FROZEN FOOD PRODUCT
20220211086 · 2022-07-07
Inventors
Cpc classification
International classification
Abstract
A frozen food product comprising a first food product portion, a second food product portion and a third food product portion is disclosed. The first food product portion, a second food product portion and a third food product portion are configured such that the second food product portion is disposed intermediate the first food product portion and the third food product portion. In some embodiments, the frozen food product is frozen Ramen wherein the first food product portion is frozen soup broth, the second food product portion is a frozen noodle mass, and the third food product portion includes at least one or more toppings commonly found in Ramen. In some embodiments, the third food product portion is a composite layer that includes one or more toppings commonly found in Ramen that are embedded within frozen soup broth.
Claims
1. A frozen food product, comprising: a first food product portion; a second food product portion; and a third food product portion; wherein: the first food product portion is frozen soup broth; the second food product portion is a frozen noodle mass; and the third food product portion includes at least one or more individual frozen food items; and the first food product portion, the second food product portion and the third food product portion are cooperatively configured such that: the first food product portion, the second food product portion and the third food product portion are a frozen unit; and the second food product portion is disposed intermediate the first food product portion and the third food product portion.
2. The frozen food product as claimed in claim 1; wherein: the frozen food product is frozen Ramen.
3. The frozen food product as claimed in claim 1; wherein: the frozen food product has a heat-receiving orientation; and while the frozen food product is disposed in the heat-receiving orientation, the first food product portion is a base of the frozen food product.
4. The frozen food product as claimed in claim 1; wherein: the frozen noodle mass comprises noodles that are partially cooked and coated in oil prior to freezing; and the noodles are selected from one of the following alternatives: Ramen noodles, egg noodles, rice noodles, buckwheat noodles, or udon noodles.
5. The frozen food product as claimed in claim 4; wherein: the oil for coating the partially cooked noodles is selected from one of the following alternatives: pork back fat, chicken oil, yuzu oil, flavoured oil, chili oil or fish oil.
6. The frozen food product as claimed in claim 4; wherein: the noodles have a predetermined cooking time; and the partial cooking of the noodles is such that the noodles are partially cooked, via boiling, for a minimum of ⅙.sup.th of the predetermined cooking time to a maximum of ⅕.sup.th of the predetermined cooling time.
7. The frozen food product as claimed in claim 1; wherein: the first food product portion has a food product-receiving surface; the second frozen food portion has a first surface disposed in contact with the food product-receiving surface of the first food product portion, and a second surface, disposed opposite to the first surface; the second food product portion includes a cavity region that extends into the second food product portion from the second surface; and the third food product portion is disposed on the second food product portion such that at least a portion of the third food product portion is disposed within the cavity region.
8. The frozen food product as claimed in claim 7; wherein: the cavity region extends radially outwardly from a central axis that extends vertically through the frozen food product while the frozen food product is disposed in the heat-receiving orientation; and the cavity region extends into the second food product portion such that the cavity region has a maximum depth, as measured along the central axis, of at least 50% to a maximum of 100% of the maximum height of the second food product portion, as measured along the central axis.
9. The frozen food product as claimed in claim 8; wherein: the cavity region is conically-shaped.
10. The frozen food product as claimed in claim 1; wherein: the third food product portion includes one or more individual food items selected from one or more of the following alternatives: meat, vegetable-based protein sources, vegetables, fungi, herbs, and seasonings.
11. The frozen food product as claimed in claim 1; wherein: the frozen food product is suitable for re-heating via conduction.
12. A frozen food product, comprising: a first frozen food portion defining a first surface and second, food product-defining surface that is disposed opposite to the first surface; a second frozen food portion defining a first surface and a second food product-defining surface, disposed opposite to the first surface; and a third frozen food portion; wherein: the second frozen food portion includes a cavity region that extends into the second frozen food portion from the second, food product-defining surface; the third frozen food portion includes one or more individual frozen food items; and the first frozen food portion, the second frozen food portion and the third frozen food portion are cooperatively configured such that: the second frozen food portion is disposed intermediate the first frozen food and the third frozen food portion; and the third frozen food portion is disposed on the second frozen food portion such that at least one of the one or more individual frozen food items is disposed within the cavity region.
