the adsorbents. The diameter of the hollow passage way (630) and orifice (640) can be configured to be larger, smaller, or completely closed in which case all smoke will flow through the filtering material (622, 624, 626).

[0126] According to an embodiment, valves (414) and (416) are closed, and valves (124) and (650) are open. Smoke with reduced water flows from the condensing filter (200) through valve (124) and into a smoke receiving chamber (660) of the subsystem (600). A fan (670) can be applied to motivate the smoke while maintaining a positive pressure inside the subsystem (600).

[0127] According to an embodiment, the smoke flow is forked into two streams. A majority of the smoke streams from the receiving chamber (660) through the through the filtering material (622, 624, 626). A minority of about 10% of smoke metered by the orifice (640) streams through the tube (630) bypassing the filtering material (622, 624, 626). The two streams of smoke join into one stream in the smoke discharge chamber (680).

[0128] According to an embodiment, subsystem (600) can operate with or without the temporary storage chamber (300), optional heater (440), and backpressure device (460).

[0129] According to an embodiment, the aerosol smoke with reduced objectionable gas compounds located in the smoke discharge chamber (680) is now ready for temperature adjustment and smoking seafood and meat. With the distasteful gas compounds substantially reduced, preservative components of the aerosol smoke retained, a finished product can be produced having the pure essence, aroma, and flavor of lightly smoked seafood that will be superior to other smoked products.

[0130] According to an embodiment, after the smoking cycle is completed, valves (124) and (650) close and valves (414) and (416) open optionally for regeneration of filtering materials (622, 624, 626).

[0131] According to an embodiment, the subsystem (600) comprises a blower (690) that supplies hot air or hot dry gas starting at 150° C. entering valve (416) and discharging through valve (414) of subsystem. One skilled in the art would appreciate that the hollow passage way (630) may run through the center of the adsorbents (622, 624, 626) serving a secondary function of expediting regeneration by providing heat to the core of the filtering material. Temperature is increased gradually to the regeneration specifications of the molecular sieve with care to avoid combustion, fire, or other safety hazards.

[0132] According to an embodiment, the present invention comprises liquid smoke system (700). Liquid smoke (710) made according to the present invention or purchased from the liquid smoke flavoring market (710) can be prepared with or without other marinade such as salt and/or sugar. Liquid smoke can be applied to meat or seafood in a solution by spray, dipping (480), liquid or vaporized gas injection.