Method for producing reduced water activity legumes

The present invention relates to a method for producing a reduced water activity legume, with the legume produced according to the present method having a hydration level ranging between about 20% and about 65% total moisture, a water activity ranging between about 0.50 and about 1.0, and an amount of humectant equal to between about 0.1% and about 15% by weight of the legume. The method includes selecting an amount of hydrated legumes and mixing a humectant solution with the hydrated legumes.

FIELD OF INVENTION
 The present invention relates to a method for producing reduced water
 activity legumes and, most preferably, to a method for producing both
 intermediate moisture and fully hydrated beans having a low water
 activity. Specifically, the present method involves exposing hydrated
 beans to a humectant solution.
 BACKGROUND
 Beans have been a basic food staple of humans for centuries. Traditionally,
 beans have been dehydrated so as to allow for storage for long periods of
 time. It has been necessary to dehydrate the beans because fresh hydrated
 beans suffer from such problems as spoilage and sprouting. In fact, fresh
 hydrated beans generally have a shelf life of less than a week and, more
 typically, approximately 3 days. The dehydration process has typically
 removed most of the water in the bean, with the amount of water generally
 being reduced from about 50% total moisture in the bean down to about 5%
 total moisture in the bean. The reduction in water down to 5% total
 moisture in the bean prevents spoilage in the bean by not leaving a
 sufficient amount of water available for microbial growth, which includes
 fungal and bacterial growth. Additionally, beans cannot sprout if there is
 not sufficient moisture available. Sprouting is undesirable in
 commercially available beans because consumers will typically refuse to
 purchase beans that have sprouted in the packaging. Also, sprouts change
 the flavor of the bean by releasing enzymes which mobilize or change
 starch to sugar and proteins to amino acids.
 While dehydrated beans have desirable storage characteristics, such as
 eliminating microbial growth and sprouting, they suffer from the inability
 to be quickly hydrated and made suitable for human consumption within a
 short period of time. The necessary time required to prepare dehydrated
 beans for human consumption is a minimum of eight hours for the home cook
 and two hours for most commercial production operations. Typically, most
 commercial production operations retort the beans, which involves using
 pressure to cook the beans. Retorting results in a quicker preparation
 time; however, retorting or canning the beans imparts disadvantages that
 will be discussed below. Thus, it is desirable to have a bean that can be
 stored for long periods of time without spoiling and sprouting, but which
 can be hydrated and suitable for human consumption within a short amount
 of time. It would be most preferred to have a bean that is table ready
 within 10 minutes.
 Attempts have been made at producing an intermediate moisture bean that can
 be prepared for human consumption in a short period of time and can be
 stored for long periods of time. One prior art method, Staley U.S. Pat.
 No. 4,510,164 discloses combining beans, water, polyglycol, and propylene
 glycol in a mixing unit and allowing the glycol and water to diffluse into
 the beans being treated. This process results in a treated bean that can
 be stored for a period of time and which can be made ready to eat or table
 ready in a short amount of time. However, the process suffers from a
 number of limitations. The resulting bean typically is wrinkled so that it
 does not have a pleasing visual appearance, which is a problem for beans
 that are placed in clear packaging. Additionally, the bean is discolored
 which also detracts from the visual appearance of the bean. Wrinkling and
 discoloration are problems because an important part of marketing food
 products is the visual appearance. If a product has a displeasing,
 non-natural look it is less likely to be purchased by consumers.
 When glycols, water, and beans are combined in the same treatment step
 osmotic competition results. The osmotic competition causes a longer
 hydration time because glycol will bind water molecules outside the bean
 which in turn prevents the bean from hydrating as readily. Also, the
 glycol is bound to the water molecules thereby preventing the glycol
 molecules from readily passing into the bean. Essentially, the glycol
 molecules are attracted to water and, as such, will not be attracted to
 the moisture in the bean. Consequently, the glycol holds the water back
 from the beans being treated, which then requires a user to increase the
 temperature and to implement the use of pressure to increase the diffusion
 of the glycol and water into the beans. Glycol also raises the boiling
 point of the water so that much higher temperatures must be used to
 diffuse the glycol into the beans. However, as the temperature is
 increased, a Maillard browning reaction occurs, as well as caramelization.
