METHOD AND APPARATUS FOR TREATING FRESH VEGETABLE PRODUCTS

Abstract: A method and apparatus for treating fresh harvested vegetable products such as herbs and spices includes a conveyor system for moving the product from a supply to a chilled water washing station which includes a drain portion; at a second station the product is steeped in a solution of citric and ascorbic or erythorbic acid and then drained; the product is then dried quickly at a third station in a fluidized bed dryer and then passed to heated huxectant bath at a fifth station and then drained again; at a sixth station, the product is rapidly cooled in a cooling chamber; at a seventh station the product may be destemmed and then chopped and packaged.

Description: BACKGROUND AND SUMMARY OF THE INVENTION The present invention relates to treatment of fresh vegetable products and particularly fresh herbs and spices so as to preserve the desirable qualities of these products while extending their shelf life. In the packaged food field, attempts have been made to package vegetable products so that the qualities or characteristics of the products will remain stable over extended periods thus enabling food merchants to stock such products for sale to consumers while reducing losses due to spoilage. In many of such products, some of the characteristics that cause consumers to purchase them are difficult to preserve for extended periods without sacrificing other qualities of these products. This problem is especially acute with fresh herbs such as those of the leafy types and a number of spices. Specifically, it is desired to preserve the color, flavor, aroma and overall natural or comminuted appearance of such products while enabling a producer to package the product with available packaging equipment and without resort to special types of containers while providing an extended shelf life for the packaged product. Early endeavors in this field which have emphasized the extension of self life have resorted to treatments of the fresh vegetable product which include rather severe dehydration of the product. Sterilization by heat, irradiation, or chemical sterilizers have also been used. The adverse impact of such processes on a number of characteristics of the products are well known and marketing demands for fresh appearing products have lessened interest in such techniques. More recent attempts to provide better appearing and tasting products have employed a variety of chemical preservatives to maintain appearance and extend shelf life. While some of these have been successful in extending shelf life, the use of such chemicals has not been attractive to consumers. In some instances, these types of preservatives detract from the taste quality of the product and some of the preservatives are no longer permitted in combination with food products. Still other procedures involve substantial alteration of the fresh product so that the natrual appearance characteristics are substantially abandoned. For example, some products are finely chopped and mixed with natural or blended oils. Others have been pureed or packaged as pastes, which are mixed with available anti-oxidants and chemical preservatives. Food processors have also used canning or freezing but these alternatives will also adversely affect the significant properties of the vegetable product. DE-A-3,624,035 discloses a process for treating a vegetable product with a solution containing citric acid, ascorbic acid and between 1 and 10% glycerine. In Food Technology 38, 138 (1984) there is disclosed an anti-oxidant preparation comprising citric acid, ascorbic acid and propylene glycol. In accordance with a first aspect of the present invention there is provided a method of treating fresh vegetable product such as spices, herbs and the like comprising the steps of: a. washing the product with a first liquid bath including an anti-browning solution; b. removing excess surface liquid of the first bath; c. immersing the product in a second liquid bath containing an humectant at a temperature of between 80-150°C to lower the water content of the product; d. removing excess surface liquid of the second bath. In a second aspect the invention provides a method of treating fresh vegetable product such as spices, herbs and the like comprising the steps of: a. washing the product with a chilled liquid; b. washing the product with a first liquid bath including an anti-oxidant acid solution where the acid is a mixture of citric acid and an acid selected from the group consisting of ascorbic acid and erythorbic acid; c. removing excess surface liquid of the first bath by draingin the product, and, subsequent to draining the product, drying the product to reduce the moisture content of the product to a selected level; d. immersing the product in a second liquid bath maintained at a selected elevated temperature of between 80° to 150°C and containing an humectant to lower the water content of the product, wherein the humectant is selected from the group consisting of glycerine, sorbitol and proplyene glycol; e. removing excess surface liquid of the second bath by draining the product; f. cooling the product by passing the product through a cooling chamber the atmosphere of which is maintained at approximately -18° to 8°C for an interval of time such that the temperature of the product is reduced to at least ambient temperature. In a third aspect, the invention provides apparatus for carrying out the methods of the first and second aspects of the invention, which apparatus comprises a conveyor means for transporting the product from a supply to a discharge point, a washing