Abstract:
Fresh potatoes, and/or other fresh vegetables or legumes, or any ingredients already frozen, processed, or otherwise prepared, are processed to make more healthful French fry products and other formed food items in any of a variety of shapes and flavor profiles while attaining the organoleptic qualities of traditional formed-food products.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of provisional application No. 61/832,757, filed on Jun. 7, 2013. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to the processing of fresh potatoes, and/or other vegetables and/or legumes, or of frozen, processed, or prepared potatoes, and/or other vegetables and/or legumes, and/or other ingredients, to make more healthful French fry products and other shaped or formed food items. 
       BACKGROUND OF THE INVENTION 
       [0003]    French fries and other prepared potato products are one of America&#39;s staple food products. There are nearly 10 billion pounds of Frozen Potatoes sold annually in the USA (Source: US Potato Board Sales Utilization Estimates, July 2011). Over 8 billion pounds of frozen potatoes are sold via foodservice channels alone, and nearly 50% of all purchases at McDonalds, Wendy&#39;s, and Burger King, the three largest quick service restaurant chains, include French fries or another fried potato product as part of the order (Source: NPD Group/Crest, 2009). French fries are often sold to consumers in a frozen form for preparation or heating at home as well as through wholesalers, distributors and directly to vendors for preparation and retail sale away from home. 
         [0004]    French fries are one of America&#39;s favorite foods in part because they taste delicious and are available in a variety of shapes and sizes ranging from traditional French fries and steak fries, to waffle fries, tots, hash browns and various shapes that are intended to appeal to children, such as smiley faces and alphabet shapes. 
         [0005]    French fries and other prepared potato products are generally considered unhealthy, because they lack substantial nutritional value with relatively low levels of vitamins and nutrients, and often include artificial colors and flavors to enhance taste and appearance. As an example, ingredients in the French fries served at a major national fast-food restaurant chain include natural beef flavor, dextrose, tertiary butylhdroquinone, dimethylpolysiloxane, and hydrogenated soybean oil. 
         [0006]    The prior art of “Traditional French fry type” products as well as “Shaped Potato Products,” for instance the products and methods disclosed in U.S. Pat. Nos. 3,812,274, 3,085,020, 4,082,855, 4,276,314, 6,274,184, and 4,156,744, do not allow for or reference the possible incorporation of non-potato ingredients. Additionally, U.S. Pat. Nos. 6,274,184, 4,156,744, 3,399,062, and Publication No. 2003-0108654, variously disclose the use of dehydrated potato, riced potatoes, or potato flour, or a dry mix which is then rehydrated, or a combination of dehydration, aggregates, cellulose ether binding and rehydration process. Further, U.S. Pat. Nos. 7,090,884 and 4,109,012 respectively disclose utilizing a puree and fine-grinding approach and exclude oil frying, and a process of baking whole unpeeled potatoes, forming the product into a mealy dough, and emulsifiers and starch control agents to maintain a mealy internal consistency that is acceptable to consumers. Disadvantages of existing processes include difficulty in achieving traditional French fry organoleptic qualities that are critical for consumer enjoyment, introducing a variety of other chemicals, processing aids or other ingredients, some of which may be artificial, into the finished product. 
         [0007]    American consumers are becoming increasingly conscious of the risks associated with unhealthy eating, and are beginning to embrace the need to include a greater amount of healthy vegetables and legumes and other natural foods as part of a well balanced diet. As an example, First Lady Michelle Obama has helped to elevate awareness through her “American Grown” vegetable garden on the South Lawn of the White House, and the “Let&#39;s Move” initiative that is focused on fighting childhood obesity and on promoting healthier, natural and whole foods. 
         [0008]    While consumers are searching for foods with better nutritional content, they have limited time for preparation and they and their children are not willing to compromise taste. French fries, in all of their forms and shapes, are generally enjoyed for their unique organoleptic qualities including a crispy exterior, and tender but firm and mealy interior texture. Conventional methods of preparation involve extended frying times and result in relatively high levels of fat. For example, the major frozen retail brands utilize a fry time typically 45-120 seconds long prior to freezing and distributing their products. McDonalds fries their French fries for exactly 3 minutes and 10 seconds on premises. 
         [0009]    Thus, there exists a consumer need for healthier French fry and chip products that possess the critical organoleptic and other visual qualities that consumers demand from traditional French fry and chip products, and which have increased amounts of naturally occurring vitamins and minerals, protein, fiber and other inherent nutritional qualities, while reducing or greatly reducing the amount of fat, carbohydrates, and/or sodium relative to conventional fried potato products. 