 A more important problem with the process of combining the beans, water,
 and glycol in the same step is that the treated beans will have a reduced
 flavor quality due to inappropriate flavor and caramelization.
 Caramelization is a reaction between the sugars in the beans that occurs
 at temperatures greater than 100.degree. C. and causes the sugars to react
 and form a caramel like or thickened sugar substance. The beans are
 caramelized as a result of having to mix the bean, water, polyglycol, and
 propylene glycol mixture at high temperatures of about 100.degree. C. to
 about 140.degree. C. so that the water and glycols will diffuse into the
 bean cell structure. If temperatures of greater than 100.degree. C. are
 not used the glycols and water will not diffuse into the beans.
 Caramelization is especially undesirable because it alters the flavor,
 color, and aroma of the treated bean, and causes skin fracturing in the
 bean. Skin fracturing is undesirable because it causes the skin of the
 bean to peel and this detracts from the visual appearance of the bean.
 Additionally, caramelized beans will have a darker color, will smell
 burnt, and will have a flavor that makes the beans taste as if they have
 been cooked.
 Combining the beans, glycols, and water in the same step also results in
 Maillard browning which is a process wherein the proteins and simple
 sugars found in the bean react with one another. When the proteins and
 simple sugars react with one another they produce a compound that is
 neither a simple sugar, carbohydrate, or a protein and which reduces the
 nutritional value of the bean. The Maillard browning reaction reduces the
 availability of protein in the treated bean so that when a human consumes
 the bean they receive less available protein than what they would receive
 from a bean not treated with this process. Maillard browning also creates
 a hard outer shell on the bean, as the Maillard browning reaction causes
 cross linking in the outer shell of the bean. Once the shell is cross
 linked, the shell becomes less penetrable to water molecules and this
 makes it more difficult for the bean to become rehydrated.
 An additional problem resulting from treating a bean in a water and glycol
 mixture is that the treated bean will have rehydration problems. The
 treated beans will not hydrate as readily because the process, which uses
 high temperatures to induce the glycol to diffuse into the bean, will
 partially cook the beans, which will in turn cook the starches and
 proteins found in the beans. The cooked starches and proteins will have an
 altered structure which will prevent some water absorption. Thus, it is
 further desired to have a process that results in a treated bean that is
 easily rehydrated, has a full complement of protein, has a pleasing visual
 appearance, and that does not have an altered flavor. Also, it is
 desirable to have a treated bean that is not caramelized, nor that has
 been subject to a Maillard browning reaction. In other words, a bean is
 desired that has characteristics similar to a fresh untreated bean, such
 as a smooth skin, natural color, and natural taste as well as breakage
 characteristics similar to a fresh bean.
 Other processes used for producing consumable beans have included canning
 beans, but canned or retorted beans suffer from the disadvantages of
 lacking flavor and freshness, because retorting the beans involves cooking
 the beans. Typically, the retorting will cause the beans to overcook,
 which results in beans that are mushy and water logged. Most importantly,
 the retorted beans tend to have a lower nutritional value as a result of
 reduced protein quality. The flavor is further altered by having the
 lining of the can influence the flavor of the beans, as the epoxy lining
 on cans can influence the flavor of the beans. Additionally, canning can
 be undesirable because the beans cannot be viewed by the consumer and,
 typically, flavoring is added to the retorted beans which the consumer may
 not want.
 A final known process uses salt and water to lower the water activity of
 the treated bean. This process does produce a bean that is natural looking
 and has extended storage capabilities; however, this process suffers from
 the disadvantage that large amounts of salt must be used. The use of salt
 is undesirable because of the negative health effects associated with
 adding too much salt to a person's diet. Not only does salt have negative
 health consequences, but if not enough salt is added, the water activity
 is not sufficiently lowered so that the potential for microbial growth
 readily exists. Thus, it is further desired to have a process that
 produces a bean that does not incorporate preservatives with harmful short
 term and long term side effects.
