METHOD AND SYSTEM FOR COOKING AND SEARING A FOOD PRODUCT IN A SHORT DURATION

Abstract

A system and process for cooking a consumable food product for an accelerated time period is described. The a system and process for cooking a food product comprising selectively heating primarily the interior of a food product, and searing the exterior of the food product using a radiative oven, wherein the radiative oven operates at greater than 900 Fahrenheit and reaches the operating temperature from an ambient temperature in a duration that is less than 30 seconds. A vending machine including the system and process of cooking is also described.

Claims

1-21. (canceled)

22. A method of cooking a food product comprising: providing a radiative oven comprising a heating element comprising a wire mesh element operating at greater than 800 Fahrenheit; heating primarily an interior of a food product; searing an exterior of the food product using the radiative oven in less than 120 seconds; and varying a time and temperature of the heating and the searing by a food type, wherein the heating element is positioned to heat the food product.

23. The method of claim 22, wherein the heating element operates at greater than 800 Fahrenheit and reaches an operating temperature from an ambient temperature in a duration that is less than 30 seconds.

24. The method of claim 22, further comprising: providing a vending machine including the radiative oven; dispensing the food product into the radiative oven; and dispensing to the consumer.

25. The method of claim 25, wherein the vending machine further comprises a microwave oven for the heating of the interior of the food product.

26. The method of claim 25, further comprising packaging the food product in a plastic pouch prior to cooking.

27. The method of claim 25, wherein the dispensing of the food product into the radiative oven is by a user.

28. The method of claim 25, wherein the dispensing of the food product into the radiative oven is by an automated dispenser.

29. The method of claim 25, further comprising removing the food product from a pouch prior to dispensing the food product into the radiative oven.

30. The method of claim 25, further comprising dispensing bread in the radiative oven along with the food product.

31. The method of claim 22, wherein the searing comprises heating an exterior of the food product to char an exterior surface of the food product.

32. The method of claim 22, wherein the heating partially cooks the food product.

33. The method of claim 22, further comprising breading the food product after the heating of the food product.

34. The method of claim 22, wherein the heating of the food product is done at a food preparation center and the searing is done at a location remote to the food preparation center.

35. The method of claim 22, wherein the food product is a ground hamburger patty, a salmon filet, a chicken filet, a French fry, or a vegetable.

36. The method of claim 22, wherein the searing produces visible sear marks.

37. The method of claim 22, wherein the searing produces visible sear marks without direct contact of the heating element with the food product.

38. A method of cooking a food product comprising: heating primarily an interior of a food product with a microwave oven; and exposing an exterior of the food product to a radiative oven comprising a wire mesh element operating at greater than 800 F. and positioned to heat the food product for a time sufficient to produce a seared food product, wherein the time sufficient to produce the seared food product is less than 120 seconds.

39. The method of claim 38, wherein the food product burns when the exposing of the food product to the operating radiative oven is for a duration greater than the time sufficient to produce a seared food product.

40. The method of claim 38, wherein the exposing comprises multiple exposures of the food product to the radiative oven.

41. The method of claim 38, wherein the exterior of the food comprises two opposing surfaces, the wire mesh element comprises a first and second wire mesh element, and the exposing comprises searing the two opposing surfaces of the food product with the first and second wire mesh elements.

42. The method of claim 38, wherein the exposing produces visible sear marks.

43. The method of claim 38, wherein the exposing produces visible sear marks without direct contact of the wire mesh element with the food product.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The same reference number represents the same element on all drawings. It should be noted that the drawings are not necessarily to scale. The foregoing and other objects, aspects, and advantages are better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which:

[0022] FIG. 1 illustrates a high speed radiative oven used in combination with a microwave oven according to one embodiment;

[0023] FIG. 2 shows the combined ovens of FIG. 1 in conjunction with a vending system;

[0024] FIG. 3 is a photograph of a hamburger cooked with the system and process according to one embodiment;

[0025] FIG. 4 is a photograph of asparagus cooked with the system and process according to one embodiment;

[0026] FIG. 5 is a photograph of a chicken breast cooked with the system and process according to one embodiment; and

[0027] FIG. 6 is photograph of a salmon filet cooked with the system and process according to one embodiment.

[0028] FIG. 7 is a photograph of a hamburger cooked using a radiative oven only.