means for washing the product with a liquid, said washing means including a drain portion and being located to receive the product discharged at said discharge point, said washing means including conveyor means for carrying the product through said washing means to said drain portion to another discharge point, a first bath container means including a drain section for containing an anti-oxidant liquid agent located adjacent said another discharge point, said first bath container means including conveyor means for carrying the product through said washing means to said drain section thereof to another discharge point, a drying chamber, a second bath container means for a liquid humectant, transport means for moving the product from said another discharge point of said first bath container means to and through said drying chamber and for depositing the product in said second bath container means, means for heating the contents of said second bath container means to a selected temperature, said second bath container means including conveyor means for carrying the product therethrough to a drain portion located externally of said second bath container means, a cooling chamber, said drain portion including conveyor means for carrying the product therethrough and through said cooling chamber to a final discharge point. The methods and apparatus of the present invention are intended for treating freshly harvested vegetable products so that the important qualities thereof associated with freshness such as colour, natural appearance, flavour, taste, aroma and product integrity will be retained while the shelf life of the product will be appreciably extended as compared to an untreated product. In addition, the method of this invention will yield a product that is substantially free of pathogens, enzyme activities, yeats and molds and will exhibit low microbiological counts. In one embodiment, the method and apparatus for treating the vegetable products such as herbs and spices includes a conveyor system for moving the product from a supply to a chilled water washing station which includes a drain portion. A second station is provided where the product is steeped in a solution of citric and ascorbic or erythorbic acid and then drained. The product is then dried quickly at a third station in a fluidized bed dryer and then passed to a heated humectant bath at a fifth station and then drained again. At a sixth station, the product is rapidly cooled in a cooling chamber and, at a seventh station, the product may be destemmed, if required, and then, if desired, chopped to any desired piece sizes prior to being packaged. In a preferred form, the humectant used is synthetic or natural glycerine which is characterized by meeting the USP grade standard of 96% pure glycerine and about 4% water content. Also, the drying and cooling steps are preferably of very short duration which is beneficial not only in terms of the integrity of the product but also in enhancement of the production capacity of the method and apparatus. Most importantly, the method is capable of providing a satisfactory product without the use of commonly and previously employed chemical preservatives. The foregoing and other advantages will become apparent as consideration is given to the following detailed description and the accompanying drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a flow chart setting forth the method of this invention; and FIGURE 2 is a schematic illustration of the apparatus used with the method. DETAILED DESCRIPTION Referring now to the drawings, wherein like numerals designate corresponding parts throughout the views, there is shown in Figure 1 a flow chart showing the sequence of steps that may be employed in the present invention. It is desired that the process be substantially continuous so that, as is customary in production facilities, the speed of the throughput conveyors will be set to accommodate the step in the process requiring the greatest dwell time. In handling of freshly harvested herbs, it will be appreciated by those skilled in the art that for different herbs, different specific treatment times throughout the steps of the process may be required. While Figure 1 will be self explanatory when read in conjunction with the following description of the apparatus and specific process steps of Figure 2, it will be noted that, in Figure 1, several alternative packaging processes are available to a user of the process after the final cooling step 10. The various packaging techniques presently available can be employed and their selection will, in large part, be determined by the type of vegetable product being treated. While the process for the present invention is theoretically applicable and useful with a wide variety of vegetable products, it is particularly applicable to preservation of herbs and spices as such products when freshly cut must reach the market within approximately three days and exhibit a shelf life of only approximately seven days. It is not uncommon for many leafy herbs and spices to lose much of their flavoring capacity relatively rapidly as compared to the more robust vegetable products such as cabbage, spinach, peas, carrots, tomatoes and the like. It is an object of the present invention to enable a food processor to treat the freshly harvested vegetable products such as herbs so that the treated product can be packaged conventionally and exhibit a shelf life of from four weeks to as much as three to six months without significant deterioration in the desirable qualities of appearance, color, flavoring capacity, aroma and overall product integrity. The