 SUMMARY OF THE INVENTION
 The present invention relates to reduced water activity legumes, with the
 most preferred legume produced according to the present method being a
 reduced water activity bean, and a method for producing the reduced water
 activity legumes. Reduced water activity is important because this means
 that the amount of water available for microbial growth and for
 germination or sprouting in the legume is greatly reduced. Essentially,
 the legume is preserved because of the low water activity. In addition to
 having reduced water activity, the legumes can be produced so that they
 are fully hydrated, meaning the legumes are hydrated to a level ranging
 between about 40% and about 65% total moisture. Alternatively, the reduced
 water activity legumes produced can be intermediate moisture legumes
 having a moisture level ranging between about 20% and about 39% total
 moisture. Whether the treated legumes are fully hydrated or intermediate
 moisture, the legumes will have reduced water activity and desirable
 characteristics discussed below.
 The present method is particularly desirable because a treated legume,
 preferably a bean, is produced that has low water activity; can be stored
 for long periods of time; has a natural looking appearance, taste, and
 feel; can be fully or partially hydrated; and can be ready to use within 5
 minutes. Additionally, the beans produced according to the present process
 have a full complement of starch and protein, meaning the beans have a
 nutritional value similar to a fresh untreated bean. The treated bean is
 suitable for human and animal consumption.
 The present method used to produce reduced water activity legumes having a
 full complement of starch and protein, requires mixing hydrated legumes
 with a humectant or a humectant in solution. Preferably, a humectant
 solution is used. Additional steps can be added, but it is crucial to the
 present invention that the humectant solution be added to hydrated
 legumes. The present method is especially desirable because it can be
 completed in a single step involving adding a humectant solution to
 hydrated legumes. The legumes can then be packaged and ready for use even
 if some of the humectant solution has not diffused into the legumes,
 meaning the legumes can be packaged in a humectant solution.
 Alternatively, the legumes can be dried and packaged without the humectant
 solution. It is emphasized that it is contrary to the presently claimed
 method to hydrate the legumes simultaneously with the addition of the
 humectant solution. Generally, the steps of the present method can include
 hydrating a selected amount of legumes, intermixing a humectant solution
 with the hydrated legumes so that the humectant in the solution will
 diffuse into the hydrated legumes, and drying the legumes after the
 infusion of the humectant. The hydrated legumes are developed by adding
 water thereto or by picking fresh legumes out of the field.
 The order in which the steps of the present method are performed is
 particularly important. If the humectant solution and water for hydration
 are combined in the same step, then it takes a greater amount of time at a
 higher temperature to hydrate the legumes. Additionally, pressure may be
 required to promote diffusion of the humectant into the legumes. Of
 greater importance than the time, is the fact that the legumes resulting
 from combining the hydration step with the humectant solution addition
 step are inferior to the legumes resulting from observing the order of the
 steps of the present method. As mentioned, the legumes produced according
 to the present method have a full complement of starch and protein, as
 well as, a desirable taste and appearance. If the humectant solution is
 added with the water in an attempt to hydrate the beans simultaneously
 with the exposure to the humectant solution, the resulting legume product
 will have an undesirable appearance and the sugars in the legume will have
 caramelized somewhat, thereby altering the taste and nutritional value of
 the treated legume. Also, the legume will not have a full complement of
 protein. Conversely, the present method produces legumes that have a
 natural looking appearance and a nutritional value similar to natural
 untreated legumes. Also, the flavor of the treated legumes is not altered.
 Most importantly, the sugars and proteins in the legumes of the present
 method have not significantly caramelized or been altered.

