SYSTEM AND METHOD OF PREPARING FROZEN COCONUTS

Abstract

The present invention relates to a system and method for preparing frozen coconuts for reliably preserving coconut meat and coconut water inside its own coconut shells. The method comprises drying dehusked coconut, partially freezing the dried dehusked coconut in a chilling unit and freezing the partially frozen dried dehusked coconut in a freezing unit. In one embodiment of the invention, dried dehusked coconut are vacuum sealed and flash frozen to preserve nutrients in a flash freezing unit. The frozen coconuts are stored in frozen storage and have shelf life of over a year. The frozen coconuts, upon thawing, have fresh taste with coconut meat and intact coconut water inside a coconut shell.

Claims

1. A method for preparing frozen coconut containing frozen coconut meat and frozen coconut water, the method comprising: a. dehusking one or more coconuts to remove an outer green layer and at least a substantial majority portion of a fibrous husk thereof; b. drying the coconuts until each of the coconuts weighs 95% or less of its weight prior to drying; and c. freezing the coconuts in an environment at or below 0 degrees Celsius.

2. The method of claim 1, further including, prior to freezing the coconuts, chilling the coconuts to partially freeze the coconuts.

3. The method, as claimed in claim 1, wherein the drying takes place in an environment with humidity less than 40% and/or temperature above 25 degrees Celsius.

4. (canceled)

5. (canceled)

6. The method, as claimed in claim 1, wherein the chilling of the coconuts is done in an environment at 5 degrees Celsius until the core temperature of at least one coconut reaches a range between 0.1 degree Celsius to 3 degree Celsius.

7. The method, as claimed in claim 1, wherein the freezing of the coconuts is done with a shock freezing unit.

8. The method, as claimed in claim 7, wherein the shock freezing unit to freeze the coconuts includes an insulated tub filled with a cooling bath mixture having a temperature in a range between 72 degrees Celsius to 65 degrees Celsius.

9. The method, as claimed in claim 8, wherein the cooling bath mixture is alcohol based, and contains at least one of dry ice and liquid nitrogen.

10. The method as claimed in claim 7, wherein the shock freezing unit includes an air blast tunnel.

11. The method as claimed in claim 1, wherein the freezing of the coconuts is done with a slow freezing unit.

12. The method as claimed in claim 11, wherein the slow freezing unit is a standard freezer having an internal temperature of 25 degrees Celsius temperature, and the freezing is performed for at least 24 hours.

13. (canceled)

14. (canceled)

15. The method as claimed in claim 1, wherein the coconuts contain at least 1.5 layers of coconut meat.

16. (canceled)

17. The method of claim 1, wherein the freezing includes subjecting the coconuts to an environment at or below 18 degrees Celsius.

18. (canceled)

19. (canceled)

20. The method of claim 1, further including treating the coconuts in a solution to minimize oxidation of the coconuts.

21. A system for preparing frozen coconut containing frozen coconut meat and frozen coconut water inside from a dehusked coconut, the system comprising: a) a drying unit capable of removing at least 5% of the initial weight of the coconut to obtain at least one dried dehusked coconut; b) a freezer to freeze the dried dehusked coconut to a fully frozen coconut.

22. The system, as claimed in claim 21, further comprising a chilling unit to chill the dried coconut to at least partially freeze the coconut before placing the partially frozen coconut into the freezer.

23. The system, as claimed in claim 21, further comprising a vacuum sealing machine configured to seal the coconut in a bag prior to freezing the coconut.

24. The system, as claimed in claim 21, 22, or 23, further comprising a coconut holding tray for holding the coconut.

25. (canceled)

26. (canceled)

27. (canceled)

28. (canceled)

29. The system as claimed in claim 21, wherein the freezer is a shock freezing unit comprising an insulated tub filled with a cooling bath mixture having a temperature in a range between 72 degrees Celsius to 65 degrees Celsius.