         [0010]    Additionally, there is a need for formed products, such as French fries, based on potatoes or other vegetables, and incorporating healthful non-potato vegetables, legumes and other ingredients such as whole grains, nuts, seeds, herbs, spices, and more. Further, there is a need to make healthful, tasty, and convenient products using whole and fresh ingredients, while maintaining moisture levels similar to those of traditional French fry products. There is a need to prepare and serve the products in a variety of shapes, to suit consumer preferences, including children. Finally, there is a need to reduce the final preparation time, for in-home or foodservice preparation, both as a means to reduce the fat content, and to increase convenience. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention meets all these needs by providing methods for preparing vegetable fries, shapes, or chips from one or more fresh or processed vegetable ingredients to produce a healthful and nutritionally-rich chopped and formed vegetable product. The product may be frozen or refrigerated and packed for wholesale, commercial, or retail sale. 
         [0012]    The present invention also provides compositions of such prepared vegetable fries, shapes, or chips, which may comprise a plurality of types of vegetables, and which may further comprise seasonings, additional ingredients for flavoring, grains, seeds, nuts, fruits, dairy and meats including poultry and fish, and other all natural ingredients to create desired textures and flavor profiles. Furthermore, the present invention delivers the critical organoleptic and other visual product qualities (such as natural appearance, external texture, and internal texture) that are consistent with traditional French fry type products as demonstrated in technical sensory attribute testing with an independent research organization, with testers who have been screened and trained in accordance with ASTM STP 758: Guidelines for the Selection and Training of Sensory Panel Members. 
         [0013]    The process disclosed entails preparing the ingredients to desired sizes, with washing, peeling, and cutting as appropriate, followed by blanching and/or parboiling for selected ingredients. The ingredients, individually or collectively, may be staged between different processing steps; any such staging step may comprise weighing, storage, cooling, or tempering. The ingredients may then be reduced in size, individually or in groups, to desired size ranges, which may vary for different ingredients, and which are herein referred to as ingredient particles or particulates, or simply as particles or particulates. Preferably the ingredients are cut into irregular shapes to produce a finished product with improved texture and mouth feel relative to the current art. Seasonings, flavorings, natural gum ingredients, starches and other ingredients may be introduced before or after the chopping, or during the blending. The ingredients are blended, preferably in a ribbon blender or a paddle blender to preserve particle size and shape without altering either. The mixed ingredients are then shaped using a forming plate or an extruder, depending on the shape of product desired. The pieces thus created may then be coated before being heated and having moisture removed, in a dehydrating step. This initial dehydrating step may also be omitted. The dehydrating may be dry or steam baking, and may be done in one or more phases of baking, or may be done in a drying tunnel or other equipment. Subsequent to dehydrating, the products may be cooled, and/or may be coated again, before being fried. The frying step may be omitted. After frying, the products may be further processed with a first dehydrating step, or a second dehydrating step if they were so treated before being fried. Following the chosen sequence of dehydrating and/or frying, all of which may be omitted in some embodiments of the invention, the products are rapidly cooled in a blast freezer, and then are packed for sale, with the type of packaging and quantity of products per package depending on whether that package is intended for commercial, wholesale, or retail sale. 
         [0014]    The present invention may also allow for significantly faster preparation times versus some traditional French fry type products. This is true for product purchased frozen or refrigerated in retail stores with final preparation in the home as well as product that is sold to the various foodservice operators for final preparation and consumption on-premise or for take-away. In both instances, the present invention can be prepared in 10-30% less time than the leading brands. 
         [0015]    Additionally, consumers wish to purchase such products in a variety of shapes, ranging from traditional French fries and steak fries, to waffle fries and shapes that are intended to appeal to children, such as smiley faces, alphabet shapes and animals. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    In the drawings, like reference characters generally refer to the same steps of the method and composition throughout the different figures.
 
In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
 
           [0017]      FIG. 1  is a schematic diagram of the four phases of the method. 
           [0018]      FIG. 2  is a schematic diagram of the first phase of the method, comprising the steps of Ingredient Preparation. 
           [0019]      FIG. 3  is a schematic diagram of the second phase of the method, comprising the steps of Mixing Ingredients. 
           [0020]      FIG. 4  is a schematic diagram of the third phase of the method, comprising the steps of Shaping and Cooking Products. 
           [0021]      FIG. 5  is a schematic diagram of the fourth phase of the method, comprising the steps of Cooling and Packing Products. 
           [0022]      FIG. 6  illustrates some of the possible shapes into which the prepared ingredient mixture may be formed. 
           [0023]      FIG. 7  sets forth, in tabular form, the possible and preferred ranges of moisture content of the shaped pieces at various steps in the method disclosed. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]      FIG. 1  illustrates a method  100  for making shaped and flavored vegetable fries or chips from one or more vegetables and other ingredients. The method includes the phases of Ingredient Preparation  200 , Mixing Ingredients  300 , Shaping and Cooking Products  400 , and Cooling and Packing Products  500 . 