DETAILED DESCRIPTION
 The present method relates to a process for producing a low water activity
 legume, which can be ready to use in a short period of time, has long
 lasting shelf stability, can be fully or partially hydrated, and in
 general has a full complement of starch and protein, and the legume
 produced by the present process. Most preferably, the present method is
 used to produce low water activity beans, including both intermediate
 moisture and fully hydrated beans. Because the resulting treated bean has
 a low water activity, this prevents the treated bean from spoiling due to
 microbial and/or fungal growth. Low water activity inhibits microbial and
 fungal growth because water that is necessary for growth and propagation
 of the various microorganisms is not made available to the microorganisms.
 Additionally, low water activity prevents sprouting of the bean.
 The method of the present invention is initiated by selecting a legume
 which is suitable for human consumption. Potentially, any food stuff
 containing starch can be used with the present process; however, the
 selected legume is preferably a bean, but peas and other legumes may also
 be used. Because beans are the preferred legumes, beans will be referred
 to throughout the present application. Among the beans that may be used in
 the present method are chick peas, red beans, navy beans, pink beans,
 pinto beans, lentils, black eyed beans, fava beans, black beans, kidney
 beans, and a variety of other edible beans and combinations of beans.
 Once the variety of the beans is selected, an amount of beans to be
 produced by the present process is determined. The amount of beans
 selected for use in the present process will depend on the desired final
 use. In other words, the amount of beans treated will be based on whether
 the present method is part of a home process or an industrial food
 production process. However, the amount of beans that can be treated
 according to the present process can range from a singular bean to
 millions of pounds of beans. Preferably, the present process is part of an
 industrial process whereby the amount of beans treated is determined by
 the size of the mixing vats used to hydrate the beans or mix the beans
 with a humectant solution. Because the present process can be continuous,
 the only limitation on the amount of beans treated according to the
 present process will be the speed and size of the equipment and the amount
 of beans and humectant solution readily available. The most preferred
 amount of beans treated in the present process will range between about
 2000 pounds and about 10,000 pounds per batch. Among the processes that
 may be used with the present process are continuous, continuous-batch, and
 batch processes.
 Once the beans are selected and fully hydrated, as a result of picking
 fresh beans or mixing the beans with an amount of water, they are mixed
 with an amount of humectant solution sufficient to lower the water
 activity of the beans to a range of between about 0.50 and about 1.00, to
 maintain a level of hydration in the beans greater than 40% total moisture
 in the beans, and to cause an amount of the humectants in the humectant
 solution to diffuse into the beans with the amount of humectants in the
 beans equal to from between about 0.1% by weight to about 15% by weight of
 the beans. More preferably the amount of humectants in the beans, as a
 result of using the present process, will range between about 5% and about
 10% by weight of the beans. Preferably, after the addition of the
 humectant solution the level of hydration in the beans is between about
 40% and about 60% total moisture in the beans and the water activity is
 equal to between about 0.75 and about 0.85.
 The humectant solution will result in the binding of free water molecules
 in the hydrated beans by the humectant, thereby lowering the water
 activity in the beans. Use of the humectant solution results in the
 humectants present in the solution migrating into the beans without
 significantly lowering the percentage of water in the beans. When the most
 preferred humectant solution is used with hydrated beans the water in the
 hydrated beans does not migrate out of the beans into the humectant
 solution in such a manner as to cause an overall weight loss in the
 treated beans, as shown in FIG. 1. Theoretically, a one to one exchange
 will occur between the humectant molecules present in the humectant
 solution and the water molecules present in the hydrated beans. However,
 an exchange may occur where one part humectant is exchanged for three
 parts water. The exchange can occur at a variety of temperatures,
 including, but not limited to, room temperature which prevents the
 caramelization of the sugars in the beans and the occurrence of Maillard
 browning which alters the structure of the starches, carbohydrates, and
 proteins in the beans. By preventing caramelization and Maillard browning
 beans are produced that are very similar to untreated fresh beans.