13. The frozen food product as claimed in claim 12; wherein: the first frozen food portion includes frozen soup broth; the second frozen food portion includes a frozen noodle mass; and the third frozen food portion includes at least one or more individual frozen food items selected from one or more of the following alternatives: meat, vegetable-based protein sources, vegetables, herbs, and seasonings.
14. The frozen food product as claimed in claim 13; wherein: the cavity region is conically-shaped and extends into the second food product portion such that the cavity region has a maximum depth, as measured along a central axis that extends vertically through frozen food product, while the frozen food product is disposed in a heat-receiving orientation, of at least 50% to a maximum of 100% of the height of the second food product portion, as measured along the central axis.
15. The frozen food product as claimed claim 12; wherein: the frozen noodle mass comprises noodles that are partially cooked and coated in oil prior to freezing; the noodles are selected from one of the following alternatives: Ramen noodles, egg noodles, rice noodles, buckwheat noodles, or udon noodles; and the oil for coating the partially cooked noodles is selected from one of the following alternatives: pork back fat, chicken oil, yuzu oil, flavoured oil, chili oil or fish oil.
16. (canceled)
17. The frozen food product as claimed in claim 15; wherein: the noodles have a predetermined cooking time; and the partial cooking of the noodles is such that the noodles are partially cooked, via boiling, for a minimum of ⅙.sup.th to a maximum of ⅕.sup.th of the predetermined cooling time.
18. A frozen food product, comprising: a first food product portion; a second food product portion; and a third food product portion; wherein: the first food product portion, the second food product portion and the third food product portion are cooperatively configured such that: the second food product portion is disposed intermediate the first food product portion and the third food product portion; and the first food product portion is a first portion of frozen soup broth; the second food product portion is a frozen noodle mass; and the third food product portion includes a second portion of frozen soup broth and a plurality of frozen food items at least partially embedded within the second portion of frozen soup broth.
19. The frozen food product as claimed in claim 18; wherein: frozen food product is frozen Ramen.
20. The frozen food product as claimed in claim 18; wherein: the frozen noodle mass comprises noodles having a predetermined cooking time that are partially cooked, via boiling, for a minimum of ⅙.sup.th of the predetermined cooking time to a maximum of ⅕.sup.th of the predetermined cooling time, the partially cooked noodles further comprising a coating of oil prior to freezing; the noodles are selected from one of the following alternatives: Ramen noodles, egg noodles, rice noodles, buckwheat noodles, or udon noodles; and the oil for coating the partially cooked noodles is selected from one of the following alternatives: pork back fat, chicken oil, yuzu oil, flavoured oil, chili oil or fish oil.
21. (canceled)
22. (canceled)
23. The frozen food product as claimed in claim 18; wherein: the third food product portion includes one or more individual food products selected from one or more of the following alternatives: meat, vegetable-based protein sources, vegetables, fungi, herbs, and seasonings.
24.-40. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of food product as disclosed in the present application, and in which:
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[0030] Similar reference numerals may have been used in different figures to denote similar components.
DESCRIPTION OF EXAMPLE EMBODIMENTS
[0031] With reference now to
[0032] In some embodiments, for example, while the food product 100 is disposed in the frozen state 200, the food product 100 is configured for reheating, via conduction, using any suitable cookware component on a conventional heat source, for example, a stove-top. However, it will be understood that any suitable heat source may be used for re-heating the product 100, via conduction, while the food product 100 is disposed in a suitable cookware component, such that the food product 100 transitions from the frozen state 200 to the re-heated state. In other embodiments, for example, while the food product 100 is disposed in the frozen state 200, the food product 100 is configured such that it is particularly suited for re-heating via radiation, for example, in a microwave oven, or other equivalent device.
[0033] In some embodiments, for example, the food product 100 is a soup product such that while the food product 100 is disposed in the frozen state 200, the food product 100 is a frozen soup product. In some embodiments, for example, the food product 100 is a Ramen product such that while the food product 100 is disposed in the frozen state 200, the food product 100 is a frozen Ramen product that may be stored within a freezer unit and re-heated at a later date.