         [0025]      FIG. 2  illustrates the phase of Ingredient Preparation  200 . Ingredient preparation  200  may comprise gathering ingredients  202 , washing ingredients  208 , peeling ingredients  212 , cutting ingredients  214 , blanching ingredients  218 , parboiling ingredients  222 , and staging the ingredients for final preparation  224 . In certain embodiments of the invention, the ingredients may be tempered  204  and/or staged  206  between gathering ingredients  202  and washing ingredients  208 , staged  210  between washing  208  and peeling  212 , staged  216  between cutting ingredients  214  and blanching ingredients  218 , and/or staged  220  between blanching ingredients  218  and parboiling ingredients  222 . Staging may refer to any of placing the ingredients, individually or in groups, into one or more totes, refrigerating them, weighing them, drying them, or keeping the ingredients in a convenient location near the machine which will be handling them next. 
         [0026]    In a preferred embodiment of the invention, one or more fresh vegetables are used. The multiple steps of ingredient preparation  200  may all be desirable in order to make the fresh ingredients ready to be combined. In other embodiments, one or more non-fresh vegetables may be used, for instance such ingredients may be canned, frozen, dried, dehydrated, or pureed. For some ingredients, it may be desirable to omit one or more of the steps of the phase of ingredient preparation  200 . As will be obvious to one skilled in the art, multiple methods of ingredient preparation may be used. 
         [0027]    Initially, ingredients are gathered  202 . In some embodiments of the invention, other ingredients may be added to the one or more vegetables. Such ingredients may include, but are not limited to, any combinations of seasonings, natural binders, liquids, and specialty flavorings. For purposes of describing such a non-exhaustive list of categories of ingredients, and without limiting ingredients that may be included in any such categories, seasonings may include but is not limited to salt, pepper, herbs, and dairy; natural binders may include but is not limited to gum, calcium casseinate, egg proteins, guar, carrageenans, xantham gum, locust bean gum, starches, and egg albumen; liquids may include but is not limited to water, wine, and chicken or other stock; and specialty flavorings may include but is not limited to dairy, meats including poultry and fish, caramelized onions, sun-dried tomatoes, grains, seeds, nuts, and fruits. For any individual ingredient, it may be desirable to omit one or more of the steps of the phase of ingredient preparation  200 . Ingredients that are seasonings, natural binders, liquids, or specialty flavorings may be prepared with multiple steps, or may be purchased commercially and used in the method of this invention described herein. 
         [0028]    After gathering ingredients  202 , some or all of the ingredients may be tempered  204 , in which an ingredient that is frozen is moved from a freezer or other location where it is kept frozen, to a refrigerator or other location where it may be slowly warmed at temperatures slightly above freezing. In some embodiments of the invention, one or more frozen ingredients may be tempered  204  for up to 14 days, with a preferred time range of 4 days to 10 days, at a temperature range of 32° F.-41° F. The step of tempering  204  is used to achieve the desired temperature, texture, and functionality for further processing in one or more ingredients. Following the step of tempering  204 , some or all of the ingredients may be staged  206  in preparation for washing  208 . 
         [0029]    In a preferred embodiment of the invention, each fresh vegetable ingredient is washed  208 , may be peeled  212 , and may be cut  214  into cut pieces. Certain of these steps may be applied to non-fresh vegetables or other ingredients, or may be omitted for certain ingredients for which a particular step is not needed, in particular but not limited to prepared spices or flavorings. The washing  208  may be done with hot or cold water, or using scrubbers or other tools to mechanically remove foreign particles. The peeling  212 , while optional, may be done mechanically, by steam peeling, or by other means known in the art. The cutting step  214  may be intended to cut the one or more ingredients into relatively large pieces, to be subsequently processed or handled and then cut to a final size. For the cutting step  214 , possible size ranges for cut size of vegetable pieces are 1.0-10.0 cm, while preferred sizes are 1.5 cm-3.0 cm. For different ingredients, there may be different shapes of cut pieces desired in the cutting step  214 . In the cutting step  214 , each ingredient can individually be cut to a preferred size, or more than one ingredient can be cut at the same time. The ingredients should be separately subjected to the cutting step  214  if different sizes of pieces are desired for different ingredients following the cutting step  214 . The ingredients may be staged  216  after being washed  208 , peeled  212 , and/or cut  214 . 
         [0030]    After being staged  216 , the ingredients may be blanched  218 , a goal of which is to preserve freshness and color of the ingredients, by being placed, individually or in sets of more than one ingredient, into hot or boiling water for a period of time between 5 and 60 seconds, preferably for 10 to 40 seconds. The water for blanching should be boiling at approximately 212° F. In some embodiments of the invention, the blanching could be carried out in water held at elevated atmospheric pressure, with pressure ranging from 2 to 50 pounds per square inch (“psi”), and preferably between 10 and 50 psi. Following the time in the hot or boiling water, the blanching  218  of the ingredients is completed by quickly placing the ingredients into cold water, which may be done for a period of time between 5 seconds and 120 seconds, preferably for 10 to 60 seconds. The water for cooling should be between 30 and 40° F., and preferably between 32 and 38° F. The ingredients may then be staged  220  by being allowed to cool for some length of time between 1 and 20 minutes, preferably for 5 to 15 minutes. 
