METHOD OF FLAVOR PROTECTION IN HERBS AND SPICES AND PRODUCTS THEREOF

Abstract

A method for preparing microbial contamination free spices and food products is provided. The invention relates to method for preparing cryogenic grinded and cold pasteurized (gamma irradiated) spices and spice related products which retains essential oils, aroma taste and color of the products and is free of any microbial contamination. The invention also relates to such microbial contamination free food products and spices thereof.

Claims

1. A method for preparing microbial contamination free spice powder which retains aroma, essential oils, taste, color, chemical compounds, and antioxidant properties, the method comprising: a. filling one or more dried raw spice into a feeding hopper; b. grinding the one or more dried raw spice under cryogenic conditions; c. packaging the powder obtained in step (b) first into primary packaging and then into secondary packaging; d. subjecting the packed spice powder to gamma irradiation; and e. obtaining microbial contamination free packed spice powder.

2. The method as claimed in claim 1, wherein combination of cryogenic grinding and gamma irradiation is used to produce the microbial contamination free spice powder.

3. The method as claimed in the claim 1, wherein the one or more dried raw spice is selected from turmeric, pepper, chilli, coriander, rasam powder, garam masala, clove, cinnamon, cumin, and cardamom.

4. The method as claimed in claim 1, wherein the step (b) of grinding under cryogenic conditions involves the following: a. mixing raw material with liquid nitrogen at a temperature of 20 to 22° C.; b. passing the mixture through a hammer mill to obtain a coarse powder; c. grinding the obtained coarse powder at a universal mill under liquid nitrogen and at a temperature of 5 to 7° C.; d. grinding the powder obtained in step c) at cryogenic mixer at a temperature of −5 to 2° C. to obtain a fine powder; and e. sieving the fine powder through a rotary sifter.

5. The method as claimed in claim 1, wherein the primary packaging is done in pouches with nitrogen purging and secondary packaging is done aseptically in cartons.

6. The method as claimed in claim 1, wherein the material for primary packaging is selected from polyethylene terephthalate, metalized polyethylene terephthalate, polyethylene, polynatural, or biodegradable plastic or food grade plastic.

7. The method as claimed in claim 1, wherein the secondary packaging is carried in 5 ply carton box.

8. The method as claimed in claim 1, wherein the packaging of the ground powder is carried with nitrogen gas.

9. The method as claimed in claim 1, wherein the microbial contamination free packed spice powder obtained is prevented from oxidation and rancidity.

10. The method as claimed in claim 1, wherein the microbial contamination free packed spice powder obtained has extended shelf life due to prevention of oxidation process of volatile oils and chemical compounds and due to microbial elimination.

11. The method as claimed in claim 1, wherein the packed spice powder is subjected to gamma irradiation of 240 kCi strength for 30-60 minutes.

12. The method as claimed in claim 11, wherein Cobalt 60 is used as a source for gamma irradiation.

13. A method for preparing microbial contamination free spice powder which retains aroma, essential oils, taste, color, chemical compounds and antioxidant properties, the method comprising: f. filling one or more dried raw spice into a feeding hopper; g. grinding the one or more dried raw spice under cryogenic conditions; h. packaging the ground powder obtained in step (b) first into primary packaging and then into secondary packaging; i. subjecting the packed spice powder to gamma irradiation; j. subjecting packed rice, nutria bar, and/or instant mixes to gamma irradiation; and k. obtaining microbial contamination free packed spice powder and packed rice, nutria bar, and/or instant mixes.