[0034] With reference to the example embodiments illustrated in
[0035] As described above, in some embodiments, for example, the food product 100 is a frozen soup product. Therefore, in some embodiments, for example, the first food product portion 12 is frozen soup broth, while the second food product portion 14 includes a frozen noodle mass. In some embodiments, for example, the third food product portion 16 includes at least one or more frozen toppings or ingredients, wherein the frozen toppings or ingredients include one or more of the following alternatives: meat (for example beef, chicken, pork and seafood), vegetable-based protein sources (for example, tofu, Beyond Meat), vegetables, fungi, herbs, and seasonings. In instances where the food product 100 is frozen Ramen, the third food product portion includes at least one or more frozen ingredients that are commonly found as toppings or food product ingredients found within the Ramen. In some embodiments, for example, the third food product portion 16 is a frozen layer that includes one or more frozen ingredients 16(1) that are encased within frozen soup broth 16(2), as will be described in further detail below in connection with the example embodiment illustrated in
[0036] Referring in particular to the example embodiment illustrated in
[0037] While the food product 100 is disposed in the frozen state 200, the first food product portion 12, the second food product portion 14, and the third food product portion 16 are co-operatively configured such that the second food product portion 14 is disposed intermediate the first food product portion 12 and the third food product portion 16. Therefore, while the food product 100 is disposed in the frozen state 200, the first food product portion 12, the second food product portion 14, and the third food product portion 16 are frozen together as a unit. Accordingly, the first food product portion 12, the second food product portion 14 and the third food product portion 16 are each disposed in a frozen condition and disposed in a stacked configuration wherein the first food product portion 12, the second food product portion 14 and the third food product portion 16 are frozen together such that, while the food product 100 is disposed in the frozen state 200, the food product 100 is a solid, frozen unit such that there is an absence of movement between each of the first food product portion 12, the second food product portion 14 and the third food product portion 16, relative to one another. Therefore, it will be understood that while the food product 100 is disposed in the frozen state 200, the first food product portion 12, the second food product portion 14 and the third food product portion 16 are not intended to be easily separable from each other.
[0038] With reference, in particular, to
[0039] In example embodiments wherein the first food product portion 12 includes frozen soup broth, the second food product portion 14 includes a frozen noodle mass, and the third food product portion 16 includes at least one or more frozen food ingredients often found as toppings associated with Ramen soup, while the frozen food product 100 is disposed in the heat-receiving orientation 20 and is disposed within a cookware component that is in contact with a heat source, the first food product 12, i.e. the frozen soup broth, will be the first layer of the food product 100 that will absorb heat with effect that the first food product portion 12 will begin to melt, thaw and re-heat. As the first food product portion 12 begins to thaw and melt, heat will begin to be transferred to the second food product portion 14 with effect that the second food product portion 14 begins to thaw and re-heat. As the first food product portion 12 and the second food product portion 14 thaw, and re-heat, the structural integrity of the frozen second food product portion or layer 14 will be compromised and the second food product portion 14 will, eventually, collapse into and become submerged within the melted soup broth that once made up the first food product portion 12 of the frozen food product 100. When the second food product potion 14 is a frozen noodle mass, as in the case of frozen Ramen, as the noodles become submerged within the soup broth that is now disposed in a liquid state, the cooking process of the thawed noodle mass is allowed to complete such that the noodles become disposed in a fully-cooked state and ready for consumption within the re-heated soup broth. Similarly, with the melting and thawing of the first food product portion 12 and the second food product portion 14, heat is transferred to the third food product portion 16, which also undergoes a thawing and/or de-frosting process as the second food product portion 14 transitions to an unfrozen state and the third food product portion 16 contacts the first food product portion 12 that is now in the liquid state. With the collapsing of the second food product portion 14 into the melted first food product portion 12, the individual components or food ingredients that make-up the third food product portion 16, that were originally stacked upon and frozen to an upper surface of the second food product portion 14, will also eventually become disposed within the warming liquid that once made up the first food product portion 12 of the frozen food product 100. Once the first food product portion 12, the second food product portion 14, and the third food product portion 16 have thawed, with the second food product portion 14 and the third food product portion 16 immersed within the re-heated, liquid soup broth that once made up of the frozen first food product portion 12, continued heating of the first, second and third food product portions 12, 14, 16 completes the cooking process of the second food product portion 14 and the third food product portion 16 until the food product 100 is ready to be consumed by the user in a fully re-heated state.
