Patent Publication Number: US-2006008558-A1

Title: Packaged peanut product and method of production

Description:
BACKGROUND OF THE INVENTION  
      1) Field of the Invention  
      The present invention relates to the preservation and packaging of seasonal fresh green peanuts in-shell to maintain the fresh flavor and texture of the green peanuts for use in making a boiled peanut snack food during out of season months for fresh green peanuts.  
      2) Description of Related Art  
      Coinsurers claim that truly delicious boiled peanuts can only be made using freshly dug green peanuts. Only in peanut growing areas are green peanuts readily available as they are highly perishable. Additionally, green peanuts are only available three to four months of the year, further reducing their availability. Therefore, outside of peanut growing areas, boiled peanuts snack foods are prepared using dried peanuts which yields a vastly inferior eating product. Frozen green peanuts are also used but produce an inferior eating product due to changes in texture and flavor as a result of freezing.  
      It is important to note that there is a difference between “green” peanuts and “raw” peanuts. Basically, the level of moisture inside the peanut is the basic difference between “green” and “raw” peanuts. Green peanuts have a higher water content so they must be refrigerated upon harvesting to maintain their freshness but have a very short shelf-life. Raw peanuts are air dried to lower the water content, which makes raw peanuts less perishable, but also provides less flavor and texture when used for making a boiled peanut product.  
      U.S. Pat. No. 5,330,781 discloses a method for preparing boiled and seasoned peanuts having an easily splitting shell. The method is directed to providing a finished peanut product for consumption, rather than preserving the freshness of green peanuts for later boiling. The method exposes the peanuts to extensive chemical and temperature processing that eliminate the fresh flavor and texture of the peanuts, but provides a read-to-eat packaged peanut product with a long shelf-life.  
      U.S. Pat. No. 4,816,270 discloses a method for producing processed peanuts which results in a dried peanut product having the taste of a boiled peanut. The method involves soaking the peanuts in water, boiling the peanuts together with shredded coconut, and microwaving the boiled peanuts until dried. There is no disclosure of a method for preserving fresh green peanuts for later boiling using minimal processing to preserve the flavor and texture of the green peanuts. While dried peanuts may be used to make boiled peanut snack foods, they produce a vastly inferior eating product without the texture of flavor of sought after fresh boiled green peanuts.  
      U.S. Pat. No. 2,510,534 discloses a process for cooking, salting, and storing unshelled green peanuts in a salt water filled, sealed container to produce a product ready for consumption. There is no disclosure of a method for preserving the freshness of the green peanuts for later boiling.  
      None of the cited patents show or disclose a process for storing fresh green peanuts to maintain their freshness for later boiling to produce a high quality boiled peanut during off season months for fresh green peanuts.  
      Accordingly, it is an object of the present invention to provide a method of storing fresh green peanuts for later boiling during off season months for fresh green peanuts while maintaining the flavor and texture of freshly dug green peanuts.  
     SUMMARY OF THE INVENTION  
      The above objective is accomplished according to the present invention by providing a packaged peanut product prepared according to a method which includes boiling fresh in-shell green peanuts in a hot water bath, air cooling the green peanuts after removing them from the hot water bath, packaging the green peanuts into a high gas barrier container while still warm from the hot water bath, vacuum sealing the container to remove air and seal the container in an airtight manner, submerging the container with the green peanuts in a cold tap water bath, and storing the container with the green peanuts in a refrigerated condition. As a result, the texture and flavor of fresh green peanuts can be preserved for an extended period of time by inhibiting enzymatic activity and microbial growth in the green peanuts without artificial preservatives or extensive high temperature pasteurization and processing.  
      Preferably, the green peanuts are rinsed in cold tap water to remove dirt and debris prior to boiling in the hot water bath.  
      Advantageously, the method preferably includes the step of boiling the green peanuts in the hot water bath for approximately 10 to 30 minutes, which is typically sufficient to inhibiting enzymatic activity and microbial growth in the green peanuts, although additional time may be required at higher elevations as the temperature of boiling water is lowered. In a further advantageous embodiment, the method includes adding salt to the hot water bath during boiling of the green peanuts.  
      In a preferred embodiment, the green peanuts are air cooling to a temperature range of between 100° F. to 175° F. Once cooled, the green peanuts are packaged into the container while within the temperature range of 100° F. to 175° F.  
      Preferably, the container with the green peanuts is submerged in the cold tap water bath until the green peanuts are chilled to the temperature of the cold tap water bath and then stored at a temperature of 38° F. or below.  
      The method also includes vacuum sealing the container using a low vacuum pressure that prevents boiling of remaining liquids in the container. High vacuum chamber methods commonly used in the food preparation industry will result in flash boiling of residual liquids on the peanuts. Accordingly, a nozzle type low vacuum system is necessary. To accommodate the nozzle type vacuum, preferably the container comprises a flexible plastic pouch having an opening for receiving the green peanuts which is sealed by crimping a metal clip around the opening following vacuumizing. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The construction designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:  
       FIG. 1  shows a representation of each step in the process according to the present invention; and,  
       FIG. 2  shows a flow chart of the method according to the present invention. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT  
      With reference to the drawings, the invention will now be described in more detail. Referring to  FIG. 1 , a process for preparing a packaged peanut product is depicted step-by-step. The process starts by providing freshly dug green peanuts, designated as reference number  10  in step  1 . The green peanuts remain in their shells throughout the process described herein. Preferably, the green peanuts are of the “Virginia Whites” variety on which the process described herein has been successfully tested, although the process will likely work equally well with other varieties of peanuts.  