30. (canceled)

31. (canceled)

32. (canceled)

33. A method for preparing frozen coconut containing frozen coconut meat and frozen coconut water inside according to the system of claim 21, the method comprising: a) dehusking of the outer green layer and the fibrous husk of a raw coconut leaving the dehusked coconut without any or with only a minimal amount of fibrous material surrounding it; b) weighing and placing at least one dehusked coconut in a drying unit to remove at least 5% of the initial weight of the coconut to obtain at least one dried dehusked coconut; c) moving at least one dried dehusked coconut into a freezing unit for completely freezing the dried dehusked coconut; and d) storing the frozen coconut shell in a temperature at or below 0 degrees Celsius.

34. The method of claim 33, further comprising: e) prior to moving the at least one dried dehusked coconut into the freezing unit, placing the at least one dried dehusked coconut into a chilling unit to partially freeze the dried dehusked coconut.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:

[0032] FIG. 1A illustrates a schematic representation of system for preparing frozen coconuts from raw coconuts, according to an embodiment of the present invention;

[0033] FIG. 1B illustrates a schematic representation of a raw coconut from getting harvested, stored and dehusked up to getting further dried into a drying unit, according to an embodiment of the present invention;

[0034] FIG. 2A illustrates a schematic representation of system for preparing frozen coconuts from dried dehusked coconuts sealed in vacuum seal bags before being frozen in shock freezing unit, according to an embodiment of the present invention;

[0035] FIG. 2B illustrates a schematic representation of system for preparing frozen coconuts from dried dehusked coconuts optionally sealed in vacuum seal bags in slow freezing unit, according to an embodiment of the present invention;

[0036] FIG. 3A illustrates a schematic representation of a coconut holding tray capable to hold partially frozen vacuum sealed or unpackaged coconuts to be completely frozen; according to an embodiment of the present invention;

[0037] FIG. 3B illustrates a schematic representation of a coconut holding tray capable to hold partially frozen coconuts without any packaging to be completely frozen; according to an embodiment of the present invention;

[0038] FIG. 3C illustrates a schematic representation of a coconut holding tray capable to hold partially frozen vacuum sealed coconuts in vacuum sealed bags to be completely frozen; according to an embodiment of the present invention;

[0039] FIG. 4 illustrates a schematic representation of the top view of a shock freezing unit comprising insulated tub, cooling bath mixture and coconut holding tray capable of containing partially frozen vacuum sealed coconuts and freezing the partially frozen vacuum sealed coconuts, according to an embodiment of the present invention;

[0040] FIG. 5 illustrates a schematic representation of side view of a shock freezing unit comprising insulated tub, cooling bath mixture and coconut holding tray containing partially frozen vacuum sealed coconuts for completely freezing the partially frozen vacuum sealed coconuts, according to an embodiment of the present invention;

[0041] FIG. 6A illustrates a schematic representation of a slow freezing unit which is a standard freezer comprising coconut holding tray containing partially frozen coconuts without any packaging for completely freezing the partially frozen coconut shell without any packaging, according to an embodiment of the present invention;

[0042] FIG. 6B illustrates a schematic representation of a slow freezing unit which is a standard freezer comprising coconut holding tray containing partially frozen vacuum sealed coconuts for completely freezing the partially frozen vacuum sealed coconuts, according to an embodiment of the present invention;

[0043] FIG. 7 depicts an exemplary flowchart illustrating a method of preparing frozen coconuts using shock freezing unit, according to an embodiment of the present invention;

[0044] FIG. 8 depicts an exemplary flowchart illustrating a method of preparing frozen coconuts using slow freezing unit, according to an embodiment of the present invention;

[0045] To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.

DETAILED DESCRIPTION

[0046] As used throughout this application, the word may is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words include, including, and includes mean including but not limited to.