process is especially useful with leafy herbs such as basil but can be used with a number of herbs and spices such as dill, marjoram, sage, thyme, oregano, rosemary, mint, parsley and similar vegetable products such as garlic, onion and those of the pepper family which include paprika, red pepper and similar products. In carrying out the process, the freshly harvested herbs are taken from a supply located upstream of a conveyor 12 which at its discharge end drops the vegetable product onto a second conveyor 14 which passes underneath a bank of spray nozzles 16. The nozzles 16 are preferably fed with chilled water at approximately 4°C from a tank 18. The conveyor 14 will of course be perforated so that the sprayed water will pass to a container 20 including an overflow outlet 22. As illustrated, the leftward portion of the conveyor 14 will function as a washing area while the rightward portion will function as a draining area. At the discharge end 24, the vegetable product will be deposited in a first bath container 26 over the leftward portion of which a second bank of nozzles 28 are provided for spraying an anti-oxidant solution, as described below. In the container 26, a sloped transport conveyor 30 is provided, the leftward portion of which is substantially submerged beneath the liquid level 32, which is maintained by operation of a suitable drain 34, as is conventional. The rightward portion of the conveyor 30 extends above the liquid level 32 to thereby function as a drain portion. Each of the conveyors of the process are preferably of the endless belt type and should be made of stainless steel wire mesh to facilitate drainage and minimize transporting of the liquid of each bath. The anti-oxidant solution sprayed from the nozzles 28 may be supplied from a make-up tank 36. The solution is preferably an anti-oxidant reducing agent and it has been found that a combination of citric acid and ascorbic acid in a solution of 0.1 to 1.0 percent by weight in water is suitable for retarding browning which results from oxidation of the many vegetables products but particularly those of the leafy type. The ascorbic acid may be replaced with erythorbic and the throughput speed in the container 26 will, of course, depend upon the character and quantity of the vegetable product being treated. Other anti-oxidants may be employed such as, for example, sodium bisulfite. In general, steeping need not consume any more time than sufficient to completely cover the surfaces of the product. Each treatment tank station 20 and 26 may employ a deep tank for submerging the product for treatment instead of spraying or a combination of spraying and submersion may be used. From the discharge end of conveyor 30, the drained product is transported by a transport conveyor to a fluidized bed drying chamber 38. At this point, the product can be destemmed to facilitate the subsequent treatment. In general, the stems of the plants have no value and the presence of the stems can delay processing due to the size of the stems. In this arrangement, the transport conveyor may simply extend into the interior of the chamber 38 or it may discharge to another conveyor which performs the function of transporting the vegetable product into the chamber 38. Preferably, the fluidized bed dryer applies heated air within the temperature range of 27° to 38°C for a length of time sufficient to reduce the moisture content of the vegetable product to a level of between 30% to 80% by weight but, preferably, on the order of 60% to 70%. The drying removes any remaining excess surface liquid. From the fluidized bed drying chamber 38, the product is deposited at one end of a second bath container 40 in which is located a substantially submerged endless belt conveyor 42. Since any vegetable products, especially herbs, may have some buoyancy in liquid, a submerging conveyor 44 is also provided having a lower side located beneath the liquid level 43. The second container bath serves to immerse the vegetable product in an humectant which may be one of glycerin, sorbitol, propylene glycol and other polyhydric water binders or a combination of these. In a preferred embodiment, synthetic glycerin is employed as it has very stable properties and exhibits no unpleasant aftertaste. As is known, a humectant will draw water from wet organic matter such as vegetable products. Further, according to the present invention, the humectant is heated to a temperature within the range of 80° to 150°C to facilitate penetration of the humectant into the vegetable product as well as to substantially, if not completely, terminate enzyme and microbiological activity in the vegetable product. As a result of treatment in the bath 40, the water level of the vegetable product will be further reduced so that the resulting water activity of the product, as that term is defined in British Patent 2014429A, will be in the order of 0.6. One of the objects of the present invention is to render the vegetable product negative in terms of peroxidase activity. As has been recognized, peroxidase is an enzyme that is relatively more resistant to inactivation by heat than other detectable enzymes which exist in fresh vegetable products. A reliable test for peroxidase activity is discussed by Kramer and Twigg in their work "Quality Control for the Food Industry", Vol. 2, p 210. It will be appreciated then that a negative test result for peroxidase will serve as a good indicator of the success of the process of this invention in terminating harmful enzyme activity. By way of example, treatment of samples of basil in the process of the present invention was carried