Process for the deep-freezing of a substantially fluid food preparation

Abstract

A frozen condiment selected from the group consisting of sauces, pastes, pts, creams and pizza toppings, having hygienic and organoleptic features comparable with those of a corresponding fresh condiment, which is in the form of granules having a porous surface, having an average weight of 6.0 g or less and essentially homogeneous in size having a diameter comprised between 1 mm and 20 mm, and apt to determine a rapid and uniform thawing of the deep-frozen condiment.

Claims

1. A deep-frozen condiment in the form of granules having a porous surface and having an average weight of 6.0 g or less, and essentially homogeneous in size having a diameter comprised between 1 mm and 20 mm, said granules being apt to determine a rapid and uniform thawing of said deep-frozen condiment, even in the absence of a prior defrosting, wherein said condiment is selected from the group consisting of sauces, pastes, pts, creams and pizza toppings, of the type suitable for use and consumption with rice, pasta, toasted bread, canaps, hot, after cooking, having hygienic and organoleptic features comparable to those of a corresponding fresh condiment prior to the deep freezing.

2. Condiment according to claim 1, consisting of tomato-based, white sauce based, fat-based, oil-based, cheese-based, mayonnaise-based, meat-based, fish-based, vegetable-based or mixed base sauces.

3. Condiment according to claim 1, wherein said condiment contains at least 3% lipids by weight as a percent of total weight.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 schematically shows a system for the deep-freezing of a substantially fluid condiment according to an embodiment of the present invention;

(2) FIG. 2 shows a detail of the system of FIG. 1, specifically a dosing device of said substantially fluid condiment according to an embodiment of the invention;

(3) FIG. 3 shows a detail of the dosing device of FIG. 2, specifically a plurality of perforated plates or grids according to alternative embodiments of the present invention;

(4) FIG. 4 shows a detail of the system of FIG. 1, specifically an end portion of a conveyor belt exiting a deep-freezing section, particularly a second deep-freezing section of said condiment, according to an embodiment of the present invention;

(5) FIG. 5 shows a detail of the system of FIG. 1, specifically a refining device of said deep-frozen condiment to obtain frozen granules of predetermined size and weight according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

(6) A process for the deep-freezing of a substantially fluid condiment A according to a preferred embodiment of the present invention is described with reference to FIGS. 1-5 showing a related implementation system, globally indicated with 1.

(7) The system 1 essentially comprises a dosing device or dosing feeder 2, a first deep-freezing section 3, a second deep-freezing section 4, a refining device 5, a packaging device 6, arranged in series with respect to each other, and conveyor means of the condiment globally indicated with M.

(8) The dosing feeder 2, wherein the substantially fluid condiment A is fed through a duct 7, preferably at a temperature comprised between 0 C. and 4 C., essentially comprises a plate 8 provided with a plurality of holes or passages 9 of a predetermined size, whereon a cylindrical body 10 abuts and is fixed, having open ends to substantially form a container having a perforated bottom.

(9) In the example of FIG. 2, according to a preferred embodiment, the dosing feeder 2 also comprises stirring-spreading means globally indicated with 11, comprising rotating blades, aiding and optimizing the distribution of the substantially fluid condiment A on the plate 8, and thus the passage of the condiment itself through holes 9 and, thus the dosing of the substantially fluid condiment in the first deep-freezing section 3, arranged below downstream of the dosing feeder 2.

(10) The first deep-freezing section 3 is a section with a particularly reduced temperature, of 150 C. or lower, and according to the example shown in FIG. 1 it essentially comprises a liquid nitrogen bath 12, particularly a tank 13 containing a liquid nitrogen head at a temperature of about 197 C.

(11) The substantially fluid condiment A is thus dosed in the first deep-freezing section 3 by means of the perforated plate 8, and particularly condiment drops indicated with B are caused to fall by gravity in the nitrogen bath 12, wherein they remain immersed for a predetermined time interval, preferably comprised between 15 and 30 seconds.

(12) Immersed in the liquid nitrogen head, the condiment drops B undergo, because of the very low temperature, a rapid deep-freezing process, and particularly the deep-freezing of the surface layer thus forming partially frozen granules of the condiment, indicated with C, having a hard and deep-frozen external surface and a soft not completely deep-frozen core.

(13) Afterwards, the partially deep-frozen granules C of condiment leave the first deep-freezing section 3 and they are fed into the second deep-freezing section 4.

(14) The partially deep-frozen granules C are transported from the first deep-freezing section 3 to the second deep-freezing section 4 by means of the above-mentioned conveyor means M which, in the embodiment shown in the examples of the figures, comprise a conveyor belt, this not excluding, however, the possibility of providing a system of conveyor belts arranged in series and/or in parallel with each other.