[0047] The phrases at least one, one or more, and and/or are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A, B and C, at least one of A, B, or C, one or more of A, B, and C, one or more of A, B, or C and A, B, and/or C means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0048] The term a or an entity refers to one or more of that entity. As such, the terms a (or an), one or more and at least one can be used interchangeably herein. It is also to be noted that the terms comprising, including, and having can be used interchangeably.

[0049] The term automatic and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be material.

[0050] FIG. 1A illustrates a schematic representation of system for preparing frozen coconuts from raw coconuts up to getting frozen coconuts

[0051] The system comprises a sorting and dehusking unit whereby the harvested coconuts are being dehusked. The dehusked coconuts are formed by firstly sorting and resting the raw coconuts in green husk for two days so to allow a first reduction of pressure inside the coconut before dehusking the coconut. The dehusked coconut can optionally be polished using polishing machines. The dehusked and optionally polished coconuts are stored in a drying unit until the dehusked coconuts loose at least 5% of their weight. The dried coconuts are then optionally sealed in vacuum bags using a vacuum-sealing machine. Vacuum bags apply uniform pressure around the dried dehusked coconut. Alternatively the dried dehusked coconuts may be left unpackaged. The system further comprises a chilling room having 5 degree Celsius temperature for partially freezing the content of dried dehusked (and optionally vacuum sealed) coconuts and a freezing unit for completely freezing the partially frozen coconuts and forming frozen coconuts enclosing entire coconut water and coconut meat within itself. The system further comprises a freezing unit where the partially frozen (optionally vacuum sealed) coconuts are moved for completely freezing the partially frozen coconuts. The freezing unit either freezes the partially frozen coconut shell by a shock freezing method or by a slow freezing method, forming a frozen coconut enclosing entire coconut water and coconut meat within its own hard shell.

[0052] FIG. 1B illustrates a schematic representation of a raw coconut from getting harvested, stored and dehusked up to getting further dried into a drying unit, according to an embodiment of the present invention

[0053] In the system 100, the raw coconuts 102 after they are collected and picked up by farmers are taken to an inspection facility for different kinds of inspections. The raw coconut 102 is being inspected for any visible outside damage, weighed via scale to ensure it meets minimum weight requirement for purchase and so on. An applied water bucket test (to determine the maturity of the coconut) is also performed to guarantee that the raw coconut 102 contains exactly two layers of coconut meat inside its inner shell. The raw coconut 102 after passing all the quality inspections are stored in a room 104 having ambient temperature and away from direct sunlight for at least 2 days for reducing the inside pressure of the coconut before being dehusked.

[0054] The raw coconut 102 after getting dehusked completely by skilled hands wielding machetes turn in to a dehusked coconut 106. The outer green layer (exocarp) and the fibrous husk (mesocarp) of the raw coconut 102 are removed, leaving the shell of the dehusked coconut 106 without or minimal amount of the fibrous material that surrounds it. All the husk is removed optionally excluding a piece of protective cone shaped husk atop the coconut. The remaining husk covers two closed holes and the spore of the shell of the dehusked coconut 106, shielding the delicate opening on top.

[0055] The dehusked coconut 106 is then weighed and measured for height and circumference. The dehusked coconut 106 is then separated according to its size which can be small, medium or large. All this information gets updated in the inventory system and tagged accordingly on their mesh bag. The dehusked coconut 106 then waits for optional polishing.

[0056] The hair around the shell of the dehusked coconut 106 is optionally removed with a polishing machine such as but not limited to copper bristle polishing machine, similar to that of a shoe shiner. Holding the shell tightly, a worker slowly turns the shell underneath rotating bristles that gently remove the coir without bothering the cone, leaving a smooth shell surface. The shell of the dehusked coconut 106 after getting polished turns into a dehusked and polished coconut 108.

[0057] The dehusked and polished coconut 108 after being polished is then placed in a bucket or successive buckets containing one or several organic or non-organic solutions with anti-oxidation, anti-bug, anti-mold or anti-fungal properties including for example but not limited an ascorbic acid solution that prevents oxidation of the surface and top husk cone of the dehusked and polished coconut 108 shell. After a brief period of time, the dehusked coconut 106 is taken out of the one or several solutions and placed in their respected numbered mesh bags and left to dry for further processing.