Description

BRIEF DESCRIPTION

[0041] Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:

[0042] FIG. 1a, shows a layout design according to embodiments of the invention;

[0043] FIG. 1b shows a layout design according to embodiments of the invention;

[0044] FIG. 1c shows a layout design according to embodiments of the invention;

[0045] FIG. 2 shows a procedure for preparation according to embodiments of the invention including testing for microbial growth;

[0046] FIG. 3 shows a procedure for testing commercial samples for microbial growth according to embodiments of the invention;

[0047] FIG. 4a shows test results for microbial contamination of the marketed spices and the spices prepared according to embodiments of the invention;

[0048] FIG. 4b shows test results for microbial contamination of the marketed spices and the spices prepared according to embodiments of the invention;

[0049] FIG. 5a shows test results for microbial load in the spice product prepared according to embodiments of the invention after gamma irradiation treatment;

[0050] FIG. 5b shows test results for microbial load in the commercial spice product after gamma irradiation treatment according to embodiments of the invention; and

[0051] FIG. 5c shows test results for microbial load in the commercial spice product after gamma irradiation treatment according to embodiments of the invention.

DETAILED DESCRIPTION

[0052] Embodiments of the present invention are directed to providing cryogenically ground spices and cold pasteurized food products wherein aroma, flavor, essential oils, chemical compounds, taste of the spice has been maintained and the product is free of any microbial contamination.

[0053] In some embodiments, there is provided a hygienic food product including spice, rice, nutritional bar or instant mix to the consumer. In some embodiments, there is provided a method to irradiate the food product including spice, rice, nutritional bar, soup powders or instant mix to kill the microorganisms like coliforms, bacteria, fungi, yeast & molds, and larvae in the manufactured products. In some embodiments, there is provided a cryogenically ground spice which have been irradiated to prevent any further oxidation.

[0054] In one aspect of embodiments of the invention there is provided a method for preparing a microbe free spice powder which retains the aroma, essential oils, taste, color, chemical compounds and antioxidant properties of the spice, the method comprising the steps of: [0055] a. Filling one or more dried raw spice into a feeding hopper, [0056] b. Grinding the raw spice(s) under cryogenic conditions, [0057] c. Packaging the ground powder obtained in step (b) first into primary packaging and then into secondary packaging, [0058] d. Subjecting the packed spice powder to gamma irradiation, and [0059] e. Obtaining microbial free packed spice powder.

[0060] In some embodiments, the combination of cryogenic grinding and gamma irradiation are used to produce microbial free spice powder. The cryogenic conditions during the grinding of the spices when combined with the gamma irradiation has provided significant reduction in microbial contamination.

[0061] In embodiments, the method improves the aroma/flavor retention of cryogenically ground spices. The claimed method retains the essential oils of the spices and increase the palatability of cryogenically grinded spices.

[0062] In some embodiments, the method is applicable for obtaining spice powder selected from turmeric, pepper, chilli, coriander, rasam powder, garam masala, clove, cinnamon, cumin, cardamom or the like.

[0063] In some embodiments, the method is also applicable to rice (black, red, unpolished and other varieties of rice), nutria bar, nutritional upma and other food products.

[0064] In some embodiments, the gamma irradiation method is used for reducing the microbial contamination. In some embodiments, the product categories which are subjected to gamma irradiation include herbs & spices, trail mix nuts, rice (red, black, unpolished rice) and nutritional bars.

[0065] In some embodiments, the grinding under cryogenic conditions involves the following steps: [0066] a. mixing the raw material with liquid nitrogen at temperature of 20 to 22° C., [0067] b. passing the mixture through hammer mill to obtain a coarse powder, [0068] c. grinding the obtained coarse powder at universal mill under liquid nitrogen and at temperature of 5 to 7° C., [0069] d. grinding the powder obtained in step c) at cryogenic mixer at temperature of −5 to 2° C. to obtain a fine powder, and [0070] e. sieving the fine powder through rotary sifter.

[0071] In some embodiments, in the above described method the primary packaging is done in pouches with nitrogen purging and secondary packaging is done aseptically in cartons. In some embodiments, the material for primary packaging is selected from polyethylene terephthalate, metalized polyethylene terephthalate, polyethylene, polynatural, or biodegradable plastic or food grade plastic. In some embodiments, the secondary packaging is carried in 5 ply carton box.

[0072] In some embodiments, there is provided a process of nitrogen packaging of cryogenically ground spices and condiments. Nitrogen reduces the oxygen content within food packaging and hence prevents the product from deterioration. Thus, packaging with nitrogen gas is efficient, cost-effective way to displace oxygen and moisture. In some embodiments, the irradiation process and packaging of cryogenically ground spices/condiments are useful in retention of their sensory properties.

