High pressure pasteurization of Curry (liquid seasoning) to achieve shelf-life of 100 days and more in the cooler (39-41 F)

Abstract

The present invention is a method for pasteurization of Curry, a sauce or simmer sauce made with onion, tomato and plethora of spices, mostly used in Indian or other Asian cuisines. CAPS uses 5 things to achieve such long shelf-life2-step unique cooking process, ingredients mainly spices, HPP (high pressure pasteurization), PET containers and refrigeration. We are not using HPP here for a 2.5-5 log cycle reduction in microorganisms as done by all products now as our cooking process itself brings microbes level to <10. However as evident from the lab reports, HPP does play a role in extending the shelf-life as we compared both pre-HPP and post-HPP samples. Our choice of PET containers (recycle code 1) has a role too on account of its 50 times less OTR than the microwavable PP containers (recycle code 5) used mostly for the restaurant take-outs.

Claims

1. CAPS is the first such method of pasteurization which extends the shelf-life of a low acid food item to 500 days in refrigeration maintaining the original taste and flavor as it does not use any preservatives.

2. Ours is the first HPPed food products with the shelf-life of 150 days and more in refrigeration as our cooking process eliminates spores and spores forming bacteria. HPP alone does not kill the spores and spores forming bacteria.

3. Ours is the first packaged Indian or Asian food in refrigeration or in the Fresh section at the US grocery stores without any preservatives with the shelf-life of 100 days and more.

4. The food products or items mentioned in claims 1, 2, 3 are Mother's Curry (onion based) and Tikka Masala Curry (tomato based). There curries are used to make entrees at an Indian restaurant. So if you order Chicken Tikka Masala or Tofu Tikka Masala at Nirmal caf in Ypsilanti, Mich., our chefs would pour Tikka Masala curry into a pan, mix grilled chicken or fried tofu into the sauce and boil it for 5-10 minutes max to get your entrees ready.

5. Both food items mentioned in claim 4 are low acid with pH>4.7 as per stipulation of FDA below though it is meant for shelf-stable food items at ambient temperatures. A low-acid canned food (LACF) is any food (other than alcoholic beverages) with a finished equilibrium pH greater than 4.6 and a water activity greater than 0.85, excluding tomatoes and tomato products having a finished equilibrium pH less than 4.7. An acidified food (AF) is a low-acid food to which acid(s) or acid food(s) are added and which has a finished equilibrium pH of 4.6 or below and a water activity (aw) greater than 0.85.

6. The pH of pre-HPP Mother's curry and pre-HPP Tikka Masala curry varies from 4.9 to 5.2. Post-HPP pH of our products vanes from 4.5 to 5.5 over 500 days testing as per our lab reports.

7. The method of making Mother's Curry and Tikka Masala Curry as mentioned in claim 4 is an unique 2-step process (appendix 1). The spices such as Turmeric, Cumin, Coriander, Ginger, Garlic, Clove do play a great role in killing of spores and spores forming bacteria as mentioned in claim 2.

8. HPP used in CAPS uses the cold water (40-50 F) at high pressure of around 85000 psi for 3 minutes to kill bacteria and other microorganisms.

9. As claimed in claim 2, our lab reports (appendix 2) show that CAPS does kill spores and spores producing bacteria. Please see attached Eureka write-up by me and an article Response of Spores to High Pressure Processing by the researchers from University of Delaware and others. We did have testing of our products at ambient temperature for 30 days and we found it satisfactory. It opens huge possibility of our HPPed products being the first such products shelf-stable at ambient temperature. As of now HPPed products are shelf-stable in the refrigeration. More lab test results are awaited.

10. As claimed in claim 3, HPP does solve the taste distortion problem of packaged Indian food now in grocery stores either shelf-stable with preservatives at ambient temperatures or in the frozen section. The spices don't gel well with preservatives or are not designed to tolerate sub-zero temperature for long.

11. Curry is the heart or soul of Indian cuisine. It is liquid or semi-liquid depending on the composition. It is used to make an entree. Let me explain. If you come to our Nirmal cafe and order say Tofu Tikka Masala or Chicken Tikka Masala, both entrees. Our chef would pour Tikka Masala curry into a pan, mix tofu or grilled chicken into it and boil it for 5 minutes. Your entree is ready. Please see attached our menu at Nirmal caf. Other Indian restaurants do it differently. We Indians eat entrees with the rice or breads. The entrees in Indian cuisine are always served hot (say 160-200 F) for the real flavor of spices. Though Curry at cold temperature (say 50-100 F) could be used as pasta sauce, barbeque sauce or dressing, dip or spread.