[0058] The dehusked and polished coconut 108 (or simply the dehusked coconut 106) is moved into a drying unit such as a dry room 110 having humidity less than 40% and temperature above 25 degree Celsius until the dehusked and polished coconut 108 has lost more than 5% of its initial inside coconut water weight. A dried dehusked coconut shell 112 is obtained.

[0059] FIG. 2A illustrates a schematic representation of system for preparing frozen coconuts from dried dehusked coconuts sealed in vacuum seal bags before being frozen in shock freezing unit, according to an embodiment of the present invention;

[0060] The system 200 (a) comprises a vacuum sealing machine 202 for sealing the dried dehusked coconut 112 in vacuum bag 204 which applies uniform pressure around the dried dehusked coconut shell 112 preventing it from breaking during freezing; a chilling unit such as a chilling room 206 for partially freezing the content of the coconuts and getting partially frozen coconuts 208; and a freezing unit 212 for completely freezing the partially frozen coconuts and forming a completely frozen coconut 216 enclosing entire coconut water and coconut meat within itself.

[0061] A dried dehusked coconut 112 is sealed in vacuum bag using vacuum sealing machine 202. Any locally available vacuum sealing machine can be used for sealing coconut shells. The vacuum bags used for sealing dried dehusked coconut 112 are K-nylon bags having 100 micron thickness which make contact with the coconut shell and prevent any liquid leakage inside the bag by applying 360 degree even pressure around the coconut shell and prevent it from rupturing during freezing process. The vacuum bags also protect the coconut shell from rupturing upon thawing.

[0062] The vacuum sealed coconut shell bag 204 is moved to a chilling room 206 having 5 degree Celsius temperature to partially froze the content of coconut shell until core temperature of coconut shell reaches anywhere in between 0.1 degree Celsius to 3 degree Celsius. The chilling room helps reducing the inner pressure of the dried dehusked coconut 112 to the levels at which to the coconut may be further freezed without risk of coconut shell cracking during the freezing process.

[0063] The partially frozen vacuum sealed coconuts 208 are arranged on a coconut holding tray 302 (a) and moved to shock freezing unit 212. Referring to FIGS. 3A-3C, each individual container basket holding only one partially frozen vacuum sealed coconut 208. The coconut holding tray 302 (a) is immersed in shock freezing unit 212.

[0064] The shock freezing unit 212 as shown in FIGS. 4 and 5 comprises an insulated tub 402 for holding coconut holding tray 302 and cooling bath mixture 404 for completely freezing the coconut shell. The coconut holding tray 302 containing partially frozen vacuum sealed coconuts 208 is fully immersed in cooling bath mixture in temperature range 72 degree Celsius to 65 degree Celsius for 40-50 minutes depending on the batch size of coconuts. The cooling bath mixture is alcohol-based, and contains at least one of dry ice and liquid nitrogen, such as, but not limited to, mixtures of 99.9% ethanol and dry ice, or mixtures of methanol and liquid nitrogen.

[0065] The completely frozen coconut shells 216 are stored in frozen storage 218 at 18 degree Celsius. Alternatively, it could be stored at 25 degree Celsius, 6 degree Celsius, or at any temperature at or below 0 degree Celsius.