 As mentioned, the humectant solution can be mixed with the beans at room
 temperature; however, any temperature can be used that allows for the
 diffusion of the humectant into the beans and which does not result in the
 alteration of the starches, sugars, or proteins in the beans. Preferably,
 the temperature of the hydrated beans and humectant solution mixture will
 range between room temperature or about 25.degree. C. and about
 100.degree. C., with the most preferred temperature being about
 37.5.degree. C. The temperature selected will be the optimal temperature
 for allowing diffusion of the humectants into the beans without the
 diffusion time being excessive by industry standards and without altering
 the structure of the beans.
 The amount of humectant solution added to the hydrated beans must be
 sufficient to result in diffusion of the humectant into the beans and the
 lowering of the water activity in the beans, while maintaining the
 percentage of water in the beans between about 20% and about 65% total
 moisture in the beans. The amount of humectant solution added is dependent
 in part on the particular humectant in the solution. More preferably, the
 amount of water in the beans is between about 40% and about 60% total
 moisture in the beans. Preferably, the amount of humectant solution added
 to the beans will equal a ratio of 1 part by weight of hydrated beans to 3
 parts by weight of humectant solution. A greater amount of humectant
 solution can be used, however, eventually it becomes cost prohibitive. An
 alternative embodiment is 1 part by weight of hydrated beans to 1 part by
 weight of humectant solution. Still another way to determine how much
 humectant solution should be added to the hydrated beans is to simply add
 from about 0.1 parts by volume to about 10 parts by volume of humectant
 solution to about 1 part by volume of beans. Preferably, the humectant
 solution is added in an amount equal to from about 1 part by volume to
 about 3 parts by volume of humectant solution to 1 part by volume of
 hydrated beans.
 The humectant solution is mixed with the hydrated beans for a time period
 equal to from about 1 minute to about 12 hours dependent upon the amount
 of water present in the beans and the humectant solution. The time period
 will also be dependent in part upon the temperature of the humectant
 solution and the desired water activity in the beans. The more preferred
 time for mixing the hydrated beans and humectant solution is equal to
 between about 5 minutes and about 45 minutes, with the most preferred time
 period for mixing the hydrated beans and humectant solution equal to about
 15 minutes. As shown in FIG. 1, it is important for the beans to maintain
 their weight prior to treatment or to gain weight as a result of the
 treatment. What the maintenance of weight or weight gain means is that the
 beans are not losing water as a result of the treatment. FIG. 1 shows that
 certain humectant solutions can initially cause the loss of water from the
 beans. The most preferred humectant solution will not cause a loss of
 water and the humectants will adequately diffuse into the bean within 15
 minutes.
 The humectant solution is formed by combining an amount of water and an
 amount of humectant to form the humectant solution. Any food grade
 humectant can be used in the humectant solution. Examples of food grade
 humectants include, but are not limited to, glycerol or glycerin(e),
 propylene glycol, polyglycols, polyols, sugar alcohols, and simple sugars
 including sucrose, fructose, glucose, galactose, and lactose, as well as
 mixtures thereof. The amount of water to humectant used in the humectant
 solution will vary according to the selected humectant to be used in the
 humectant solution. Certain humectants more readily attract water than
 other humectants, for example propylene glycol, which means a lesser
 amount of humectant will be needed in the humectant solution. If too much
 humectant is used it will pull too much water out of the hydrated beans,
 thereby preventing the formation of a fully hydrated low water activity
 bean. Also, the use of too much humectant may increase the length of time
 of treatment. Thus, the amount of humectant used in the humectant solution
 must be an amount sufficient to lower water activity while preventing the
 hydrated bean from becoming at least partially dehydrated. Typically, the
 humectant solution will be comprised of an amount of water equal to from
 about 0% to about 99% by weight of total humectant solution and an amount
 of humectant equal to from about 100% to about 1% by weight of the total
 humectant solution. More preferably, the humectant solution will be
 comprised of an amount of water equal to from about 30% to about 70% by
 weight of total humectant solution and an amount of humectant equal to
 from about 70% to about 30% by weight of the total humectant solution.