[0073] In some embodiments, microbial free sterile spice powder packed in fully sterile pouch retains volatile oil content and antioxidant properties. In some embodiments, the spice powder obtained according to the method has 20-30% additional recovery of volatile oils.

[0074] In some embodiments, the method for preparing the spice powder provides the spice powder which is prevented from oxidation and rancidity. In some embodiments, the method for preparing the spice powder provides the spice powder which has extended shelf life due to prevention of oxidation process of volatile oils and chemical compounds and due to microbial elimination.

[0075] In other embodiment, Gamma Irradiation at 6 to 14 kGy of Cryogenic ground powders retains 99% of the phenolic compounds and volatile oil of a Spice powder with full sterilization. Other sterilization techniques like fumigation or steam are heat based which reduces volatile oils and other chemical components and results in oxidation of spice powders. Prevention of oxidation in ground spice powders by using Gamma irradiation at 6-14 kGy post cryogenic grinding prevents microbial oxidation of essential oils and other chemical components.

[0076] In some embodiments, the method employs subjecting the packed spice powder to gamma irradiation of 240 kCi strength for 30-60 minutes. In some embodiment, the source used for gamma irradiation is Cobalt 60.

[0077] In embodiments, the method reduces the power consumption and specific energy compared to the ambient temperature grinding. Usually spices are contaminated with the microbial load and cryogenic spices having higher level of volatile oils, oleoresins and chemical compounds which is prone to spoil by microbes in the spices and oxidize the product. The gamma irradiation (cold pasteurization) reduces/kills the microbes which are present in spices and other food products.

[0078] In some embodiments, higher level of volatile oils oleoresins and chemical compounds recovery and protection of the same by 2nd stage Cryogenic grinding & Gamma irradiation respectively. Process improvement in extension of shelf life in spice powders, by prevention of oxidation process by microbial elimination using Gamma irradiation.

[0079] Embodiments of the invention also relate to cryogenic grinding and irradiation processing and packaging of food products including spices, rice, nutritional bar or instant mix food for retention of quality with easy serve in a hygienic wholesome way.

[0080] In an embodiment, the method is particularly advantageous in providing efficient size reduction, improved product flow, better retention of natural flavoring principles, free of microbial contamination and has large potential for commercial exploitation when compared to the conventional heat based methods.

EXAMPLES

Example 1: Procedure for Producing Cryogenic Grinding and Gamma Treated Spices

[0081] a. Cryogenic grinding: Raw material (RM) were dumped into the feed hopper/dump booth cleaning of RM in cyclone separator and graded in the grader. The RM was mixed with liquid nitrogen and was taken to the cryogenic mixture 1 and temperature maintained at 20 to 22° C. Air Coolers and Moisture separators ensure no heat and moisture add into the system aiding the prevention of any oxygen. Then the mixture was taken to the hammer mill and made into coarse powder. The coarse mixture was further taken to the cryogenic mixture and temperature maintained −5 to 2° C. Then the product was grounded as fine powder at universal mill and further passed through with rotary sifter for sieving and was stored in the batch hopper 1. Air Purging ensures no particles strand for any scope of oxidation. Then the product was mixed at vertical mixer and goes to batch hopper 2 and passed through the metal detector for metal particles and removed and discharged through internal bulk containers (IBC) or bulk bagging.

[0082] b. Packaging: The product from IBC was taken in to packing machine for the retail pouches (100 g, 200 g). The primary packing material was composed of 12 micron PET, 12 micron metalized PET and 90 micron poly natural and secondary packaging material was 5 ply carton box. Bulk bagging (1 to 25 kg) material was composed of Kraft paper 80GSM outer layer and inner layer composed of HDPE fabric mesh 10×10, HDPE Denier 860 and LDPE lamination 118G.