(15) For example, in the case of conveyor belts in series, a first conveyor belt can be contemplated in the first deep-freezing section and a second conveyor belt in the second deep-freezing section, arranged so that the condiment is moved from the first belt to the second conveyor belt in a point of the system comprised between the two deep-freezing sections. In this way it is possible to adjust at will the speed of each conveyor belt and thus the residence time of the condiment in the respective deep-freezing section, residence time which can be also determined, independently for the two deep-freezing sections even in case of a single conveyor belt, on the basis of the length of the first and second deep-freezing sections.

(16) Going back to the example of FIG. 1, a conveyor belt crossing the first and second deep-freezing sections is contemplated, and precisely a conveyor belt at least partially immersed in the liquid nitrogen bath 12 of the first deep-freezing section 3, whereon the condiment partially deep-frozen granules C are collected.

(17) In detail, again as shown in the example of FIG. 1, conveyor means M immerse in the liquid nitrogen bath 12, they cross at least a length of the nitrogen bath while being immersed in the liquid nitrogen head and in that length they collect the condiment partially deep-frozen granules C, meaning that the partially deep-frozen granules descending into the liquid nitrogen head deposit on the conveyor means which emerge from the nitrogen bath 12 at an end of the tank 13 transporting the condiment partially deep-frozen granules C out of the first deep-freezing section 3 to feed them into the second deep-freezing section 4.

(18) The second deep-freezing section 4 essentially comprises a tunnel provided with inlet and outlet openings, at a temperature comprised between about 30 C. and 90 C., preferably between 60 C. and 70 C., suitably of about 65 C., wherein the condiment and particularly the partially deep-frozen granules C, transported by the conveyor means M, complete the deep-freezing process.

(19) Condiment completely deep-frozen granules D are obtained at the output of the second deep-freezing section 4, as shown in particular in the example of FIG. 4.

(20) Still according to the examples of the figures, condiment granules D are subsequently fed into the refining device 5, wherein a respective refining step is performed, i.e. of size reduction of at least part of condiment granules D coming from the second deep-freezing section 4, wherefrom condiment granules of a predetermined size are obtained, indicated with E.

(21) The refining device 5, which is substantially a granulator, essentially comprises a tapered-section container or tank 16, at the bottom of which is placed a screw 17, preferably double-spiral, having a length extending beyond the tank 16, housed in a tube 18 abutting onto the tank 16, to substantially form an Archimedean screw, which optionally ends with a grid 19 according to the example of the figures.

(22) The grid 19, removably associated to the tube 18, can be chosen according to the predetermined and desired condiment granulometry, and it is preferably a grid having perpendicular mesh wires forming passages having a substantially square section of a width comprised between 5 mm and 15 mm.

(23) Condiment deep-frozen granules D fed into the tank 16 of the refining unit 5 are transported by the screw 17 towards the grid 19, and both in the path along the screw, and in the passage through the mesh wires of the grid 19 they are reduced in size, providing said granules E.

(24) In substance, the refining step is carried out because granules of a predetermined size are desired, and particularly homogeneous in size and of particularly reduced dimensions, lower than those of the granules at the output of the second deep-freezing section which are determined by the holes or passages of the dosing device plate or grid.

(25) Moreover, frozen granules at the end of the second deep-freezing step can optionally also take the form of agglomerates, which can be due for example to aggregation phenomena of the drops, of the partially deep-frozen granules or of the deep-frozen granules of condiment, or which can derive from condiment oversized drops due, for example, to an excessive fluidity of the condiment itself.

(26) Condiment frozen granules, exiting the refining device are then sent to the packaging device 6, of the known type, where they are prepared for storage at a temperature generally comprised between 20 C. and 25 C., in packages of the rigid type such as cartons and the like, or of the soft type such as for example bag-type packages, for example of plastic material.

(27) With respect to further details of the present invention, it must be added that according to a preferred embodiment, the nitrogen vapors released in the first deep-freezing section 3 from the liquid nitrogen bath 12 are used to cool the second deep-freezing section 4, where they are conveyed through a dedicated duct or system of ducts, suction fans, and directing or dispersion devices like blades, not shown in the examples of the figures.

(28) In this way nitrogen vapors coming from the first deep-freezing section are directed all around condiment granules within the second deep-freezing section where the deep-freezing process is completed.

(29) Advantageously, there is therefore an saving of energy in maintaining the second deep-freezing section at the desired temperature, which does not require additional energy for its cooling.

(30) Moreover, the refining and packaging of the condiment are performed at the temperature of the deep-frozen granules and, thus, these steps too do not require the use of energy to maintain the process temperature since it is exclusively given by the deep-frozen product itself.

Example

(31) A tomato sauce containing the below-indicated ingredients (% w/w) was prepared using traditional methods known in the field.

(32) Tomato pulp 61.47

(33) Semi-concentrated tomato 14.5

(34) Water 11.2

(35) Olive oil 9.2

(36) Salt 1.9

(37) Basil 1.2

(38) Dehydrated pre-fried onion 0.5

(39) Dehydrated garlic 0.03

(40) In particular, the tomato pulp and the semi-concentrated tomato were put in a mixer wherein water and oil were subsequently added in the above-indicated proportions. The remaining ingredients were then added and mixed, and the resulting mixture was cooked for about 15 minutes, obtaining a substantially fluid tomato sauce.