out where the second bath container was glycerin at approximately 95°C and the treatment duration was for two minutes. The water activity was reduced to 0.65 and the resulting shelf life at a temperature range of 4°C to 33°C was approximately three to six months without appreciable change in appearance and with non-detectable enzyme activity and no significant microbiological counts. Flavor and aroma values were retained. A monitoring system 46 for the bath 40 is preferably employed, particularly in high production capacity facilities. In such a system, sampling of the bath will be effected and the water content measured using one of the wet chemistry methods, e.g., titration, instrumental analysis or conventional heating methods. When the monitoring device detects a level of water in the sample above a selected amount, an alarm can sound to alert a worker to adjust the glycerin/water ratio in the bath 40 to offset the accumulated water. Alternately, automatic monitoring and dispensing of the required amount of glycerin can be effected with available process control techniques. From the discharge end of the conveyor 42, the product is passed to a drain conveyor 50 located above a container 52 in which drippings of glycerin can be recovered and recycled back to the bath 40. Thereafter, on the conveyor 50, the product is passed to a cooling chamber 54 where the product is quickly chilled to halt the effects of any residual heat from the bath 40. The duration of treatment should be such that at the least, the temperature of the product is lowered to room temperature or approximately 20°C although lower temperatures, if desired, can be achieved. Preferably the cooling is effected in five minutes or less. From the cooling chamber 54, some types of vegetable products such as those having large stems that have not previously been removed can be passed to a destemming zone 56 where destemming is carried out. Thereafter, several options are available to a user of the process. Specifically, some types of herbs and spices are conventionally chopped or finely comminuted prior to packaging. Others are simply packaged such as the leafy herbs. In such circumstances, it may be desirable to employ vacuum packaging as contemplated in the schematic of Figure 1. Vacuum packaging or controlled atmosphere packaging is presently available and can be usefully employed with a number of herbs and spices. The process of the present invention and the apparatus lend themselves to batch processing in large quantities so that the operator will have the option of diverting selected portions of the output of the process to one of several packaging alternatives.

Claims: 1. A method of treating fresh vegetable product such as spices, herbs and the like comprising the steps of: a. washing the product with a first liquid bath including an anti-browning solution; b. removing excess surface liquid of the first bath; c. immersing the product in a second liquid bath containing an humectant at a temperature of between 80-150°C to lower the water content of the product; d. removing excess surface liquid of the second bath. 2. The invention as claimed in claim 1, including the step of washing the product prior to step (a). 3. The invention as claimed in claim 2, wherein the step of washing the product prior to step (a) includes washing the product with a chilled liquid. 4. The invention as claimed in claim 1, wherein the step of washing the product in the first bath includes using a mixture of citric and ascorbic acid in water in the first bath. 5. The invention as claimed in claim 4, wherein the mixture is a solution of 0.1% to 1.0% of citric and ascorbic acid mixture. 6. The invention as claimed in claim 1, wherein the step of washing the product in the first bath includes using a mixture of erythorbic and citric acid in water in the first bath. 7. The invention as claimed in claim 6, wherein the mixture is a solution of 0.1% to 1.0% of erythorbic and citric acid solution. 8. The invention as claimed in claim 1, wherein the step of removing excess surface liquid includes draining the product. 9. The invention as claimed in claim 8, wherein the step of removing excess surface liquid further includes, subsequent to draining the product, drying the product to reduce the moisture content of the product. 10. The invention as claimed in claim 9, wherein the step of drying the product includes exposing the product to heat sufficient to reduce the moisture content of the product to a level of between 30% to 80% by weight. 11. The invention as claimed in claim 9, wherein the step of drying the product includes exposing the product to heat sufficient to reduce the moisture content of the product to a level of between 60% to 80% by weight. 12. The invention as claimed in claim 9, wherein the step of drying includes using a fluidized bed dryer to dry the product. 13. The invention as claimed in claim 12, wherein the step of drying includes passing air at a temperature of approximately 25 to 38°C by the product. 14. The invention as claimed in claim 1, wherein the humectant is selected from the group consisting of glycerine, sorbitol and propylene glycol. 15. The invention as claimed in claim 1, wherein the second bath is glycerine. 16. The invention as claimed in claim 1, wherein the second bath is synthetic glycerine. 17. The invention as claimed in claim 1, wherein during step (d), the method includes the step of recovering the liquid of the second bath and recycling the recovered liquid to the second bath. 18. The invention as claimed in claim 1, wherein subsequent to step (d), the method includes the step of cooling the product. 