[0083] c. Gamma Irradiation: Packed finished cryogenic spice products and rice nutritional bar, instant mix etc., was taken for the gamma irradiation and the product was inspected at gamma center as packaging condition and batch/lot number. The product was labeled with Radura label and loaded in to the tote box and exposed for gamma irradiation.

[0084] Cobalt 60 was the source for gamma irradiation. Based on the source strength set the cycle time in the PLC for 6-14 kGy dose. Reference dosimeters were placed along with the product to know the absorbed dose. After completion of treatment dosimeters were evaluated.

[0085] Gamma Irradiation Source: Cobalt 60

[0086] Strength: 240 kCi

[0087] Time: 30 min

[0088] The Table 1 shows the comparison of physical parameters after traditional grinding and cryogenic grinding.

TABLE-US-00001 TABLE 1 Physical Parameters S. Ambient Cryogenic No Parameter grinding grinding 1 Energy consumption High Low 2 Throughput Low High 3 Mill clogging Frequent No clogging 4 Volatile losses Higher Minimum 5 Grinding of soft material Not possible Possible 6 Control on particle size No control Effective 7 Fire risk High No risk 8 Microbial load Possible Does not exist 9 Colour of ground powder Not original Original 10 Prevention of oxidation Low High and rancidity 11 Power saving low High

[0089] Table 2 shows the volatile oil content and Table 3 shows oleoresin after ambient grinding and after cryogenic grinding of various spices.

TABLE-US-00002 TABLE 2 Volatile oil Content Volatile Oil S. Name of Raw Ambient Cryogenic % of No. the spice Material Grinding Grinding Recovery 1 Turmeric 5.5 3.4 5.4 58.8 2 Coriander 0.6 0.4 0.6 50.0 3 Chilli 1.9 0.9 1.6 77.8 4 Black Pepper 3.4 2.5 3.0 20.0 5 Garam Masala 4.5 2.2 4.0 81.8 6 Cardamom 8.5 5.7 8.3 45.6 7 Cloves 17.0 11.9 16.6 39.5 8 Cumin 3.4 2.3 3.2 39.1 9 Ajwain 5.1 4.2 4.8 14.3 10 Oregano 3.2 2.6 3.0 15.4 11 White Pepper 3.3 2.2 3.1 40.9 12 Mace 15.0 9.3 14.2 52.7 13 Piminto 3.2 2.6 3.0 15.4

TABLE-US-00003 TABLE 3 Oleoresin Content Oleoresin S. Name of Raw Ambient Cryogenic % of No. the spice Material Grinding Grinding Recovery 1 Turmeric 15.0 10.1 13.3 31.7 2 Coriander 20.0 11.1 18.5 66.7 3 Pepper 12.8 7.7 9.4 22.1 4 Fenugreek 8.0 4.6 5.5 19.6 5 Cumin 18.0 11.6 15.0 29.3 6 Ajwain 25.0 19.9 23.0 15.6

[0090] Table 4 shows the antioxidant activity after ambient grinding and after cryogenic grinding of various spices.

TABLE-US-00004 TABLE 4 Antioxidant Activity Antioxidant activity Total Phenolic Content Total Flavonoids C Antioxidant content (mg GAE) (mg QE) (mg BHT E) Scavenging % S. Name of Ambient Cryogenic Ambient Cryogenic Ambient Cryogenic Ambient Cryogenic No. the spice Grinding Grinding Grinding Grinding Grinding Grinding Grinding Grinding 1 Turmeric 1.6 2.1 15.1  28.0  0.5 1.3 78.0 81.8 2 Coriander 0.8 1.0 6.9 12.1  0.4 0.8 39.0 89.5 3 Cumin 99.0  110.5  27.1  39.4  6.5 8.8 18.9 23.5 4 Fenugreek 4..5 5.7 69.0  79.3  6.0 10.0  48.5 80.7 5 Ajwain 75.3  115.0  343.0  523.0  133.2  145.2  48.0 94.5

[0091] Table 5 shows chemical Compound Recovery after ambient grinding and after cryogenic grinding of various spices.