 Generally, if certain humectants are used the amount of humectant in the
 humectant solution will be equal to the percentage of moisture in the
 hydrated beans. A preferred example of a humectant solution contains an
 amount water equal to about 44% by weight of the total humectant solution
 and an amount of glycerine equal to about 56% by weight of the total
 humectant solution to be used with hydrated beans having a moisture level
 equal to or greater than 56% total moisture. The preferred humectant
 solution is added to an amount of hydrated beans for a time period equal
 to about 15 minutes. Dependent upon the amount of water in the beans and
 the type of humectant selected the composition of the humectant solution
 can be altered.
 As mentioned, the beans need to be hydrated before treatment with the
 humectant solution. If the beans are not hydrated, then additional steps
 must be included in the present method. Additionally, some of the steps
 mentioned hereinafter can be used regardless of whether the bean is
 hydrated initially. If the beans are dehydrated initially, they are placed
 in a mixing vat and mixed with a selected amount of water. The amount of
 water added to the mixing vat will be dependent upon the amount of water
 necessary to adequately hydrate the beans within a desired amount of time.
 Any amount of water can be used that is sufficient to hydrate a selected
 amount of beans to an amount of about 40% to about 60% total moisture in
 the beans and preferably about 50% to about 55% total moisture in the
 beans. The amount of water added will be in part dependent upon the bean
 variety, as the amount of water absorbed by the bean variety will depend
 upon the amount of starch in the bean variety. A typical dehydrated bean
 contains from about 5% to about 8% total moisture and from about 95% to
 about 92% solid matter, a preferred hydrated bean will contain about 50%
 total moisture and about 50% solid matter, with the mass of the bean
 increasing as a function of the absorption of water. Typically, the beans
 are mixed with an amount of water equal to a ratio of about 1/3 by volume
 of beans to about 2/3 by volume of water. Thus, for example, approximately
 2000 pounds of beans can be mixed with water in excess of about 1800
 pounds of water to equal about 3800 pounds of hydrated beans. The mixing
 chamber may range in size from a pot capable of being used on a stove top
 to an industrial sized chamber capable of holding about 50,000 pounds of
 the bean and water mixture or more. Generally, the amount of beans treated
 with the present method will range between about 2000 pounds of beans per
 batch and about 50,000 pounds of beans per batch.
 When the beans are placed in the mixing chamber the water added thereto
 will have a temperature ranging between room temperature or about
 20.degree. C. and about 100.degree. C. The more preferred water
 temperature will equal about 100.degree. C. Additionally, the mixing
 chamber may be jacketed so as to maintain the preferred water temperature
 range and may also have a mixing paddle or similar device that can be used
 to actively mix the bean and water mixture. Other means can be used
 besides a jacketed mixing chamber to maintain the water temperature.
 Mixing the bean and water mixture is desirable because this helps speed
 hydration of the beans; additionally, as the temperature of the water is
 raised so is the speed of hydration. Potable water or clean water is
 preferred because it will minimize the microbial load carried into the
 mixing process.
 Typically, the beans take between 0 and eight (8) hours to hydrate in water
 temperatures ranging between about 20.degree. C. and 100.degree. C., which
 is hydration according to the standard methods in the industry.
 Preferably, the beans are placed in the water for between 0 and two (2)
 hours at 100.degree. C. The beans will hydrate at a faster rate in water
 having a higher temperature, so that as the temperature of the water is
 raised the beans will hydrate faster. Regardless of the time and
 temperature, the beans must be fully hydrated meaning the moisture level
 in the beans should be from about 40% to about 60% of the total moisture
 percentage in the beans. The preferred moisture level will be equal to
 about 50% of the total moisture percentage in the beans.
 After the beans have been hydrated, the excess water remaining in contact
 with the beans is removed from the mixing chamber. In place of the water
 the humectant solution is added to the mixing chamber. Instead of draining
 the excess water, an alternative method can be used wherein the humectant
 solution is formed in the tank using the excess water.