12. As mentioned in the abstract, PET containers have good impact strength (needed for HPP), 50 times less OTR (Oxygen transmission rate), important for extended shelf-life and very low MVTR (Moisture vapor transmission rate), important for Curry with almost 99% moisture content. See attached for link print-out-http://www.alphaplastic.com/bottle-basics/plastics-comparison-chart.php for the comparison chart of various plastics. PET containers beat all types in our requirements. Only drawback of PET containers is its being not Microwavable.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0044] The present invention generally relates to the use of disruptive technology (high pressure pasteurization) to bring the restaurant quality Indian food to the nearby grocers or to your doorstep (via Amazon.com, we are already approved to sell at their platform and online ordering at www.CurryFresh.net), Indian food being the key to our mission of fighting the obesity and overweight prevalence here as explained at www.DisruptiveEating.com, see attached print-outs of our website. The present shelf-life of 500 days for HPPed Curry has huge potential to reduce the global food waste and change the food industry in general.

[0045] 1. The food products or items mentioned in claims 1, 2, 3 are Mother's Curry (onion based) and Tikka Masala Curry (tomato based). There curries are used to make entrees at an Indian restaurant. So if you order Chicken Tikka Masala or Tofu Tikka Masala at Nirmal caf in Ypsilanti, Mich., our chefs would pour Tikka Masala curry into a pan, mix grilled chicken or fried tofu into the sauce and boil it for 5-10 minutes max to get your entrees ready.

[0046] 2. Both food items mentioned in claim 4 are low acid with pH>4.7 as per stipulation of FDA below though it is meant for shelf-stable food items at ambient temperatures.

[0047] A low-acid canned food (LACF) is any food (other than alcoholic beverages) with a finished equilibrium pH greater than 4.6 and a water activity greater than 0.85, excluding tomatoes and tomato products having a finished equilibrium pH less than 4.7.

[0048] An acidified food (AF) is a low-acid food to which acid(s) or acid food(s) are added and which has a finished equilibrium pH of 4.6 or below and a water activity (aw) greater than 0.85.

[0049] The pH of pre-HPP Mother's curry and pre-HPP Tikka Masala curry varies from 4.9 to 5.2. Post-HPP pH of our products varies from 4.5 to 5.5 over 500 days testing as per our lab reports.

[0050] 3. The method of making Mother's Curry and Tikka Masala Curry is an unique 2-step process (appendix 1). The spices such as Turmeric, Cumin, Coriander, Ginger, Garlic, Clove do play a great role in killing of spores and spores forming bacteria as mentioned in claim 2.

[0051] HPP used in CAPS uses the cold water (40-50 F) at high pressure of around 85000 psi for 3 minutes to kill bacteria and other microorganisms.

[0052] 4. As claimed in claim 2, our lab reports (appendix 2) show that CAPS does kill spores and spores producing bacteria. Please see attached Eureka write-up by me and an article Response of Spores to High Pressure Processing by the researchers from University of Delaware and others.

[0053] 5. We did have testing of our products at ambient temperature for 30 days and we found it satisfactory. It opens huge possibility of our HPPed products being the first such products shelf-stable at ambient temperature. As of now HPPed products are shelf-stable in the refrigeration. More lab test results are awaited.

[0054] 6. As claimed in claim 3, HPP does solve the taste distortion problem of packaged Indian food now in grocery stores either shelf-stable with preservatives at ambient temperatures or in the frozen section. The spices don't gel well with preservatives or are not designed to tolerate sub-zero temperature for long.

[0055] 7. Curry is the heart or soul of Indian cuisine. It is liquid or semi-liquid depending on the composition. It is used to make an entree. Let me explain. If you come to our Curry Fresh cafe and order say Tofu Tikka Masala or Chicken Tikka Masala, both entrees. Our chef would pour Tikka Masala' curry into a pan, mix tofu or grilled chicken into it and boil it for 5 minutes. Your entree is ready. Please see attached our menu at Nirmal caf. Other Indian restaurants do it differently. We Indians eat entrees with the rice or breads. The entrees in Indian cuisine are always served hot (say 160-200 F) for the real flavor of spices. Though Curry at cold temperature (say 50-100 F) could be used as pasta sauce, barbeque sauce or dressing, dip or spread.

[0056] 8. As mentioned in the abstract, PET containers have good impact strength (needed for HPP), 50 times less OTR (Oxygen transmission rate), important for extended shelf-life and very low MVTR (Moisture vapor transmission rate), important for Curry with almost 99% moisture content. See attached for link print-out-http://www.alphaplastic.com/bottle-basics/plastics-comparison-chart.php for the comparison chart of various plastics. PET containers beat all types in our requirements. Only drawback of PET containers is its being not Microwavable.