         [0031]    The ingredients may be parboiled  222  by being placed, individually or in sets of more than one ingredient, into boiling water for a period of time between 1 and 6 minutes, preferably for 2 to 3 minutes. The water for parboiling should be boiling at approximately 212° F. In some embodiments of the invention, the parboiling could be carried out in water held at elevated atmospheric pressure, with pressure ranging from 2 to 50 pounds per square inch (“psi”), and preferably between 10 and 50 psi. 
         [0032]    After being parboiled  222 , the ingredients may be staged  224 , in preparation for the phase of Mixing Ingredients  200 . It will be readily understood by one of skill in the art that not every ingredient will need all of these steps for preparation; by way of example without limiting the forgoing, some seasonings, natural binders, or liquids may be ready to use in mixing together with other ingredients. 
         [0033]      FIG. 3  illustrates the phase of Mixing Ingredients  300 , in which the ingredients are combined together into an ingredient mixture. One or more ingredients are reduced in size in a cutting step  302 . The cutting step  302  may be carried out in a cutting or chopping bowl, which may have a blade speed ranging from 0 to 6000 rotations per minute (rpm), with a bowl rotation speed of 10-20 rpm. As will be obvious to one skilled in the art, other means of reducing the ingredients from their original size to the preferred particulate size may be used, including but not limited to grinding. In a preferred embodiment, each vegetable ingredient is separately passed through the cutting step  302 . In some embodiments, more than one vegetable ingredient may be cut, chopped, ground, or otherwise reduced in size in the cutting step  302  at the same time. Preferably, the ingredients are cut or otherwise reduced into shapes that are irregular in three dimensions. 
         [0034]    Preferred size ranges may vary for each vegetable ingredient, and some specialty ingredients, for final particulate size after the cutting step  302 . For potatoes, the preferred range of particulate sizes is 0.2-0.8 centimeters (cm), and the range of possible particulate sizes is 0.02-2.0 cm. For carrots, the preferred range of particulate sizes is 0.1-0.8 cm, while the range of possible particulate sizes is 0.005-2.0 cm. For broccoli, the preferred range of particulate sizes is 0.05-0.8 cm, while the range of possible particulate sizes is 0.05-2.0 cm. For other vegetable ingredients, the preferred range of particulate sizes is 0.3-0.8 cm, while the range of possible particulate sizes is 0.005-2.0 cm. For some ingredients, especially non-vegetable ingredients such as seasonings and natural binders, the particulate sizes may be much smaller. 
         [0035]    After the cutting step  302 , the ingredients may be staged  304 . This may include a rest period of, in preferred embodiments, up to 15 minutes with the ingredients being held at ambient temperature of 50° F.-80° F. If the ingredients are held for longer than 15 minutes, they should be stored at refrigeration temperatures of 33° F.-44° F., preferably 36° F.-44° F., for 15 minutes to 24 hours. The ingredients may also be combined into containers for or during this staging  304 , and then moved to the blending step  306 . 
         [0036]    All of the ingredients are moved to the blending step  306  for blending to combine the ingredients into an ingredient mixture with the desired density, viscosity, and moisture content, without reducing the size of the individual particulate elements of each ingredient. The blender should, preferably, be capable of 5 to 100 rpm, and preferably will reduce vegetable ingredient particulate size by less than 3%. In some embodiments it may be acceptable to have the ribbon blender, paddle blender, or other blender reduce vegetable ingredient particulate size by as much as 10%. In some embodiments of the invention, the desired ingredient mixture will have a viscosity in the range of 400 to 1500 mPas and preferably 600 to 1000 milli-Pascal-seconds (mPas) as measured with a viscometer such as a Brookfield Viscometer or comparable instrument. The desired ingredient mixture will also have moisture content, as measured by the percent of the ingredient mixture that is moisture, in the range of 40% to 85%, and preferably 45% to 80%, for ingredient mixtures that are to be Shaped and Cooked  400  with a step of Heated Dehydration  406  prior to Frying  410 . 
         [0037]    After the blending step  306 , the ingredients may be staged  308 . This may include a rest period of, in preferred embodiments, up to 15 minutes with the ingredients being held at ambient temperature of 50° F.-80° F. If the ingredients are held for longer than 15 minutes, they should be stored at refrigeration temperatures of 33° F.-44° F., preferably 36° F.-44° F., for 15 minutes to 24 hours. The ingredients may be held in the blender or in containers for or during this staging  308 , and then moved to phase of shaping and cooking  400 . 