[0040] With reference, again to
[0041] While the food product 100 is disposed in the frozen state 200, the first food product portion 12 and the second food product portion 14 are co-operatively configured such that the second food product portion 14 has a first surface 26 that is disposed in face-to-face stacking arrangement with the second surface 24 of the first food product portion 12, thereby defining a first food product portion and second food product portion interface 25. A second surface 28 of the second food product portion 14 is disposed opposite to the first surface 26 and serves as food portion-receiving surface that is configured for receiving the third food product portion 16. Accordingly, it will be understood that in example embodiments wherein the third food product portion 16 is comprised of a plurality of individual toppings or ingredients 16, the plurality of individual toppings are positioned on top of the second surface 28 of the second food product portion 14, thereby defining a second food product portion and third food product portion interface 27. Accordingly, in some embodiments, for example, it will be understood that the second food product portion and third food product portion interface 27 is not necessarily a continuous interface across the entire second surface 28 defined by the second food product portion 14.
[0042] In the subject example embodiment, the first food product portion 12 is frozen independently of the second food product portion 14 and the third food product portion 16 in a mold 60. In some embodiments, for example, the second food product portion 14 and the third food product portion 16 are frozen together at the same time, while disposed on top of the independently frozen first food product portion 12, in the same mold 60. Accordingly, in such example embodiments, the second food product portion 14 is frozen to the second side 24 of the first food product portion 12, thereby establishing the first food product portion and second food product portion interface 25, while the third food product portion 16 is frozen to the second surface 28 of the second food product portion 14, thereby establishing the second food product portion and third food product portion interface 27. In other embodiments, for example, the second food product portion 14 and the third food product portion 16 are each frozen independently of one another prior to the layered structure of the food product 100 being established. Accordingly, in some embodiments, the first food product portion and the second food product portion interface 25 is established prior to the second food product portion and third food product portion interface 27 being established in instances where the noodle mass is frozen to the second surface of the frozen soup broth, or first food product portion 12, prior to the toppings and other ingredients, i.e. the third food product portion 16, being frozen to the second surface 28 of the second food product portion 14.
[0043] With reference now to
[0044] In some embodiments, for example, the cavity region 30 is configured such that the second surface 28 of the second food product portion 14 includes an annular region 36 that is extends around the cavity region 30, extending from the outermost edge 38 of the cavity region 30 to the outer edge or outer perimeter 40 of the second food product portion 14. In some embodiments, for example, the cavity region 30 is configured such that the cavity region 30 occupies about 5% to about 25% of the surface area defined by the second surface 28 of the second food product portion 14 within the outer edge or outer perimeter 40 of the second food product portion 14. Accordingly, it will be understood that in some embodiments, the first food product portion 12 and the second food product portion 14 are each, generally cylindrical in shape, the second surface 28 of the second food product portion 14 being circular in shape with the cavity region 30 being defined within the second food product portion 14 such that the maximum diameter, D1, defined by the cavity region 30 is less than 50% of the maximum diameter, D2, defined by the second food product portion 14. In some embodiments, for example, the diameter D1 of the cavity region is about ¼ inches to about 1 ½ inches. In some embodiments, for example, the cavity region 30 is configured such that the cavity region 30 has a maximum depth, H1, of about ¼ inches to about ¾ inches of the total height, H2, of the second food product portion 14, as measured along the central axis 32 of the food product 100. In other embodiments, for example, the cavity region 30 extends through the second food product portion 14 such that the depth, H1, of the cavity region 30 is between about a minimum of 50% to a maximum of 100% of the total height, H2, of the second food product portion 14. Accordingly, in some embodiments, for example, the second food product portion 14 includes cavity region 30 such that the second food product portion 14 has a non-uniform thickness. Incorporating a cavity region 30 into the central area of the second food product portion 14 assists with the re-heating of the food product 100 from the frozen state 200 to the re-heated state since the overall thickness and density of the food product 100 is reduced within the central region of the food product 100. As the central area or central region of the food product 100 often takes the longest to re-heat, by reducing the overall thickness of the food product 100 within the central area helps to ensure a more even re-heating process so as to avoid having the portions of the food product 100 disposed at the edges of the food product 100 overcook while waiting for the central region of the food product 100 to thaw and re-heat.