(41) The tomato sauce was cooled at 4 C. and then fed into a deep-freezing system of the above-described type.

(42) In particular, drops of tomato sauce having a diameter of about 10 mm were obtained through a perforated plate provided with round passages having a diameter of 8 mm, which were caused to fall by gravity in a first deep-freezing section and in particular in a liquid nitrogen bath (at the temperature of 197 C.).

(43) The tomato sauce drops in the liquid nitrogen bath underwent a rapid deep-freezing of the external surface with subsequent hardening thereof and formation of partially deep-frozen granules having a deep-frozen external crust and a not completely deep-frozen core.

(44) Then, the tomato sauce partially deep-frozen granules were collected on a conveyor belt partially immersed in the nitrogen head.

(45) Then, after a residence of about 20 seconds in the liquid nitrogen bath, by means of the conveyor belt, the tomato sauce partially deep-frozen granules were caused to emerge from the liquid nitrogen bath and they were fed into a second deep-freezing section at 65 C. wherein, in about 100 seconds, the deep-freezing was completed, thus obtaining tomato sauce completely deep-frozen granules. Then, the tomato sauce deep-frozen granules were fed into a refining device of the granulator type.

(46) In the granulator the tomato sauce deep-frozen granules were transported through an Archimedean screw and pushed towards a grid having 10 mm-wide square-shaped passages, thus obtaining at the output of the granulator tomato sauce deep-frozen granules essentially homogeneous in size, having a diameter of about 10 mm and a weight of about 2.5 g. The density of the granules was of about 1.0 g/cm.sup.3.

(47) Tomato sauce deep-frozen granules essentially homogeneous in size were then packaged and stored according to known procedures at a temperature of 25 C.

(48) The condiment in granules of the present invention has the advantage that it is easily dosed, and the user is not constrained, when using it, by the size of large blocks (in comparison with the portion size) as in the prior art.

(49) In other words, the user can use the exact quantity of condiment, required by the specific case, by drawing it from the package in a simple and fast way, and put the unused part back into the freezer.

(50) Moreover, thanks to the granular shape and particularly to the reduced size of the granules, the thawing of the condiment according to the invention is rapid and homogeneous, independently of the need to heat or not the condiment.

(51) In case of heating, in fact, this is homogeneous and rapid, and the organoleptic features of the product being heated and served are thus similarly homogeneous.

(52) Without heating, for example also in cases in which it is not even recommended, the thawing time of the present condiment at room temperature is in any case short by virtue of the granule size and, therefore, the user rapidly has at their disposal a condiment, in this case cold, with optimal organoleptic properties.

(53) Advantageously, the thawing time of the condiment according to the invention is comprised between 60 and 180 seconds, preferably between 60 and 120 seconds.

(54) Advantageously the condiment according to the invention can optionally be heated or cooked in a microwave oven, pan, wok, vapor oven, bain-marie, without suffering from the drawbacks due to a temperature uneveness.

(55) Moreover, the small granule size and their consequent short thawing time minimize any problems caused by phase separation of the condiment upon thawing, due to the presence of lipids in the composition of the condiment.

(56) Moreover, the condiment according to the present invention, thanks to the portioning versatility, allows a reduction of wastes, since it is possible to use only and exactly the required quantity.

(57) Thanks to the above-described features, the condiment according to the present invention lends itself to being used in various combinations and associations, allowing recipes to be considerably varied and personalized. This advantage is even more appreciated when it is considered that the pre-emptive defrosting of the product is not required, by virtue of the reduced size of the granules, and that granules can be directly drawn from the freezer in the desired quantities without creating waste.

(58) The above-mentioned advantages are considerable both at the domestic level and at the catering level.

(59) Moreover, the weight being equal and with respect to known condiments, the condiments according to the present invention has the advantage of lower overall bulkiness, due to the shape and size of the granules, with consequent lower transport and storage costs.

(60) Moreover, concerning the deep-freezing system according to the invention, it must be added that advantageously there is no need for pauses for the cleaning and sterilization of the surfaces, which are required neither during the deep-freezing of a given condiment, nor when passing from one recipe to another.

(61) The above is made possible by the nitrogen bath which has the advantageous effect of deep-freezing the external layer of the condiment drops before they can stick to any surface of the deep-freezing sections, for example to the conveyor means, and therefore undesirable phenomena such as the formation of patinas, fouling and the like do not occur, since there is no contact with the condiment in its liquid state.

(62) Moreover, given the very low temperatures, the conditions within the system are virtually aseptic.

(63) Finally the above-mentioned advantages in terms of energy saving must be considered, which are made possible by the use of liquid nitrogen vapors released in the first deep-freezing section to cool the second deep-freezing section.

(64) In order to meet specific and contingent requirements, a person skilled in the art can bring several modifications to the deep-freezing system and method in the embodiments shown and described, all nevertheless falling within the scope of protection of the invention as defined by the following claims.