[0029] FIG. 8 is a photograph of a hamburger cooked using a microwave oven only.

[0030] FIG. 9 is a photograph of a hamburger cooked with the system and process according to one embodiment.

DETAILED DESCRIPTION

[0031] FIGS. 1-6 and the following descriptions depict specific embodiments to teach those skilled in the art how to make and use the best mode of the teachings. For the purpose of teaching these principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these embodiments that fall within the scope of the teachings. Those skilled in the art will also appreciate that the features described below can be combined in various ways to form multiple variations. As a result, the teachings are not limited to the specific embodiments described below, but only by the claims and their equivalents.

[0032] In some embodiments, a system and process for cooking a food product comprising selectively heating primarily the interior of a food product, and searing the exterior of the food product using a radiative oven, wherein the radiative oven operates at greater than 1100 Fahrenheit and reaches the operating temperature from an ambient temperature in a duration that is less than 5 seconds is described.

[0033] As shown in FIG. 1, a food product 110 is heated according to the system and method 100 described herein. Specifically, an interior portion of food product 120 is heated to heat primarily (or selectively) an interior portion of food product 110. The time and temperature that the interior portion of food product 120 is heated will vary depending upon the type of food product 110 and the heat source. Non-limiting examples of heat sources to heat the interior portion of food product 120 include microwave ovens, steam baths, or other sources of conduction. In some examples, the heat source requires direct contact with food product 110. In some examples, the heat source requires indirect contact with food product 110. In one example, food product 110 is placed within a microwave oven and heated via microwaves.

[0034] Once the interior portion of food product 120 is sufficiently heated, the partially heated food product 120 is transferred to a second heat source where the exterior portion of food product 120 is seared 130. The time and temperature that the exterior portion of food product 120 is seared will vary depending upon the type of food product 110 and the heat source. Non-limiting examples of sources to sear the exterior portion of food product 120 include radiation ovens, grills, broilers, etc. In some examples, the searing heat source requires direct contact with food product 120.In some examples, the searing heat source requires indirect contact with food product 120. In one example, food product 120 is placed within a 10 kW (or more) radiative oven and heated via radiation.

[0035] Importantly, the ability to sear the exterior portion of food product 120 must occur quickly. Thus, a source of heat to sear or char food product 120 must be able to reach charring temperature from ambient temperature in short duration. In some embodiments, the source of heat can reach about 900 F., about 1000 F., about 1100 or about 1200 F. in less than about 30 seconds. In some embodiments the source of heat can reach about 900 F., about 1000 F., 1100 or about 1200 F. in less than about 20 seconds. In some embodiments, the source of heat can reach about 900 F., about 1000 F., 1100 or about 1200 F. in less than about 10 seconds from ambient temperature. In some embodiments, the source of heat can reach about 900 F., about 1000 F., 1100 or about 1200 F. in less than about 5 seconds from ambient temperature.

[0036] The exterior portion of food product 120 must occur quickly, or in short duration without burning food product 120, and allowing the interior portion of food product 120 to finish cooking. In some embodiments, the charring of exterior portion of food product 120 must occur in less than 120 seconds. In some embodiments, the charring of the exterior portion of food product 120 must occur in less than about 110, about 100, about 90, about 80, about 70, about 60, about 50, about 40, about 30, about 20, about 10 or about 5 seconds, or any interval therebetween.

[0037] In some embodiments, the charring of the exterior portion of food product 120 can occur from a single exposure to a searing heat source. In some embodiments, the charring of the exterior portion of food product 120 can occur from multiple exposures to a searing heat source. For example, food product 120 that has already had an interior portion partially heated can be exposed to a searing heat source for 20 seconds, when the searing heat source sears both a top portion and a bottom portion of food product 120 concurrently. In another example, food product 120 that has already had an interior portion partially heated can be exposed to a searing heat source for a total of 30 seconds, with a first exposure of 15 seconds to a top portion of food product 120, and a second exposure of 15 seconds to a bottom portion of food product 120. Of course, other protocols for exposing food product 120 that has already had an interior portion partially heated are contemplated.

[0038] In a preferred embodiment, food product 110 is heated using a microwave oven until the interior portion of food product 120 is sufficiently heated. Food product 120 is then transferred to a 13-14 kW (or more) radiative oven capable of reaching about 1100 F. in less than 5 seconds from an ambient temperature. The external portion of food product 120 is then exposed to radiant heat from the 13-14 kW (or more) radiative oven for a time sufficient to sear the external portion of food product 120.