[0045] In some embodiments, for example, the cavity region 30 is formed by hand as the noodles 15 that form the second food product portion 14 are disposed on the first food product portion 12. In some embodiments, for example, the cavity region 30 is formed using a male mold portion that is lowered on to the noodle mass that is disposed atop the frozen first food product portion 12 thereby creating the cavity region 30. In some embodiments, for example, the cavity region 30 is maintained prior to the freezing process due to the disposition of one or more toppings that form the third food product portion 16 within the cavity region 30. Once subjected to the freezing process the cavity region 30 is further solidified.
[0046] In example embodiments that include a cavity region 30, as shown for example in
[0047] As described above, when the food product 100 is ready for use, the food product 100 is disposed within any suitable cookware component, in the heat-receiving orientation 20, wherein the first surface 22 of the first food product portion 12 is disposed in contact with the base of cookware component (not shown). As heat is transferred through the cookware component, via conduction, the first food product portion 12 begins to thaw and re-heat. As the first food product portion 12 thaws and re-heats, heat is transferred to the second food product portion 14 with effect that the second food product portion 14 will eventually collapse into the thawed first food product portion 12 that has transitioned from the frozen state to a liquid state. The collapse of the second food product portion 14 into the thawed first food product portion 12 is also with effect that the third food product portion 16 will collapse into the thawed first food product portion 12. Once the second and third food product portions 14, 16 are disposed within the thawed first food product portion 12, continued re-heating of the product 100 completes the cooking and/or re-heating process of the second food product portion 14 and the third food product portion 16 such that the food product 100 is disposed in a fully, re-heated state wherein the food product 100 is suitable for consumption. Accordingly, a single cookware component is required for the re-heating process and the re-heating process is effectively a single-step process that requires heating the food product 100 on, for example, a medium heat setting until the second food product portion 14 and the third food product portion 16 are disposed within the thawed first food product portion 12 at which time the heat can be increased in order to bring the food product 100 to a boil or until the desired temperature and “doneness” for consumption of the food product is reached.
[0048] Referring now to the
[0049] In the subject example embodiment, while the food product 100 is disposed in the frozen state 200, the first food product portion 12, the second food product portion 14, and the third food product portion 16 are co-operatively configured such that the second food product portion 14 is disposed intermediate the first food product portion 12 and the third food product portion 16, with the food product 100 being disposed within the container such that the first food product portion 14 serves as the base of the food product 100. As in the previously described embodiment, in the subject example embodiment, the first food product portion 12, the second food product portion 14, and the third food product portion 16 are also frozen together as a unit. However, in the subject example embodiment, the frozen unit is disposed within a container 50 that is suitable for use in re-heating the food product 100 within a microwave oven.
[0050] As in the previously described embodiment, while the food product 100 is disposed in the frozen state 200, the first food product portion 12 and the second food product portion 14 are co-operatively configured such that the second food product portion 14 has a first surface 26 that is disposed in face-to-face stacking arrangement with the second surface 24 of the first food product portion 12, thereby defining a first food product portion and second food product portion interface 25. A second surface 28 of the second food product portion 14 is disposed opposite to the first surface 26 and serves as food portion-receiving surface that is configured for receiving the third food product portion 16.
[0051] In the subject example embodiment, the first food product portion 12 is frozen independently of the second food product portion 14 and the third food product portion 16. More specifically, in example embodiments wherein the food product 100 is a frozen soup product, such as frozen Ramen, the first food product portion 12 is soup broth that is disposed within the container base 50 and frozen, thereby establishing the first food product portion 12, the container base, thereby serving as a mold. Once the first food product portion 12 (i.e. the soup broth) is disposed in the frozen state, the second food product portion 14 is disposed on the second, food product-receiving surface 24 of the first food product portion 12 and frozen, thereby establishing the first food product portion and second food product portion interface 25. As in the previously described embodiment, in the subject example embodiment, the second food product portion 14 is a frozen noodle mass that is frozen to the top surface 24 of the frozen soup broth base.
[0052] In the subject example embodiment, the second food product portion 14 is configured such that the second food product portion 14 has a generally uniform or continuous thickness across the diameter of the second food product portion 14. Accordingly, unlike the previously described food product 100 that is particularly suited for re-heating, via conduction, in the subject example embodiment, the second food product portion 14 does not include a cavity region 30 disposed within the central area of the second food product portion 14.