19. The invention as claimed in claim 18, wherein the step of cooling the product comprises passing the product through a cooling chamber the atmosphere of which is maintained at approximately -18 to 8°C for an interval of time such that the temperature of the product is reduced to at least ambient temperature. 20. The invention as claimed in claim 1, including the step of comminuting the product subsequent to step (d). 21. The invention as claimed in claim 1, wherein the product is of the type having a stem and the method includes the step of destemming the product subsequent to step (d) and followed by the step of comminuting the product. 22. The invention as claimed in claim 20, further including the step of packaging the product directly after the comminuting step. 23. The invention as claimed in claim 18, including the step of comminuting the product subsequent to step (d). 24. The invention as claimed in claim 18, wherein the product is of the type having a stem and the method includes the step of destemming the product subsequent to step (d) and followed by the step of comminuting the product. 25. The invention as claimed in claim 23, further including the step of packaging the product directly after the comminuting step. 26. The invention as claimed in claim 1, including the step of monitoring the concentration of the humectant in the second bath and adding additional humectant in the event the concentration thereof is detected to be below a selected value. 27. The invention as claimed in claim 1, wherein conveyor means are provided to move the product through steps of the method and the method includes the step of moving the product on the conveyor means from a supply through the first bath. 28. The invention as claimed in claim 27, wherein the conveyor means includes porous sections and at least portions of the draining steps take place on said porous sections. 29. A method of treating fresh vegetable product such as spices, herbs and the like comprising the steps of: a) washing the product with a chilled liquid; b) washing the product with a first liquid bath including an anti-oxidant acid solution where the acid is a mixture of citric acid and an acid selected from the group consisting of ascorbic acid and erythorbic acid; c) removing excess surface liquid of the first bath by draining the product, and, subsequent to draining the product, drying the product to reduce the moisture content of the product to a selected level; d) immersing the product in a second liquid bath maintained at a selected elevated temperature of between 80° to 150°C and containing an humectant to lower the water content of the product, wherein the humectant is selected from the group consisting of glycerine, sorbitol and propylene glycol; e) removing excess surface liquid of the second bath by draining the product; f) cooling the product by passing the product through a cooling chamber the atmosphere of which is maintained at approximately -18° to 8°C for an interval of time such that the temperature of the product is reduced to at least ambient temperature. 30. The invention as claimed in claim 29, wherein the step of cooling the product is completed within five minutes. 31. The invention as claimed in claim 1, wherein the product includes stems and including the step of removing the stems prior to passing the product to the second liquid bath. 32. Apparatus for carrying out the method of any one of claims 1-31 comprising: conveyor means for transporting the product from a supply to a discharge point, a washing means for washing the product with a liquid, said washing means including a drain portion and being located to receive the product discharged at said discharge point, said washing means including conveyor means for carrying the product through said washing means to said drain portion to another discharge point, a first bath container means including a drain section for containing an anti-oxidant liquid agent located adjacent said another discharge point, said first bath container means including conveyor means for carrying the product through said washing means to said drain section thereof to another discharge point, a drying chamber, a second bath container means for a liquid humectant, transport means for moving the product from said another discharge point of said first bath container means to and through said drying chamber and for depositing the product in said second bath container means, means for heating the contents of said second bath container means to a selected temperature, said second bath container means including conveyor means for carrying the product therethrough to a drain portion located externally of said second bath container means, a cooling chamber, said drain portion including conveyor means for carrying the product therethrough and through said cooling chamber to a final discharge point. 33. The invention as claimed in claim 32, wherein said second bath container means includes monitoring means for monitoring the condition of the contents of said second bath container means. 34. The invention as claimed in claim 33, wherein said monitoring means includes conditioning means for restoring the condition of the contents of said second bath container means in response to detection of a selected condition. 35. The invention as claimed in claim 32, wherein said draining portion includes means for passing material recovered by said draining portion to said second bath container means.

Inventors: ALBRECHT JAMES JOSEPH, HSIEH RON CHING
Applicants: MCCORMICK & COMPANY, INC.
Application year: 1988
Main classification: A23B7
IPC codes: A23B7