[0066] FIG. 2B illustrates a schematic representation of system for preparing frozen coconuts from dried dehusked coconuts optionally sealed in vacuum seal bags in slow freezing unit, according to an embodiment of the present invention;

[0067] In this system, the dried dehusked coconuts 112 are either vacuum sealed using vacuum sealing machine to form vacuum sealed coconuts 204 or used as dried dehusked coconuts without any packaging 112 for partially freezing the content and reducing the inner pressure of the dried dehusked coconuts 112. The vacuum sealed coconuts 204 and the completely dried dehusked coconuts 112 are moved to a chilling unit such as a chilling room 206 for forming partially frozen vacuum sealed coconuts 208 and partially frozen coconuts without any packaging 210 respectively. Referring to FIGS. 3B and 3C, the partially frozen coconuts without any packaging 210 and the partially frozen vacuum sealed coconuts 208 are arranged in a porous coconut holding tray 302 (b), 302 (c) respectively. The coconut holding tray 302 (b), 302 (c) are placed in slow freezing unit. The slow freezing unit 214, referring to FIGS. 6A and 6B, is a standard freezer having 25 degree Celsius temperature. The coconut are kept for at least 24 hours depending on the batch size of coconut shells. This freezing unit 214 is used for freezing both partially frozen vacuum sealed coconuts 208 and partially frozen coconuts without any packaging 210.

[0068] FIG. 3A illustrates a schematic representation of a coconut holding tray capable to hold partially frozen vacuum sealed or unpackaged coconuts to be completely frozen; according to an embodiment of the present invention;

[0069] A coconut holding tray 302 (a) comprising a top cover 304, a base 306, a plurality of side casings 314, 316, at least one partitioned compartment 308, 310, 312 comprising individual container basket 318 for holding one partially frozen vacuum sealed coconut shell bag 208. Each compartment 308, 310, 312 comprise at least one round shaped opening. The individual container basket 318 comprises partially frozen vacuum sealed coconut shell bag 208 (or an unpackaged coconut not shown in the figure). After loading the coconut holding tray 302 (a) with the partially frozen vacuum sealed coconut 208, the top cover 304 is closed. In this situation the at least one partially frozen vacuum sealed coconut 208 is accessible only through the at least one round shaped opening which is located on the top cover 304 of the coconut holding tray 302 (a) which allows free liquid flow across the compartments but prevents partially frozen vacuum sealed coconuts 208 to touch other each other to prevent them from sticking together or from potential cracking of the vacuum bags sealing the vacuum sealed coconuts.

[0070] FIGS. 3B and 3C illustrate a schematic representation of a coconut holding tray 302 capable of holding partially frozen vacuum sealed coconuts 208 or partially frozen coconut shell without any packaging 210 for producing completely frozen coconut shell 216, according to an embodiment of the present invention.

[0071] A coconut holding tray 302 (b), 302 (c) comprising porous air holes 320, peripheral side-walls 322, and space 324 for holding coconut shell. The porous air holes 320 in the coconut holding tray allows good air flow inside freezing unit.

[0072] FIGS. 4 and 5 illustrates a schematic representation of top and side view of shock freezing unit comprising insulated tub for holding coconut holding tray and cooling bath mixture for completely freezing the partially frozen vacuum sealed coconuts and producing frozen coconuts.

[0073] The shock freezing unit 212 (as shown in FIG. 2A) comprises an insulated tub 402 for holding coconut holding tray 302 and cooling bath mixture 404 for completely freezing the partially frozen vacuum sealed coconuts 208.

[0074] FIGS. 6A and 6B illustrates a schematic representation of a slow freezing unit 214 comprising coconut holding tray containing partially frozen coconuts and standard freezer for freezing the partially frozen vacuum sealed coconuts 208 or partially frozen unpackaged coconut 210 and producing frozen coconuts respectively

[0075] The slow freezing unit 214 is a standard freezer having 25 degree Celsius temperature for completely freezing the partially frozen coconut shell bag. This freezing unit 214 is used for freezing both partially frozen vacuum sealed coconut shell bag 208 and partially frozen coconut shell without any packaging 210.