 An alternative to determining the amount of humectant solution added to the
 beans is to add the humectant solution in an amount equal to from about
 0.1% to about 100% by volume of the total water added in the hydration
 step of the present method. The humectant solution is added in amount
 equal to from about 60% to about 100% by volume of the total volume of
 water used to hydrate the beans, with the most preferred amount of
 humectant used equal to about 100% by volume of the total volume of water.
 Regardless of how the humectant solution is added, enough of the humectant
 solution must be added to lower the water activity in the beans to between
 about 0.50 and about 1.00.
 An additional element that can be added is salt, preferably sodium
 chloride. The salt can be added in the hydration step or with the
 humectant solution. The amount of salt added is equal to between about
 0.1% and about 10% of the total amount of water in the hydrated beans,
 with the salt enhancing the preservation characteristics of the treated
 beans.
 Another constituent, an acidulant or a like composition can be added to the
 hydrated beans prior to, simultaneous with, or after the exposure of the
 beans to the humectant solution. Any acidulant can be used, however, the
 preferred acid is a food grade acidulant, such as food grade acetic acid
 or phosphoric acid. The acetic acid can be added in amount equal to from
 about 0.01% to about 50% by volume of the total solution in the mixing
 chamber, which is either the total water or humectant solution present in
 the mixing chamber. The preferred amount of acetic acid added is equal to
 about 10% or less by volume of the total water or humectant solution
 present in the mixing chamber. The addition of the acetic acid is
 desirable because it speeds or enhances the hydration of the beans, kills
 the bean embryo, and enhances the preservation characteristics in the
 treated bean. Killing the bean embryo is desirable because this will
 eliminate any chance of sprouting of the bean after it has been packaged,
 as water can enter the packaging. The acetic acid helps to preserve the
 treated beans by preventing the growth of microorganisms, such as bacteria
 and fungus or molds, which could be present in the beans or the water used
 to hydrate the beans. The acetic acid lowers the pH of the bean and water
 or bean and humectant solution thereby killing the microorganisms. Among
 the food grade acidulants that may be used are food grade acetic acid,
 phosphoric acid, food grade hydrochloric acid, citric acid, malic acid,
 lactic acid, ascorbic acid, erythorbic acid, and combinations thereof.
 Also, phosphates can be used as an acidulant. Whichever acid is selected
 it is preferred to select enough of the acid to lower the pH in the beans
 to below 4.5. While a pH below 4.5 is most preferred, the acid can be
 added in amounts sufficient to lower the pH in the beans to from about 6.0
 to about 2.0. Acetic acid is most preferred because it volatizes easily
 when the treated beans are prepared at home or in retail channels. Also,
 the acetic acid can speed the hydration of the beans by opening
 microscopic pores or channels in the bean. It should be pointed out that
 the coupling of lowering water activity and treating the beans with acid
 will protect against microorganisms and thus result in greater
 preservation characteristics in the beans.
 After the beans have been sufficiently exposed to the humectant solution so
 as to lower the water activity in the beans, the beans are removed from
 the mixing chamber and the excess moisture may be optionally removed from
 the beans. Removal of the excess moisture from the surface of the beans
 may be accomplished by drying the beans in any device capable of removing
 excess water from the beans without scorching the skin of the beans. The
 beans can be dried at a temperature ranging between about 32.degree. C.
 and any temperature below scorching the bean skin. The time period for
 drying the beans will be equal to a time period ranging between about 0 to
 about 3 hours. Among the devices that may be used to dry the beans are a
 drum dryer, flash dryer, tunnel dryer, flat bed dryer, and a fluid bed
 dryer. Regardless of the parameters chosen the beans must be dried in such
 a manner so as to preferably lower the moisture level in the beans to from
 about 55% to about 20% of the total moisture in the beans. The reduced
 moisture beans are then ready to be commercially packaged or placed into a
 food stuff for human consumption.
 An alternative step to drying the beans involves packing the beans in a
 humectant solution. Enough of the humectant solution can be added so as to
 cover all of the beans in the packaging. The humectant solution used to
 package the beans should have a similar ratio of water to humectant, as
 the humectant solution used to treat the beans so as to maintain the water
 humectant equilibrium in the beans.