         [0038]      FIG. 4  illustrates the phase of Shaping and Cooking Products  400 . The ingredient mixture is shaped  402  into shaped pieces  602  of one or more particular sizes and shapes. In some embodiments of the invention, a forming plate may be used to create shaped pieces  602  shaped as French fries, steak fries, waffle fries, hash browns, tots, curly fries, smiley faces, animal silhouettes or faces, or other shapes, including but not limited to those illustrated in  FIG. 6 . A forming plate may be used, or other comparable instrument capable of up to 80 stamps per minute at variable pressure in the range of 10 to 200 psi, and preferably in the range of 50 to 150 psi, such as those made by Formax or Koppens, or other similar devices. In other embodiments, a variable pressure extruder may be used to create shaped pieces  602  shaped as French fries, string fries, curly fries, steak fries, nuggets, or other shapes. When using an extruder, the pressure used may be in the range of 10 to 200 psi, and preferably is in the range of 50 to 150 psi. Other methods of forming or shaping the pieces may be used, as is apparent to one skilled in the art. 
         [0039]    During the step of shaping  402 , shapes should be made into sizes that adults and children are familiar with, and are comfortable eating in up to several bites. For instance, French fries may be shaped in the size range of 3.0-10.0 cm×0.2-1.5 cm×0.2-1.5 cm (length×width×depth), and preferably in the range of 5.0-9.0 cm×0.6-1.2 cm×0.6-1.2 cm. The shaped pieces  602  should have viscosity in the range of 400 to 1500 mPas, and preferably 600 to 1000 mPas. In embodiments of the invention with sequences of cooking steps, as discussed below, that include a Dehydrating step  406  prior to Frying  410 , the shaped pieces  602  should have moisture content in the range of 40% to 85%, and preferably 45% to 80%. In embodiments of the invention with sequences of cooking steps that do not include a Dehydrating step  406  prior to Frying  410 , the shaped pieces  602  should have moisture content in the range of 40% to 85%, and preferably 45% to 73%. 
         [0040]    In the steps of the Shaping and Cooking Products  400  phase that relate to cooking the shaped pieces  602 , the cooking may follow several paths in different embodiments of the invention, depending on the product being made, its ingredients, and whether it is intended to be sold to retail consumers or to foodservice businesses for preparation and sale to customers in ready-to-eat form. Depending on those factors, the shaped pieces  602  may be processed for cooking with one or more cooking steps, as 1) Heated Dehydration  406  alone, 2) Frying  410  alone, 3) Heated Dehydration  406  then Frying  410 , 4) Frying  410  then Heated Dehydration  414 , 5) Heated Dehydration  406 , then Frying  410 , then Heated Dehydration  414 , or 6) no Heated Dehydration or Frying, instead going directly from shaping  402  to cooling  502 ; and the above sequences of cooking steps may have a first coating step  404  and/or a second coating step  408  and/or a step of removing excess oil  412  as well, including the possibility of processing the ingredient mixture with shaping  402  to create shaped pieces  602 , treating them with a first coating step  404  and possibly a second coating step  408 , and then cooling  502  the shaped pieces  602 . In different embodiments of the invention, with different sequences of cooking steps, the possible and preferred ranges of moisture content for the ingredient mixture when mixed and after each of the chosen cooking steps may vary, as may the time and temperature ranges selected in such cooking steps, as will be readily apparent to one skilled in the art.  FIG. 7  provides details of possible and preferred ranges of moisture content for different embodiments of the invention with different sequences of such cooking steps. 
         [0041]    Following shaping  402  the ingredient mixture into shaped pieces  602 , the shaped pieces  602  may be treated with a first coating step  404 . The first coating step  404  is expected to not alter the size of the shaped pieces  602  significantly. In preferred embodiments of the invention, the pieces are coated  404  with a coating mixture comprising some or all of dextrin, tapioca starch, rice starch, corn starch, potato starch, and other ingredients. The goal of this first coating step  404  is to contribute to an appealing crispy texture on the outside of the finished and prepared pieces, while reducing the fat content of the pieces relative to traditional French fries and the prior art. Other coating mixtures may be used to meet this goal. The first coating step  404  may preferably be carried out by misting the coating mixture onto the pieces, sprayed at a pressure of 0-30 psi, or preferably at 5-15, or the coating mixture may be applied by other means, including but not limited to immersion in the coating mixture, or a waterfall-type application of the coating. The first coating step  404  may be carried out in a machine at a temperature of 35° F.-70° F., or preferably at 35° F.-60° F., with the targeted internal temperature of the shaped pieces  602  of 20° F.-65° F., or preferably 25° F.-50° F. The coating mixture may be applied for up to 10 seconds, though in preferred embodiments, it may be applied for 1.0 seconds or less time. The coating mixture may have an approximate viscosity of 1-5 centipoids, or in preferred embodiments of the invention, 2-4 centipoids. The coating mixture applied may be measured as a density, in mg per unit area, with a range of 0.001 mg coating mixture per square centimeter (mg/cm2) of shaped pieces  602 , up to 2.0 mg/cm2. Following the first coating step  404 , the pieces must rest so that the coating mixture has time to dry. This may be done for 0-60 seconds, or in preferred embodiments of the invention, for 2-40 seconds. 