[0053] With reference, in particular to
[0054] Once the one or more ingredients or toppings 16(1) and second portion of soup broth 16(2) and frozen together establishing the third food product portion 16, the third food product portion 16 is removed from its corresponding mold and is disposed on top of the second food product portion 14, within the container 50, thereby establishing the second food product portion and third food product portion interface 27.
[0055] Accordingly, in some embodiments, the second food product portion 14 is frozen to the second side 24 of the first food product portion 12 establishing the first food product portion and second food product portion interface 25 prior to the third food product portion 16 being frozen to the second surface 28 of the second food product portion 14 establishing the second food product portion and third food product portion interface 27. Specifically, in the example embodiment of
[0056] When the food product 100 according to the example embodiment of
[0057] While the above-described example embodiment has been described in connection with a food product 100 that is disposed within a container 50 and is particularly suited for re-heating via a microwave oven, it will be understood that the above-described embodiment, may also be prepared as a standalone food product 100 that does not include a separate container 50 for storing and re-heating the frozen food product 100. Therefore, in some embodiments, for example as shown in
[0058] Re-heating of the frozen food product 100 illustrated in
[0059] A method of making the food product 100 according to example embodiments of the present disclosure will be described in further detail below with reference, in particular to
[0060] As described above, in some embodiments, for example, the food product 100 is a frozen soup product such as frozen Ramen. In such example embodiments, the soup broth, which serves as the first food product portion 12, is prepared according to any suitable method known in the art. In some embodiments, for example, the first food product portion 12 is soup broth that includes tare. In some embodiments, for example, the soup broth and tare are boiled together with additional vegetables, which the vegetables are then removed from the soup and tare mixture, after partial cooking, for use as toppings or food item ingredients for the finished soup product. In some embodiments, the soup broth is made in a batch that includes 24 individual servings of soup. However, it will be understood that the batches of soup broth can be made to include more than 24 individual servings or less than 24 servings, depending on the required number of servings of individual soup that are required.
[0061] Once the soup broth is prepared and has been cooled to about room temperature, a serving of soup broth is disposed in a mold 60. The mold 60, together with the serving of soup broth, is disposed in a freezer for freezing of the soup broth such that the soup broth is disposed in a frozen state, thereby forming the first food product portion 12. In some embodiments, for example, the first food product portion 12, is frozen to a temperature of at least −20 degrees Celsius. In some embodiments, for example, the first food product portion 12 is frozen to a temperature of at least −40 degrees Celsius. In some embodiments, for example, the first food product portion 12 is frozen to a temperature no colder than −60 degrees Celsius.
[0062] In some embodiments, for example, the freezing of the first food product potion 12 is for a period of at least 8 hours.
[0063] Once the first food product potion 12 is disposed in the frozen state, the mold 60 is removed from the freezer in order to receive at least the second food product portion 14, before being returned to the freezer, as will be described in further detail below.
[0064] In order to form the second food product portion 14, which is comprised of a frozen noodle mass 15, the noodles are first disposed in boiling water and are boiled for only a portion of the total, predetermined cooking time for the particular type of noodle that is being prepared. In some embodiments, for example, the noodles are cooked for less than 50% of the total, predetermined cooking time for the particular noodle type. In some embodiments, for example, the noodles are cooked, between a minimum of greater than 1/7.sup.th of the total, predetermined cooking time for the particular noodle type to a maximum of no more than ½ of the total, predetermined cooking time for the particular noodle type. In some embodiments, for example, the noodles are cooked, between a minimum of at least ⅙.sup.th of the total, predetermined cooking time for the particular noodle type to a maximum of no greater than ⅕.sup.th of the total, predetermined cooking time for the particular noodle type.
[0065] Once the noodles have been partially cooked, via boiling, the noodles are removed from the boiling water and quenched in a cold water bath. In some embodiments, for example, the cold water bath is at a temperature between about a minimum of 6 degrees Celsius to a maximum of 15 degrees Celsius. In some embodiments, for example, the noodles are quenched in the cold water bath for a period of time such that the noodles achieve thermal equilibrium with the water bath. In some embodiments, for example, the noodles are quenched in the cold water bath for a period of at least 45 seconds to a maximum of 60 seconds. Quenching the partially cooked noodles within a cold water bath has been found to halt the cooking process to ensure that the noodles maintain a desired firmness for tolerating the freezing process, and to maintain the integrity of the noodles in the re-heated food product 100. Quenching the partially cooked noodles within a cold water bath has also been found to remove any excess flour that may have remained on the surface of the noodles. Excess flour is often found on the surface of raw, uncooked noodles as excess flour has been found to maintain the quality of the uncooked, raw noodles while they are being stored and/or transported. The excess flour on the surface of the noodles helps to keep the noodles from sticking together and also helps to keep the noodles dry. Removal of any excess flour from the outer surface of the noodles, prior to serving, is important as any excess flour remaining on the outer surface of the noodle may contribute to the noodles having a sandy or gritty texture, which is considered undesirable in a finished Ramen product.