[0039] The process of heating primarily an interior portion of food product 120 and searing an exterior portion of food product 130 advantageously not only cooks and sears food very quickly, but produces a fully cooked seared food product 140 with superior taste, consistency and mouth feel when compared to traditional cooking processes which take much longer to produce. In part, such results are due to considerations such as molecular make-up, thickness, and solidity of the food product.

[0040] FIG. 2 illustrates one example of the process described herein when incorporated into a vending machine 200. In one example, a user selects food product 240 from a menu or display. A first food product 240 is then transferred to a heat source (e.g., a microwave 210) which selectively partially cooks an interior portion of first food product 240 for a predetermined time (step 210). Once the predetermined time has elapsed, first food product 240 is transferred to a second heat source (e.g., a 10 kW (or more) radiative oven), where the exterior portion of food product 240 is seared as the interior portion of food product continues to finish cooking (step 220). Once seared, food product is dispensed to a user 248. In some embodiments, a second food product 250, such as a bun for a burger or hotdog, can also be heated along with first food product 240. In this instance, second food product 250 can be exposed to a radiative oven 220 briefly to warm and toast the food product 250. In such instances, second food product 250 can be dispensed with first food product 240 to a user at step 248. In some instances, second food product 250 can be dispensed before first food product 240 is dispensed to a user at step 248. In some instances, second food product 250 can be dispensed after first food product 240 is dispensed to a user at step 248.

[0041] In some embodiments of vending machine 200, both a microwave and a radiative oven can be housed in the same machine. In some embodiments, vending machine 200 may only house a radiative oven, and the heat source which heats primarily the interior portion of food product 240 is located nearby. For example, the vending machine may house the radiative oven, but the microwave may be across a room, or located in another room in a commercial setting. In an example where vending machine 200 houses both a microwave oven and a 10 kW, 11 kW, 12, kW, 13 kW or 14 kW oven, these heat sources may share a single power source such as energy from a standard 110 V wall outlet. In some embodiments where vending machine 200 houses both a microwave oven and a 10 kW, 11 kW, 12, kW, 13 kW or 14 kW radiative oven, these heat sources may have different power sources. For example, the microwave oven may include a standard plug for a 110 Volt outlet, and the microwave oven may be powered by a stored energy device.

[0042] In some embodiments, a food product can be distributed as a fully cooked, but refrigerated or frozen product that required heating. Such packaging would allow the food product to have an adequate shelf life to not degrade or spoil until ready to be consumed. In some embodiments, the food product can be distributed as wholly uncooked products, and will be fully cooked by exposure to the first and second heat sources.

[0043] Food product may contain a single food product, or may contain several distinct portions. For example, the food product may be a single chicken breast. In another example, the food product may be a hamburger patty, French fries and hamburger bun. In some examples, the food product is purchased by the end user separately for use of the cooking system. In some embodiments, the food product is purchased with use of the cooking system at the time of cooking.

[0044] In embodiments wherein the food product is purchased at the time the system is used to cook the food product, the packaging may individually package each food item. In other embodiments, a food product made of multiple components may be packaged together.

[0045] As discussed above, the present process optimizes the heating of the food product based on the intrinsic molecular make-up of the foods cooked by the system. Foods have different heat permeability characteristics depending upon type, density, size, and weight. For example, a 111 beef steak has a lower heat permeability than a 111 cubed potato, which has a lower heat permeability to 111 hamburger patty of ground beef. A skilled artisan would readily understand how to adjust the cooking parameters in order to cook partially the interior portion of the food product only enough to allow the exterior portion to be seared sufficiently while allowing the interior portion to finish cooking. Thus, a skilled artisan would be able to adjust the cooking parameter to sear a 1 thick beef steak to a rare, medium rare, medium or well interior temperature.