[0076] FIG. 7 illustrates an exemplary flowchart 700 illustrating a method of preparing the frozen coconuts using shock freezing unit, according to an embodiment of the present invention;

[0077] Initially at step 702, the raw coconuts after having been harvested preferably in the afternoon and after 25 days so that they have preferably two layers of coconut meat, and after inspection, are stored for at least two days in a storage room having ambient temperature and away from direct sunlight for reducing the inner pressure of raw coconuts;

[0078] At step 704, the outer green layer and the fibrous husk of raw coconuts are dehusked leaving the coconut shells without any or minimal amount of fibrous material surrounding the coconut shells;

[0079] At step 706, the dehusked coconut shells are sorted according to their sizes, weight and thickness;

[0080] At step 708, the outer hairs of the dehusked coconut shells are optionally polished using a polishing machine such as copper bristle polishing machine;

[0081] At step 710, to prevent oxidation and contamination by mold or fungus of the dehusked and polished coconut shells surfaces and top husk cones, the coconut shells are optionally put into one or several organic or non-organic solutions such as an ascorbic acid solution, and then taken out of the solution to get dry;

[0082] At step 712, the dehusked (and optionally polished) coconut shells are weighed and moved into a dry room having humidity less than 40% and temperature more than 25 degree Celsius and kept there until the coconuts lose more than 5% of their initial weight prior to drying;

[0083] At step 714, the dried dehusked coconut shells can be optionally sealed in vacuum bags using vacuum sealing machine;

[0084] At step 716, the either vacuum sealed coconuts or unpackaged coconuts are moved into a cold storage unit such as a chilling room having 5 degree Celsius temperature for at least 2-3 days until the coconut water in the coconut shell becomes partially slushy and with a core temperature of 0.1 degree Celsius to 3 degree Celsius and inner pressure inside the partially frozen coconut has decreased;

[0085] At step 718, the partially frozen vacuum sealed or unpackaged coconuts are placed in individual container basket of coconut holding tray;

[0086] At step 720, the coconut holding tray containing partially frozen vacuum sealed or unpackaged coconuts proceeds to a shock freezing unit. The coconut holding tray can for example be immersed in insulated tub filled with cooling bath mixture for 40-50 minutes at 72 degree to 65 degree Celsius depending on the batch size of coconut shells or be processed through an air blast flash freezing tunnel; and

[0087] At step 722, after the shock freezing unit, the frozen coconuts are brought to frozen storage and stored at 18 degree Celsius. Alternatively, they could be stored at 25 degree Celsius, 6 degree Celsius, or at any temperature at or below 0 degree Celsius.

[0088] FIG. 8 depicts an exemplary flowchart illustrating a method of preparing frozen coconuts using slow freezing unit, according to an embodiment of the present invention;

[0089] Initially at step 702, the raw coconuts after having been harvested preferably in the afternoon and after 25 days so that they have preferably two layers of coconut meat, and after inspection, are stored for at least two days in a storage room having ambient temperature and away from direct sunlight for reducing the inner pressure of raw coconuts;

[0090] At step 804, the outer green layer and the fibrous husk of raw coconuts are dehusked using a sharp edged weapon leaving the coconut shells without any fibrous material surrounding it;

[0091] At step 806, the dehusked coconut shells are sorted according to their sizes, weight and thickness;

[0092] At step 808, the outer hairs of the dehusked coconut shells are optionally polished using a polishing machine such as copper bristle polishing machine;

[0093] At step 810, to prevent oxidation and contamination by mold or fungus of the dehusked (and optionally polished) coconut shells surfaces and top husk cones, the coconut shells are optionally put into one or several organic or non-organic solutions such as an ascorbic acid solution, and then taken out of the solution to get dry;

[0094] At step 812, the dehusked (and optionally polished) coconut shells are weighed and moved into a dry room having humidity less than 40% and temperature more than 25 degree Celsius and kept there until the coconuts lose more than 5% of their initial weight prior to drying;

[0095] At step 814, the dried dehusked coconuts without any packaging are moved into a cold storage having 5 degree Celsius temperature for at least 2-3 days until the coconut water in the coconut becomes partially slushy forming partially frozen coconut and with a core temperature of 0.1 degree Celsius to 3 degree Celsius and inner pressure inside the partially frozen coconut has decreased;