[0066] Once the quenching process is complete, the noodles are removed from the cold water bath using a strainer (or any other suitable means) and are allowed to dry. The drying process is with effect that excess moisture is removed from the partially cooked noodles. In some embodiments, for example, excess water is removed from the partially cooked noodles using a food spinner wherein centrifugal forces separate excess water from the noodles, thereby drying the noodles. Once the noodles have been dried, for example, in a food spinner, the noodles are tossed with oil. In some embodiments, for example, the oil used is selected from one of the following alternatives: pork back fat, chicken oil, yuzu oil, flavoured oil, chili oil or fish oil. In some embodiments, for example, the noodles are tossed with the oil, via hand-mixing. In some embodiments, for example, the noodles are hand-mixed with oil using a generally circular, folding motion bringing noodles from the bottom of the strainer (or any other suitable container) towards the top of the noodle mass until the noodles gain an all-over shiny, oily appearance. In example embodiments wherein a solid fat is used as the oil product (e.g. pork back fat), the noodles are mixed with the solid fat (e.g. pork back fat) until there are no lumps or clumps of solid fat (e.g. pork back fat) remaining amongst the noodles and the noodles have an all-over glossy or shiny appearance.
[0067] Once the noodles have been uniformly coated in the oil, the noodles are divided into portions that correspond to the portion of soup broth that has been frozen as the first food product portion 12 within the mold 60. The mold 60 that contains the frozen first food product portion 12 is removed from the freezer and the corresponding serving of oil-coated, partially cooked noodles 15 are disposed on the second or food product-receiving surface 24 of the first food product portion 12, the oil-coated noodles thereby forming the second food product portion 14. Once the oil-coated, partially cooked noodles 15 are disposed on the food product-receiving surface 24 of the first food product portion 12, the noodles 15 are arranged on the first food product portion 12 such that the cavity region 30 is formed within the central area of the mass of oil-coated, partially cooked noodles 15. See for instance
[0068] In some embodiments, for example, once the second food product portion 14 is disposed on the first food product portion 12 and the cavity region 30 is arranged within the second food product potion 14, the third food product portion 16 is disposed on top of the second food product portion 14 within the mold 60 such that at least a portion of the third food product potion 16 is disposed within the cavity region 30. In example embodiments wherein the third food product portion 16 includes a plurality of individual ingredients or toppings, such as meat and vegetables, for example, the individual ingredients are at least partially cooked prior to being positioned on the second food product portion 14. When the third food product portion 16 includes meat, the meat is fully cooked to the required doneness, as is known in the art, prior to being positioned on top of the second food product portion 14. In the case of vegetables, the vegetables are partially cooked and quenched in a cold bath prior to being positioned on top of the second food product portion. In some embodiments, for example, the vegetables are cooked in boiling water, or via any suitable means, for about 3-15 seconds of the total, predetermined cooking time prior to quenching and positioning on the second food product portion 14. In some embodiments, for example, when the third food product portion 16 includes a plurality of individual ingredients or toppings, such as meat and vegetables, for example, the portion of the third food product portion 16 that is disposed within the cavity region 30 includes the at least the meat. See for instance
[0069] Once the second and third food product portions 14, 16 are disposed within the mold 60 in their layered relationship, the mold 60 is returned to the freezer with effect that the second food product portion 14 and the third food product portion 16 become disposed in the frozen state 200. In some embodiments, for example, the second food product portion 14 and the third food product portion 16 are frozen to a temperature of at least −20 degrees Celsius. In some embodiments, for example, the second food product portion 14 and the third food product portion 16 are frozen to a temperature of at least −40 degrees Celsius.