         [0042]    Following the first coating step  404  and a rest period of up to 30 seconds to allow the coating mixture to dry on the pieces  602 , the shaped pieces  602  may be treated with a first step of Heated Dehydration  406 , referred to here as a first dehydrating step  406  or simply first dehydrating  406  for brevity. A goal of the first dehydrating step  406  is to create a firm outside, referred to as an external wall or crust. The first dehydrating  406  may be carried out for 0-20 minutes, and in a preferred embodiment of the invention, the first dehydrating  406  may be for 30 seconds-10 minutes. The first dehydrating  406  may be at a temperature in the range of 200° F.-500° F., to create a target internal temperature of the pieces  602  in the range of 40° F.-200° F. In a preferred embodiment, the first dehydrating  406  temperature may be in the range of 300° F.-450° F., to create a target internal temperature of the pieces  602  in the range of 100° F.-200° F. A goal of the first dehydrating step  406  is to create a tougher external wall or crust on the pieces  602 , which creates additional consumer appeal in appearance and in mouth feel, and helps to seal in moisture, which contributes to the mouth feel of the finished product, and helps to reduce fat content by reducing frying time in embodiments of the invention in which the shaped pieces  602  are fried. 
         [0043]    The first dehydrating step  406  may be carried out by dry baking or steam baking in a conventional oven, or in a drying tunnel, a belt dryer, a conveyor dryer, or other device for removing moisture, for instance in an industrial Koppens oven, an Imtech drying tunnel, or a Bühler conveyor dryer. In some embodiments of the present invention, the equipment used for heated dehydration may have more than one zone of control over parameters such as temperature, duration of processing, and belt speed, to enable better dehydration and crust formation, and control thereover in the independent zones of dehydration. Following the first dehydrating step  406 , if the cooking process is to include a Frying step  410 , the target moisture content of the shaped pieces  602  is in the range of 38% to 80%, and preferably 43% to 73%. If the embodiment of the invention includes a cooking process with no Frying step  410  after this dehydrating step  406 , the target moisture content of the shaped pieces  602  after the dehydrating step  406  is in the range of 38% to 80%, and preferably 43% to 73%. 
         [0044]    Following the dehydrating step  406 , the shaped pieces  602  may be treated with a second coating step  408 . In preferred embodiments of the invention, the pieces  602  are given a second coating  408  with a coating mixture comprising some or all of dextrose, tapioca starch, rice starch, potato starch, corn starch, and other ingredients, which may be the same as the coating mixture used in the first coating step  404 . The goal of this second coating step  408  is to contribute to an appealing crispy texture on the outside of the finished and prepared pieces, while reducing the fat content of the shaped pieces  602  relative to traditional French fries and the prior art. Other coating mixtures may be used to meet this goal. The second coating step  408  may preferably be carried out by misting the coating mixture onto the pieces, sprayed at a pressure of 0-30 psi, or preferably at 5-15, or the coating mixture may be applied by other means. The second coating step  408  may be carried out in a machine at a temperature of 35° F.-70° F., or preferably at 35° F.-60° F., with the targeted internal temperature of the shaped pieces  602  of 40° F.-65° F., or preferably 30° F.-50° F. The coating mixture may be applied for up to 10 seconds, though in preferred embodiments, it may be applied for 1.0 seconds or less time. The coating mixture may have an approximate viscosity of 1000-4000 mPas, or in preferred embodiments of the invention, 1500-3000 mPas. The coating mixture applied may be measured as a density, in mg per unit area, with a range of 0.001 mg coating per square centimeter (mg/cm2) of shaped pieces  602 , up to 2.0 mg/cm2. Following the second coating step  408 , the pieces must rest so that the coating mixture has time to dry. This may be done for 0-60 seconds, or in preferred embodiments of the invention, for 2-40 seconds. 