[0046] For example, a skilled artisan would know how to adjust cooking beef or lamb to the following internal temperatures shown in Table 1:

TABLE-US-00001 Rare 120 to 125 center is bright red, pinkish toward the degrees F. exterior portion Medium Rare 130 to 135 center is very pink, slightly brown degrees F. toward the exterior portion Medium 140 to 145 center is light pink, outer portion is degrees F. brown Medium Well 150 to 155 not pink degrees F. Well Done 160 degrees F. meat is uniformly brown throughout and above

EXAMPLE 1

[0047] A study of the heating and absorption characteristics of water and various lipids was performed using a microwave oven or a 14-15 kW radiative oven was performed. In a first study, the time for 50 grams (g) of water or 100% olive oil to reach 200 degrees was measured. In a second study, the time for 75 grams of water or 100% olive oil to reach 300 degrees was measured. A Panasonic brand microwave model SD997 operating at 1250 W was used in the microwave portion of the study. A radiative oven operating at about 14-15K watts, similar to those described in U.S. Application Publications Nos. 2010/0166397 Al and 2010/0169196 A1 was used in the radiative portion of the study. The results of the study are presented in Table 2:

TABLE-US-00002 TABLE 2 Food/ Time for 50 g of food Time for 75 g of food Heat Source product to reach 200 F. product to reach 300 F. Water/ 25 seconds Not feasible (max temp Microwave reached: 212 F.) Water/ 50 seconds Not feasible (max temp 15 kW Oven reached: 212 F.) 100% Olive Oil/ 45 seconds 110 seconds Microwave 100% Olive Oil/ 8 seconds 25 seconds 15 kW Oven

[0048] As seen from the table, the microwave is able to raise the temperature of the water, but is not as effective with respect to raising the temperature of the olive oil. In fact, the maximum temperature of the water reached was 212 F. degrees. Searing of food occurs at 300 F. As such, a microwave oven cannot easily produce charred food. In contrast, the high radiation oven is able to raise the temperature of the fat and water, but is not able to do so as effectively for the water as a microwave.

EXAMPLE 2

[0049] The optimized accelerated cooking protocols of various food products were performed using a microwave oven and a 14-15 kW radiative oven. Specifically, asparagus, french fries (raw and frozen), chicken breast, salmon filets or hamburger patties were cooked using microwaves and a radiative oven. A Panasonic brand microwave model SD997 operating at 1250 W was used in the microwave portion of the study. A radiative oven operating at 14-15 kW watts, similar to those described in U.S. Application Publications Nos. 2010/0166397 A1 and 2010/0169196 A1 was used. The specific cooking times and protocols are presented in Table 3:

TABLE-US-00003 TABLE 2 FOOD MICROWAVE TIME OVEN TIME Asparagus 40 seconds (wrapped 12 seconds (6 pieces-avg. diameter = in a damp paper (top and bottom) 0.39 inch) towel) French fries-raw 50 seconds 20 seconds (6 pieces-avg. thickness = (top and bottom) 0.33 inch) French fries-frozen 60 seconds 15 seconds (6 pieces-avg. thickness = (top and bottom) 0.38 inch) 7 oz. Chicken Breast 70 seconds 50 seconds (max. thickness range: Flip chicken breast (top and bottom) 1.2-1.7 inches) 70 seconds (inside 20 seconds microwave safe bowl (bottom only) and covered in plastic 10 seconds wrap) (top and bottom) 7 oz. Salmon Filet 40 seconds (inside 35 seconds (1.25 inch thick) microwave safe bowl (top and bottom) and covered in plastic 10 seconds wrap) (bottom only) 6 oz hamburger patty 60 seconds 60 seconds (top and bottom)

[0050] As seen from the table and FIGS. 3-6, exposure of the food product to microwaves and then to radiative heat is able to cook thoroughly the various foods while producing an adequate seared crust. FIG. 3 illustrates a 6 oz. ground beef hamburger patty 300 that has had an interior portion partially cooked using a microwave oven at high power for 60 seconds. The hamburger patty 300 was then transferred to a 14 kW high-speed radiative oven and exposed to radiative heat for 60 seconds, using top and bottom radiative wire mesh burners concurrently. As a result, sear marks 302 can be viewed on a significant portion of the exterior portion of the hamburger patty 300.

[0051] FIG. 4 illustrates 6 asparagus spears 400 that have had an interior portion partially cooked using a microwave oven at high power for 40 seconds wrapped in a wet paper towel. The asparagus spears 400 was then transferred to a 14 kW oven and exposed to radiative heat for 12 seconds, using top and bottom radiative wire mesh burners concurrently. As a result, sear marks 402 can be viewed on a significant portion of the exterior portion of the asparagus spears 400.