 The beans treated according to the present process are desirable because
 they will have a natural looking appearance, low water activity which will
 prevent spoilage, and allow for a ready to use bean within 5 to 10 minutes
 of placement into boiling water. While boiling water is the preferred way
 to make the low water activity bean ready to use, the bean can be made
 ready to use by placing the bean in an aqueous solution having a
 temperature of at least 15.degree. C. for at least five (5) minutes. The
 beans treated according to the present invention are especially desirable
 when compared to dehydrated beans which typically require overnight
 soaking followed by boiling the beans in order for the beans to be ready
 for use.
 EXAMPLES
 Example 1
 Reduced water activity fully hydrated red beans were produced by mixing 453
 grams of dehydrated red beans containing approximately 6% moisture by
 weight of the total beans or 28 grams of water with enough water to cover
 the beans with an excess amount of water, such that the beans were covered
 with 2 inches of tap water. The beans were soaked in the tap water for
 approximately eight hours in a standard three quart stainless steel pot.
 At the end of eight hours the water that had not migrated into the beans
 was separated from the beans which had become fully hydrated. The hydrated
 beans weighed 923 grams, meaning they absorbed approximately 470 grams of
 water. The hydrated beans contained a total moisture content of
 approximately 53.95% total moisture by weight of the beans and an amount
 of solids equal to 47.05% solids by weight of the beans.
 After the hydrated beans were prepared, a humectant solution was prepared.
 The humectant solution contained 200 grams of water and 250 grams of
 glycerin USP 96% manufactured by The Dow Chemical Company, Midland, Mich.
 Thus, the humectant solution was comprised of an amount of water equal to
 approximately 44% by weight of the total humectant solution and an amount
 of glycerin or humectant equal to about 56% by weight of the total
 humectant solution.
 150 grams of hydrated beans were then mixed with 450 grams of the humectant
 solution in a stainless steel pot. The beans were mixed with the humectant
 solution at room temperature for 15 minutes. At the completion of 15
 minutes the beans weighed 159.4 grams and there was approximately 438
 grams of humectant solution remaining in the stainless steel pot. This
 means that the hydrated beans absorbed approximately 9.4 grams of
 humectant solution.
 The finished beans had a natural color and texture and a water activity of
 approximately 0.85. Some of the beans (approximately 50 grams) were then
 heated in water for ten minutes after completion of the process and were
 table ready at the completion of the ten minute time period. Also, some of
 the beans, the remainder, were stored in a refrigerator at 4.degree. C.
 for 60 days, so that after the passage of the 60 days the beans were not
 spoiled and had not sprouted.
 Example 2
 150 grams of the hydrated red beans of Example 1 were mixed with 450 grams
 of the humectant solution produced according to the method recited in
 Example 1. The hydrated beans and humectant solution were mixed together
 for approximately 30 minutes. The finished beans had essentially the same
 characteristics as the beans disclosed in Example 1.
 Example 3
 150 grams of the hydrated beans of Example 1 were mixed with 450 grams of
 the humectant solution produced according to the method recited in Example
 1. The hydrated beans and humectant solution were mixed together for
 approximately five (5) minutes. At the completion of five minutes the
 beans weighed 145.2 grams and the humectant solution weighed 454 grams.
 This means that the humectant solution actually caused water to diffuse
 out of the hydrated beans and reduced the level of hydration in the beans.
 This shows that before the humectants diffused into the beans some of the
 water diffused out of the beans. Thus, sufficient exposure time must occur
 for the beans to have the humectant adequately diffuse into the beans.
 Thus, there has been shown and described a novel method for producing
 reduced water activity legumes which fulfills all of the objects and
 advantages sought therefor. It will be apparent to those skilled in the
 art, however, that many changes, variations, modifications, and other uses
 and application for the subject method are possible, and also changes,
 variations, modifications, and other uses and applications which do not
 depart from the spirit and scope of the invention are deemed to be covered
 by the invention which is limited only by the claims which follow.