[0070] In some embodiments, for example, the second food product portion 14 and the third food product portion 16 are frozen to a temperature of at least −60 degrees Celsius. In some embodiments, for example, the freezing of the second and third food product portions 14, 16 is for a period of at least 8 hours.
[0071] Once the second food product portion 14 and the third food product portion 16 become disposed in the frozen state 200, the mold 60 is removed from the freezer and the first food product portion 12, the second food product portion 14 and the third food product portion 16 are removed from the mold 60 as a frozen unit, with effect that the frozen food product 100 is released from the mold 60. See for instance,
[0072] As described above, in some embodiments, for example, first food product portion 12, the second food product portion 14 and the third food product portion 16 are each frozen to a temperature of at least −60 degrees Celsius. In some embodiments, freezing of the soup broth, the noodles and the toppings to at least −60 degrees Celsius has been found to maintain the quality and freshness of the respective food product portions. More specifically, in the case of the soup broth 13, freezing the soup broth 13 to at least −60 degrees Celsius has been found to freeze the soup broth 13 quickly such that the cellular structure within the soup broth 13 is retained. In the case of the noodles 15, it has been found that freezing the noodles to a temperature of less than −20 degrees Celsius, such as at least −60 degrees Celsius, allows the noodles 15 to freeze quickly which prevents the partially cooked oil-coated noodles 15 from absorbing additional moisture, which can alter the overall texture of the noodles 15 upon re-heating. In particular, the absorption of additional liquid can cause the noodles 15 to stretch or have a softer, overcooked texture upon re-heating. In the case of the individual toppings, it has been found that freezing of the toppings to a temperature that is colder than −20 degrees Celsius, such as at least −60 degrees Celsius, maintains the quality of the individual toppings upon the re-heating of the product. In particular, in the case of meat toppings, the freezing process to a temperature that is colder than −20 degrees Celsius, such as at least −60 degrees Celsius, has been found to maintain the quality of meat as moisture is retained within the meat during the freezing process which results in meat that has a more enjoyable texture and that is not dried-out upon re-heating.
[0073] Referring now to
[0074] Once the first food product portion 12, the second food product portion 14 and the third food product portion 16 are frozen together and removed from the mold, the food product 100 is vacuum packaged. Once the food product 100 is sealed within the outer packaging, the food product 100 can be stored in a suitable freezer unit until the product 100 is ready to be enjoyed.
[0075] With regards to the example embodiment illustrated in
[0076] As shown in
[0077] In the subject example embodiment, once the oil-coated partially cooked noodles 15 are disposed on the food product-receiving surface 24 defined by the first food product portion 12, the container 50 is returned to the freezer where the oil-coated, partially-cooked noodles 15 are frozen to a temperature of less than −20 degrees Celsius, for example to a temperature of at least −60 degrees Celsius, for forming the second food product portion 14.
[0078] In the subject example embodiment, the third food product portion 16 is a frozen layer that includes one or more frozen ingredients 16(1) that are encased within a second portion of frozen soup broth 16(2). The third food product portion 16 is formed separately from the first food product portion 12 and the second food product portion 14 in a separate mold (not shown). Accordingly, the soup broth 16(2) and the plurality of individual food products 16(1) are frozen together in a separate mold such that the plurality of individual food products 16(1) become encased or embedded within frozen soup broth 16(2). The soup broth and the plurality of individual food products are frozen under the same conditions as described in connection with the previous embodiments, and is frozen to a temperature of less than −20 degrees Celsius, for example to a temperature of at least −60 degrees Celsius, thereby forming the third food product portion 16. In some embodiments, for example, the combined soup broth with the plurality of individual food products are frozen to a temperature of at least −60 degrees Celsius for at least a period of 8 hours. Once the frozen third food product portion 16 is formed, the third food product portion 16 is removed from the corresponding mold and is disposed on second, or food product-receiving surface 28 of the second food product portion 14 within the container 50, the food product 100 is vacuum packaged in an outer wrapping and labelled accordingly and stored in a freezer until the food product 100 is ready for use. Accordingly, it will be understood that, in some embodiments, the second food product 14 is frozen and formed separately to the third food product portion 16. With regard to the example embodiment illustrated in
[0079] While various example embodiments of frozen food products and the methods of manufacturing the same have been described, it will be understood that certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.