TABLE-US-00005 TABLE 5 Chemical Compound Recovery Spice Chemical compound Recovery Ambient and Cryogenic grinding S. Ambient Cryogenic Recovery No. Spice Name Parameter g/100 g % 1 Chilli Capsaicinoids 0.26 0.29 11.5 2 Turmeric Curcuminoids 4.4 6..0 36.3 3 Black Pepper Piperine 5.0 6.2 24.0

Example 2: Effect of Gamma Irradiation on Cryogenic Grinded Spices

[0092] The cryogenically ground spices as prepared according to method described in Example 1 were tested before and after gamma irradiation for microbial contamination and results have been shown in Table 6.

TABLE-US-00006 TABLE 6 Microbial Content of Foods Spices Before and after Gamma Treatment Microbial Parameters Spices Before and after Gamma Treatment S. Before Gamma After Gamma No. Parameters Chilli Coriander Pepper Turmeric Chilli Coriander Pepper Turmeric 1 Total Plate  573  530 2400 796 0 0 0 0 count, cfu/g 2 Yeast and Mould  320 1012  100  0 0 0 0 0 count, cfu/g 3 E. Coli, cfu/g   4   3   1  3 0 0 0 0 4 Pseudomonas   0   0   0  0 0 0 0 0 spp,/g 5 Staphylococuus   0   3   0  0 0 0 0 0 Aureus 6 Salmonella spp, Abs Abs Abs Abs Abs Abs Abs Abs cfu/25g 7 Aspergillus spp, 1080  15  30 110 0 0 0 0 cfu/g

[0093] As can be seen from the results of the above given Table 6, for the cryogenic ground spices there was significant decrease in microbial contamination after gamma irradiation.

[0094] EXAMPLE 3: Evaluation of microbial contamination for spices prepared according to embodiments of the invention (cryogenic grinding and gamma irradiation) and the marketed spices after gamma irradiation:

[0095] Usually spices and its products contains microbial contaminants. We tested the spice samples (cryogenic ground according to embodiments of the invention and marketed spice samples) after gamma irradiation treatment for microbial contaminants. The protocol followed for the spices prepared according to embodiments of the invention involving both cryogenic grinding and gamma irradiation were according to process flow diagram given in FIG. 2 and for marketed samples according to process flow diagram in FIG. 3.

[0096] Finished product of spice powder samples were opened in sterile condition under biosafety cabinet and weighed one gram of sample in eppendorf. Then aliquoted 10 ml of normal saline in the test tubes, and added the one gram of sample into the tube. Mixed the sample with sterile tip and vortex and leave to settle. Labeled the media plates and then took 100 μl of sample and added into the media plate. Then by using sterile L rods spread on the media, incubated the media plates in the calibrated 35° C. incubator for 48 hours for bacterial pathogens and 25° C. incubator for 3 to 5 days for fungal and other pathogens. Observed the plates and recorded the growth.

[0097] Tested for pathogens—E. coli, coliform, Staphylococcus aureus, Pseudomonas aeruginosa, Salmonella spp, Aspergillus spp, yeast and molds.

[0098] 1. Staphylococcus spp—Mannitol salt agar

[0099] 2. Pseudomonas spp—Cetrimide agar

[0100] 3. E. coli—MacConkey agar

[0101] 4. Coliform—Eosin methylene blue agar

[0102] 5. Salmonella spp—Xylose lysine deoxycholate agar

[0103] 6. Yeast molds & Aspergillus spp—Sabouraud dextrose agar

[0104] The results obtained have been shown in FIGS. 4a, 4b, 5a, 5b, and 5c. It was found that the microbial contaminates were reduced in the market samples, however no contaminants were observed in the spices prepared according to embodiments of the invention. The study showed the way to reduce the microbial load and prevention of oxidation in the products.

[0105] Although the invention has been illustrated and described in greater detail with reference to the preferred exemplary embodiments, the invention is not limited to the examples disclosed, and further variations can be inferred by a person skilled in the art, without departing from the scope of protection of the invention.

[0106] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.