      After harvesting, green peanuts  10  are rinsed in cold tap water  12 , shown in step  2 , to remove dirt, sand, and other debris from the shells of the green peanuts. Preferably, green peanuts  10  are washed two to three times to thoroughly remove contaminants before proceeding with the next step in the processing.  
      In step  3 , green peanuts  10 , remaining in their shells, are placed into boiling water. Preferably, a large cooking vessel such as a steam jacketed kettle  14  capable of holding at least five (5) gallons of water  16  is used for providing a hot water bath in which to boil green peanuts  10 . In the preferred embodiment, green peanuts  10  are vigorously boiled in the hot water bath for approximately 10 to 30 minutes to inhibit enzymatic activity which causes the peanuts to grow, as well as to inhibit microbial growth, such as yeast and vegetative bacteria cells in the green peanuts, making them stable to store for extended time periods of several months when the rest of the steps are completed. Additional boiling time may be required at higher elevations as the temperature of boiling water is lowered. In a further advantageous embodiment, the method includes adding salt  18  to the hot water bath during boiling of the green peanuts to help season, as well as preserve the peanuts during storage. The addition of salt is not, however, a necessary step and is done primarily as a matter of taste.  
      In step  4 , green peanuts  10  are removed from the boiling water and air cooled to a temperature range of between 100° F. to 175° F. Preferably, green peanuts  10  are placed on rack  20 , which allows for adequate drainage of excessive water from green peanuts  10 . Ideally, the peanuts are cooled no lower than 140° F. for the best results in texture and flavor, although the process can be successfully completed at any temperature within the stated range.  
      Next, moving on to step  5 , green peanuts  10  are packaged into a high gas barrier container  22  while still warm from the hot water bath. In the preferred embodiment, green peanuts  10  are packaged into container  22  while within the temperature range of 100° F. to 175° F., and ideally the green peanuts are not below 140° F.  
      Turning to step  6 , container  22  is vacuum sealed to remove air and seal the container in an airtight manner. In the preferred embodiment, container  22  is vacuumized using a low vacuum pressure to prevent boiling of remaining liquids in the container. High vacuum chamber methods commonly used in the food preparation industry will result in flash boiling of residual liquids on the peanuts. Accordingly, a nozzle type low vacuum system  24  is necessary. To accommodate nozzle type low vacuum system  24 , container  22  preferably comprises a flexible plastic pouch having an opening  26  for receiving green peanuts  10  and nozzle  28 . Once the air is vacuumed out of container  22 , the container is sealed by crimping a metal clip  32  around neck  30  following vacuumizing. This packaging method is for illustrative purposes of a preferred embodiment and the invention is not limited only to this packaging method as various other means of packaging are well known to those skilled in the art that will also work to vacuum seal the peanuts.  
      In step  7 , container  22 , having been fill with green peanuts  10  and vacuum sealed, is then submerged in a cold tap water bath  34  to cool green peanuts  10 . Preferably, container  22  is submerged in cold tap water bath  34  until green peanuts  10  are chilled to the temperature of the cold tap water bath, which stabilized green peanuts  10  for storage.  
      In step  8 , once green peanuts  10  have chilled, container  22  is stored in a refrigerated condition, designated generally as  36 . In the preferred embodiment, container  22  with green peanuts  10  is stored at a temperature of 38° F. or below. To achieve the best texture and flavor, containers  22  are stored in a refrigerated unfrozen condition and can be stored for a period of several months. However, acceptable flavor and texture can still be achieved if the containers are stored in a frozen condition, which extends the storage period substantially.  
      As a result, the texture and flavor of fresh green peanuts can be preserved for an extended period of time by inhibiting enzymatic activity and microbial growth in the green peanuts without artificial preservatives or extensive high temperature pasteurization and processing.  
      Referring to  FIG. 2 , a flow chart outlines the various steps in the process. In summary, the process for preparing a packaged peanut product begins by providing fresh green peanuts in the shell,  38 . The green peanuts are preferably washed in cold water to remove debris,  40 . The green peanuts are then boiled in water for approximately 10-30 minutes,  42 . Salt may be added to the boiling water if desired for taste,  44 . The green peanuts are air cooled after boiling to a temperature of range of between 100° F. to 175° F.,  46 . Next, the green peanuts are rapidly packaged into a high gas barrier container when within the stated temperature range,  48 . The container is vacuum sealed to maintain an air tight seal,  50 . The container is then placed in a cold water batch, preferably until the green peanuts are chilled to water temperature,  52 . Finally, the containers with the green peanuts are stored at a temperature below 38° F., preferably in an unfrozen condition,  54 .  
      While a preferred embodiment of the invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.