[0052] FIG. 5 illustrates chicken breast 500 that has had an interior portion partially cooked using a microwave oven at high power for 70 seconds, then the chicken breast was flipped, and microwaved again for 70 seconds. The chicken was cooked inside a microwave safe bowl and covered in plastic wrap. The chicken breast 500 was then transferred to a 14 kW oven and exposed to radiative heat for 50 seconds using top and bottom wire mesh burners concurrently. The chicken breast was then exposed to radiative heat for an additional 20 seconds using bottom wire mesh burners only. Finally, the chicken breast was exposed to radiative heat for 10 seconds using both top and bottom wire mesh burners concurrently. As a result, sear marks 502 can be viewed on a significant portion of the exterior portion of the chicken breast 500.

[0053] FIG. 6 illustrates salmon filet 600 that has had an interior portion partially cooked using a microwave oven at high power for 40 seconds inside a microwave safe bowl and covered in plastic wrap. The salmon filet 600 was then transferred to a 14-15 kW oven and exposed to radiative heat for 35 seconds using top and bottom wire mesh burners concurrently. The salmon filet 600 was then exposed to radiative heat for an additional 10 seconds using a bottom wire mesh burners only. As a result, sear marks 602 can be viewed on a significant portion of the exterior portion of the chicken breast 600.

EXAMPLE 3

[0054] FIG. 7 illustrates a 6 oz. that has had an exterior seared using a 14-15 kW radiative oven for 30 seconds. The hamburger patty 700 comprised about 93% lean ground beef, about 7% beef fat in a hamburger patty 700 of about 0.5 inches in thickness, and a diameter of about 4.75 inches. Hamburger patty 700 showed distinctive sear marks 702 on the exterior portion of the patty. However, an interior portion of the patty 704 reveal uncooked raw beef Thus, cooking a hamburger patty for short durations with a high power radiative oven is insufficient to cook both in interior portion and a seared exterior portion of a hamburger patty 700.

EXAMPLE 4

[0055] FIG. 8 illustrates a 6 oz. that has had an interior potion cooked using a 1.3 kW microwave oven for 90 seconds. The hamburger patty 800 comprised about 93% lean ground beef, about 7% beef fat in a patty of about 0.5 inches in thickness, and a diameter of about 4.75 inches. Hamburger patty 800 had a final internal temperature of about 195 F. (relating to well done beef) and showed no external sear marks on patty 800. Thus, cooking a hamburger patty for short durations with a microwave oven is insufficient to cook both in interior portion and a seared exterior portion of a hamburger patty 800.

EXAMPLE 5

[0056] FIG. 9 illustrates a 6 oz. that has had an interior potion cooked using a 1.3 kW microwave oven for 45 seconds, and the hamburger patty was immediately transferred to a 14-15 kW radiative oven and cooked for an additional 20 seconds. The hamburger patty 900 comprised about 93% lean ground beef, about 7% beef fat in a patty about 0.5 inches in thickness, and a diameter of about 4.75 inches. Hamburger patty 900 had a final internal temperature of 165 F. after microwaving (relating to well done beef) but showed no external sear marks on patty 900. After transfer to the 14-15 kW radiative oven and cooked for 20 seconds, hamburger patty 900 had an internal temperature of 160 F., external sear marks 902, and was thoroughly cooked. Thus, cooking a hamburger patty for short durations with a microwave oven and a high powered radiative oven is sufficient to cook both in interior portion and a seared exterior portion of a hamburger patty 900.

[0057] These examples demonstrate the versatility of the system described herein, cooking fresh and frozen food products, as well as both ground beef patties and solid animal protein food products such as chicken breasts and salmon filets. The process can be implemented according to any of the embodiments in order to obtain several advantages, if desired. An effective and fast process of searing a food product with superior taste, texture and mouth feel can be provided. Advantageously, the food product is produced faster and with higher quality than with any process currently available.

[0058] The various embodiments described above are provided by way of illustration only and should not be construed to limit the invention. Those skilled in the art will readily recognize the various modifications and changes which may be made to the present invention without strictly following the exemplary embodiments illustrated and described herein, and without departing from the true spirit and scope of the present invention, which are set forth in the following claims.