         [0045]    Following the second coating step  408  and a rest period of up to 60 seconds to allow the coating mixture to dry on the pieces  602 , the shaped pieces  602  may be fried  410 . The frying  410  may be carried out for 0-90 seconds, and in a preferred embodiment of the invention, the duration may be for 5-35 seconds. The frying  410  may be at a temperature in the range of 300° F.-400° F., to create a target internal temperature of the shaped pieces  602  in the range of 180° F.-230° F. In a preferred embodiment, the frying temperature may be in the range of 350° F.-400° F., to create a target internal temperature of the pieces in the range of 180° F.-220° F. Following the frying  410 , the shaped pieces  602  should have moisture content in the range of 36% to 77%, and preferably in the range of 42% to 73%, if the sequence of cooking steps used in the particular embodiment of the invention does not include a second heated dehydration step  414  after the frying  410 . If the shaped pieces  602  are to follow a cooking path of frying  410  then a heated dehydration step  414 , moisture content after frying  410  should be in the range of 38%-80%, and preferably 43%-73%. If the shaped pieces  602  are to follow a cooking path of heated dehydration  406 , then frying  410 , and then a second heated dehydration step  414 , moisture content after frying  410  should be in the range of 36%-77%, and preferably 42%-72%. The frying oil used may be an oil mixture comprising some or all of canola, olive, cottonseed, sunflower, vegetable, and other oils. In a preferred embodiment of the invention, the frying oil is canola oil or sunflower oil. A goal of the frying step is to create a product with a fat percentage between 2%-15%. A further goal of the frying step  410  is to create a tougher external wall on the pieces, which creates additional consumer appeal in appearance and in mouth feel, and helps to provide a tender internal texture, which contributes to the mouth feel of the finished product, and can reduce fat content by reducing frying time or fat or oil required in other cooking methods in the final preparation step  512 . 
         [0046]    Following Frying  410 , the shaped pieces  602  may have excess oil removed from them in a step of removing excess oil  412 . This can be implemented by, typically, blowing air over the shaped pieces  602 , or in some embodiments, by placing them in a large centrifuge or strainer, or by other means. 
         [0047]    The shaped pieces  602  may be treated with a second step of Heated Dehydration  414 , referred to here as a dehydrating step  414  or dehydration  414  for brevity. The second dehydrating  414  may be carried out for 0-20 minutes, and in a preferred embodiment of the invention, the second dehydrating  414  may be carried out for 30 seconds-10 minutes. The second dehydrating  414  may be at a temperature in the range of 200° F.-500° F., to create a target internal temperature of the pieces in the range of 60° F.-200° F. In a preferred embodiment, the second dehydrating temperature  414  may be in the range of 300° F.-450° F., to create a target internal temperature of the pieces in the range of 100° F.-180° F. A goal of the second dehydrating step  414  is to crisp the exterior of the shaped pieces  602  to create a tougher external wall or crust on the pieces, which creates additional consumer appeal in appearance and in mouth feel. Additional goals of this second dehydrating step  414  are to further reduce the moisture content of the shaped pieces  602 , and to retain moistness, which contributes to the mouth feel and interior tenderness of the finished product, and helps to reduce fat content by reducing frying time in embodiments of the invention in which the shaped pieces  602  are fried. 
         [0048]    The second dehydrating  414  may be carried out by dry baking or steam baking in a conventional oven, or in a drying tunnel, a belt dryer, a conveyor dryer, or other device for removing moisture, for instance in an industrial Koppens oven, an Imtech drying tunnel, or a Bühler conveyor dryer. In some embodiments of the present invention, the equipment used for heated dehydration may have more than one zone of control over parameters such as temperature and belt speed, to enable better dehydration and crust formation. Following the second dehydrating  414 , the target moisture content of the shaped pieces  602  is in the range of 36% to 77%, and preferably 40% to 72%. 
         [0049]      FIG. 5  illustrates the phase of Cooling, Optional Cooking, Optional Cooling, and Packing Products  500 , in which the shaped pieces  602  are cooled or frozen in a cooling  502  step, may optionally be cooked in an optional cooking  504  step, may optionally have oil removed in an optional oil removal  506  step, may optionally be cooled or frozen in an optional cooling step  508 , and thereafter are packaged for sale in a packing  510  step. 
         [0050]    In a preferred embodiment of the invention, the shaped pieces  602  are cooled  502  in a blast freezer. In other implementations of the cooling  502  step, the shaped pieces  602  may be slowly frozen, or may be cooled to refrigerated temperatures, in the range of 32° F.-42° F., and maintained in refrigeration. Using a blast freezer for the cooling step  502 , the machine may be set to a temperature in the range of −20° F.-32° F., and preferably to a temperature in the range of 20° F.-32° F. The shaped pieces  602  may be frozen for 10-60 seconds, and preferably for 30-50 seconds. If the shaped pieces  602  are cooled  502  in a slow freezer, the machine may be set to a temperature in the range of −20° F.-32° F., and preferably to a temperature in the range of 10° F.-30° F., and the shaped pieces  602  may be frozen for 30 minutes-48 hours, and preferably for 45 minutes-4 hours. The target internal temperature for the shaped pieces  602  at this step is −20° F.-30° F., and preferably 16° F.-22° F. Following the cooling step  502 , the shaped pieces  602  should have moisture content in the range of 30% to 75%, and preferably 40% to 72%, as set forth in  FIG. 7 . 