[0096] At step 816, the partially frozen coconut without any packaging are arranged in porous plastic coconut holding tray;

[0097] At step 818, the coconut holding tray containing partially frozen coconut without any packaging is kept in a freezer having 25 degree Celsius temperature for at least 24 hours depending on the batch size of coconuts;

[0098] At step 820, the dried dehusked coconut is sealed in vacuum bag using vacuum sealing machine. In this step, the vacuum sealed coconuts are moved to into a cold storage having 5 degree Celsius temperature for at least 2-3 days until the coconut water in the coconut shell becomes partially slushy forming partially frozen vacuum sealed coconuts with a core temperature of 0.1 degree Celsius to 3 degree Celsius and inner pressure inside the partially frozen coconut has decreased;

[0099] At step 822, the partially frozen vacuum sealed coconuts are arranged in porous plastic coconut holding tray;

[0100] At step 824, the coconut holding tray containing partially frozen vacuum sealed coconuts is kept in a freezer having 25 degree Celsius temperature for at least 24 hours depending on the batch size of coconuts;

[0101] At step 826, the frozen coconuts are brought to frozen storage and stored at 18 degree Celsius. Alternatively, they could be stored at 25 degree Celsius, 6 degree Celsius, or at any temperature at or below 0 degree Celsius.

EXAMPLES

[0102] The following example is illustrative of the present invention, however, it will be understood that the invention is not limited to the specific details set forth in the example:

Example 1 Frozen Coconut Shell Obtained by Using Shock Freezing Unit

[0103] One hundred forty four raw coconuts were harvested; quality-checked and was stored in a store room having ambient temperature and away from direct sunlight to reduce the inner pressure of the raw coconuts for 2 days. The raw coconuts were dehusked, sorted, polished to get dehusked and polished coconut shells. The dehusked and polished coconuts were weighed and stored in a dry room having humidity less than 40 percent and temperature above 25 degree Celsius until they lost more than 5% of their initial weight before drying. The dried dehusked and polished coconuts were sealed in 100 micron thick K Nylon vacuum bags using vacuum sealing machine to apply 360 pressure on the outer coconut shell. The vacuum sealed coconuts were moved to a chilling room having 5 degree Celsius temperature for 2-3 days until the core temperature of coconuts reaches in range 0.1 degree Celsius to 3 degree Celsius temperature. Now, a partially frozen vacuum sealed coconut was placed in an individual container basket of coconut holding tray and 36 such partially frozen vacuum sealed coconut shell bags were arranged in single coconut holding tray. Four such coconut holding trays were fully immersed at the same time in shock freezing unit comprising insulated tub filled with mixture of 99.9% pure ethanol and dry ice at the same time. The temperature of cooling bath was 72 degree Celsius to 65 degree Celsius. More dry ice was added to maintain temperature of the cooling bath. The coconut holding trays were left in insulated tub containing mixture of 99.9% pure ethanol and dry ice for 40-50 minutes and taken out at the same time. Frozen coconuts were further stored in the frozen storage and can be used for more than a year.

[0104] The foregoing discussion of the present invention has been presented for purposes of illustration and description. It is not intended to limit the present invention to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features of the present invention are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects may be combined in alternate embodiments, configurations, or aspects other than those discussed above. For example, many of the process steps disclosed herein are optional steps that may or may not improve the process or which may only be used in certain situations. By way of non-limiting example, the steps of sorting coconuts, storing coconuts in ambient conditions for some time period, preventing oxidation of the coconuts, vacuum sealing the coconuts in bags, polishing the coconuts, and partially freezing the coconuts prior to freezing are optional and may not be necessary. This method of disclosure is not to be interpreted as reflecting an intention that the present invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the present invention.

[0105] Moreover, though the description of the present invention has included description of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the present invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments, configurations, or aspects to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.