Food or edible material: processes – compositions – and products – Surface coating of a solid food with a liquid
Reexamination Certificate
1999-01-26
2001-08-14
Corbin, Arthur L. (Department: 1761)
Food or edible material: processes, compositions, and products
Surface coating of a solid food with a liquid
C426S512000, C426S516000, C426S637000
Reexamination Certificate
active
06274184
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to shaped large-piece dried potato products, such as French fries, fried potato slices, Rösti slices, potato dumplings or potato noodles, which may be readily rehydrated, and to a process for their production.
BACKGROUND OF THE INVENTION
The texture of rehydrated dried potatoes is to a great extent determined by the swelling state of the cell aggregate at the end of the stipulated preparation time. When potato pieces are dried, the volume shrinks during the drying process to approximately 50% of the starting volume. This compression of the cell aggregate makes rehydration more difficult and incomplete reabsorption of the water removed during drying occurs during the rehydration. The prepared product no longer swells to its original shape, the consistency is frequently tough and the larger the potato pieces, the more difficult it is to achieve good rehydration properties.
The object underlying the invention is therefore to provide large-piece dried potato products which exhibit good rehydration properties, rapid and complete rehydration being sought after.
A number of production processes are known for dried potato products which are prepared by subsequent rehydration and cooking.
Abstract of WO 9622029-A discloses a process for producing potato chips. Dehydrated potato pieces, for example potato flakes, are rehydrated to form a paste, which is then extruded.
Abstract of JP 9000196-A discloses the production of potato products by rehydration of dried thinly sliced potatoes.
Coleman, et. al, U.S. Pat. No. 5,486,369 discloses a fried potato product suitable for processing in the microwave. Raw potatoes are sliced into strips, blanched in a solution comprising table salt and sugar, cooked, dried and fried, producing a product having a moisture content of 10 to 40%, which is then packaged and is said to be able to be kept without freezing and sterilization. It can be reconstituted by heating in a microwave oven without using water or sauces.
Stubbs, et. al, U.S. Pat. No. 5,492,704 discloses a process for dehydrating potatoes for the production of hash browns. In this process, small potato pieces, for example elongate grated potato, is coated with a dry mixture which comprises a particulate component, e.g. granular starch or ground potatoes, which ensures the separation of small adjacent potato pieces. The coating is carried out in this case to ensure that the small potato pieces, even after drying, remain separate and do not stick to one another. There is no shaping to large piece potato products before drying. After reconstitution, when heated in the pan, the small potato pieces may stick together.
In contrast therewith, according to the present invention, the potato pieces are shaped before drying to form large-piece potato products. Although they are made up of individual potato particles, the potato pieces are shaped large-piece items not only during, but also after drying and after rehydration, such as French fries, fried potato slices, Rösti corners, potato dumplings, etc.
Surprisingly, it has been found according to the invention that small coated potato particles can be shaped to form large pieces which retain their shape and do not fall apart, but nevertheless have an open structure which ensures good and rapid drying and rapid and complete rehydration. By means of the process according to the invention, a web-like product is obtained which possesses open cavities into which the drying air and the rehydration water can penetrate, although the overall shape is retained. A porous structure which possesses closed pores, such as are formed in the action of baking powder, does not possess the desired properties of the present invention. During the drying of the shaped pieces according to the present invention, the surface dries more rapidly and becomes dimensionally stable, whereas in the interior, the drying takes place more slowly, so that the desired open-pore structure is formed by shrinkage.
SUMMARY OF THE INVENTION
In the process according to the present invention, raw potatoes are peeled, cut to a particle size of 0.6 to 2 mm in one dimension and then blanched. If appropriate, after prior removal of surface water, the particles are covered with a coating and the coated particles are shaped to form the desired product shape, whereupon the shaped product is then dried to a water content below 12% by convection drying at temperatures below 100° C. The products, according to the present invention, are shaped large-piece dried potato products.
In a further aspect of the present invention, raw potatoes may first be cut to a particle size larger than finally desired, blanched, cooled, and subsequently cut into the finally desired smaller particle size.
DETAILED DESCRIPTION OF THE INVENTION
For the process according to the invention, preferably, use is made of potatoes having a starch content range between 10 and 16%. Low-starch potatoes have a higher water binding capacity and thus give a better structure.
The potatoes are preferably peeled by steam peeling.
The particle size of the potatoes is of critical importance for the properties of the product and is dependent on the type of products to be produced. Different potato particles are required for producing fried potato slices than, for example, for producing potato dumplings. It is of importance that at least in one dimension the particle size is 0.6 to 2 mm, preferably 1.0 to 1.6 mm. If this size is maintained in one dimension, the size in the other dimensions is of lesser importance. Preferably, small strips are cut into a cross-section of 1.0 to 1.6 mm. A coarsely grated material is also suitable and preferred, for example, for Rösti corners. The shape and dimensions of the potato particles influence, as structure-forming element, the density of the shaped final product.
The blanching, firstly, inactivates the enzymes, and secondly pregelatinizes the starch to a desired extent. Depending on the shape and size of the potato particles, the properties of the product can therefore be varied by the blanching conditions. Because the stability and elasticity of the potato strips are influenced by the blanching, the porous structure in the shaped final product can also be influenced by this means. Generally, the blanching is carried out for 6-12 minutes at 85-95° C.
Preferably, a cooling stage is provided immediately after the blanching. The cooling can be performed with cold water, by dipping or pouring, for example. The cooling is expedient to control a degree of blanching exactly and to prevent post-blanching.
After the blanching, and prior to the coating, expediently, adherent surface water is removed. This can be performed by centrifuging or by pressing in a belt press. Removing the surface water promotes uniform coating without lump formation.
If the potato particles are too small, it can be a disadvantage, in that too much starch is washed out due to the relatively large surface in relation to the particle mass. Thereby a product loss of up to 20% by weight can occur.
This problem can be avoided according to a further aspect of the present invention, in that the potatoes are first cut into a particle size larger than finally desired and only after blanching and cooling these larger particles are cut into the finally desired smaller particle size. Hereby it is necessary to allow or to effect a retrogradation after the blanching before the further cutting, because otherwise the small particles cannot be accurately cut.
In this modification of the process according to the present invention, the potatoes are first coarsely cut, preferably into slices of about 15 mm thickness. These are then blanched and cooled, preferably to 5-20° C. for 10-30 hours, whereby sufficient retrogradation takes place so that the coarsely cut potato pieces subsequently can be cut to the desired final size of 0.6 to 2 mm cross-section, preferably into strips with a cross section of 1 mm. Subsequently, the potato strips are mixed with the coating agent, shaped into the form of the final product, and dried.
Bosch Thomas
Detje Peter
Lung Oliver
Pfeilstetter Hans
Bestfoods
Corbin Arthur L.
Norris & McLaughlin & Marcus
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