         [0051]    Following the step of cooling  502  the shaped pieces  602 , the shaped pieces  602  may be subjected to a step of optional cooking  504 . The optional cooking  504  may be implemented by frying the shaped pieces  602 , or as will be clear to one skilled in the art, by other means now known or later discovered, including but not limited to heated dehydration. If the optional cooking  504  is implemented as frying, the optional cooking  504  may be carried out, in some embodiments of the invention, for durations of time and at temperatures and in oil mixtures that are the same or similar to those disclosed above for the frying  410  step. Alternatively, as will be apparent to one skilled in the art, other ranges of frying time and frying temperature may be desirable, to bring about a desired shaped pieces  602  product. Likewise, in embodiments of the invention in which the optional cooking  504  step is carried out by frying the shaped pieces  602 , the target ranges for moisture content and fat content of the shaped pieces  602  may be desired to be the same or similar to those desired in the shaped pieces  602  after the step of frying  410 , or as will be apparent to one skilled in the art, may be different to bring about the desired finished shaped pieces  602  product. A further goal of the optional cooking step  504  is to create a tougher external wall on the shaped pieces  602 , which creates additional consumer appeal in appearance and in mouth feel, and helps to provide a tender internal texture, which contributes to the mouth feel of the finished product, and can reduce fat content by reducing frying time or fat or oil required in other cooking methods in the final preparation step  512 . 
         [0052]    Following the step of cooling  502  the shaped pieces  602 , and after any treatment or processing of the shaped pieces  602  by implementation of optional cooking  504 , the shaped pieces  602  may be subjected to a step of optional removal of oil  506 . This can be implemented by, typically, blowing air over the shaped pieces  602 , or in some embodiments, by placing them in a large centrifuge or strainer, or by other means. 
         [0053]    Following the step of cooling  502  the shaped pieces  602 , and following any optional cooking  504  and/or optional removal of oil  506  if either or both of said optional cooking  504  and optional removal of oil  506  are implemented in an embodiment of the invention, the shaped pieces  602  may be subjected to a step of optional cooling  508 . As will be apparent to one skilled in the art, the optional cooling  508  step may be implemented with the same or similar equipment and the same or similar ranges of time and temperature as may be implemented for the cooling  502  step, and the optional cooling  508  step may be intended to achieve the same or similar target internal temperatures and moisture content of the shaped pieces  602  as the cooling  502  step is, as disclosed above. Alternatively, in some embodiments of the invention implementing the optional cooling step  508 , it may be desirable to use different equipment and ranges of time and temperature, and/or it may be desirable to achieve different ranges of target internal temperatures and moisture content of the shaped pieces  602 , than are described above for the cooling  502  step. 
         [0054]    Following the step of cooling  502  the shaped pieces  602 , and following any optional cooking  504  and/or optional removal of oil  506  and/or optional cooling  508 , the shaped pieces  602  are packed  510  for sale. Several packaging options are available, including but not limited to bags, boxes, and bulk, and they are differently preferred for different intended avenues of sale. Possible sizes for packing  510  range from trial sizes, of approximately 2 to 3 ounces, retail sales packaging of 8-32 ounces, club store packing of 1-5 pounds, and food service packaging of 1-50 pounds. During packing  510  and later transport of shaped pieces  602  that were frozen in the cooling step  502 , the target internal temperature for the shaped pieces  602  is −20° F.-30° F., and preferably 16° F.-22° F. For shaped pieces  602  that were refrigerated in the cooling step  502 , the packing  510  may incorporate “Modified Air Packaging” as it is known to those skilled in the art, or some other means of preserving freshness during the shelf life of the shaped pieces  602 . 
         [0055]    The shaped pieces  602  are packed  510  in packaging material. Such packaging material may be marked with varying instructions for final preparation  512  depending on whether the package was sold to a retail consumer, or to a restaurant or other foodservice provider. For preparation by consumers, possible final preparation  512  instructions include instructions for baking, in a preferred embodiment at 450° F. for 18-23 minutes, and in other embodiments at 350° F.-475° F. for 6-30 minutes. For preparation by foodservice establishments, preparation instructions may include similar instructions for baking, such as in a preferred embodiment at 450° F. for 18-23 minutes, and in other embodiments at 350° F.-475° F. for 6-30 minutes. Instructions for final preparation  512  by foodservice establishments may also include frying, in a preferred embodiment of the invention at 375° F. for 45-150 seconds, and in other embodiments at 350° F.-400° F. for 20-200 seconds. 
         [0056]    Certain embodiments of the present invention were described above. It is expressly noted that the present invention is not limited to those embodiments, but rather the intention is that additions and modifications to what was expressly described herein are also included within the scope of the invention. Moreover, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations, even if such combinations or permutations were not made express herein, without departing from the spirit and scope of the invention. In fact, variations, modifications, and other implementations of what was described herein will occur to those of ordinary skill in the art without departing from the spirit and the scope of the invention. As such, the invention is not to be defined only by the preceding illustrative description.