Patent Description:
Coconuts are popularly known for their great numbers of usages, ranging from traditional usages for food and cosmetics. Coconuts are part of regular dishes in many cultures around the world living in tropics and sub-tropics. The primary distinctiveness of coconuts from other fruits is they contain large quantity of drinkable "water", and when immature, are known as tender-nuts or jelly-nuts and may be harvested for potable coconut water. When coconuts mature, they still contain some water and can be used as seed nuts. They can also be processed to give oil from the kernel, charcoal from the hard shell, along with coir from their fibrous husk. Dried coconut flash is called copra. The oil and milk derived from coconuts are commonly used in cooking and frying, as well as in soaps and cosmetics. The husks and leaves can be used to make a variety of products for furnishing and decorating.

Naturally refreshing, coconut water has a sweet and nutty taste. It contains easily digestable carbohydrate in the form of sugar and electrolytes. Not to be confused with high-fat coconut milk or oil, coconut water is a clear liquid in fruit's center which is tapped from young and green coconuts. Coconut water has fewer calories, less sodium, and more potassium than any other sports drink. Ounce per ounce, most unflavoured coconut water contains <NUM> calories, <NUM> grams of sugar, <NUM> milligrams (mg) of potassium, and <NUM> of sodium compared to Gatorade, which has <NUM> calories, <NUM> grams of sugar, <NUM> of potassium, and <NUM> of sodium. As coconut water has less sugar than many sports drinks, sodas and some fruit juices, drinking coconut waters is always a better choice for adults and kids looking for a beverage that is less sweet.

Coconut water has always been a very popular drink in the tropical countries and getting popular beyond the tropics because of their healthy and thirst quenching water, which has increased consumer demand and triggered on increasing sales of the processed coconut water. Once the coconut water is exposed to the environment it becomes highly perishable for contamination and will lose all its nutrients. Shipping raw coconuts in its natural state is highly uneconomical because of their weight, size, and limited shelf life. Currently, standard process is followed for extending the shelf-life of young fresh coconut water is through high heat pasteurization. Coconut water is pasteurized, processed and stored in cans, bottles, canisters or boxes which kill all its nutrient, electrolytes and flavor, which in turn reduces consumer satisfaction and trust. One more method generally used for preserving coconut water is adding artificial flavors, stabilizers, and sweeteners for increasing the shelf life of coconut water, which reduce the natural flavor of the coconut water. After adding, artificial preservatives in to coconut water all its nutrients are destroyed. In some cases, coconuts are also preserved to increase the shelf-life by dipping in chemicals, but there is a high possibility of the chemicals seeping into, and poisoning the coconut meat and water.

Growing health consciousness and consumer demand for coconut water that contains natural flavor and nutrients has stimulated interest in finding alternative technology for preservation of coconut shell with coconut water and coconut meat. Different processes for production of frozen food products are currently known. For example, <CIT> discloses a method for isolating and freezing coconut water from coconuts. Either the coconut water is canned or frozen in containers with artificial preservatives or coconut meat is grated and stored in an airtight bag in the fridge. Most of the known processes do not assure preservation of fresh coconuts along with natural flavor, when they are thawed, mainly due to the large amount of water contained inside the coconut. Also, there is no method reported yet which preserves young coconut water inside its own natural environment and no known method to consistently and safely freeze fresh coconut inside its own natural environment without frequently breaking the coconut shell during the freezing process.

For these reasons, in view of above prior art, it is desired to have an improved system and a method for preparation of frozen coconuts, which preserve entire coconut shell intact with coconut meat and coconut water inside the coconut shell.

The primary objective of the present invention is to provide a method for preparation of frozen coconuts, which has coconut meat and coconut water enclosed and intact inside its own hardened coconut shells.

Another objective of the present invention is to provide a method for preparing frozen coconuts assuring there is no or virtually no damage to the coconut shell having coconut meat and coconut water, even after they are thawed after freezing.

Another objective of the present invention is to provide a method for preparing frozen coconuts, which do not lose their taste characteristics and which are similar to a fresh coconut.

Another objective of the present invention is to provide a method for preparing frozen coconuts in which untapped young coconut water is preserved inside its coconut shell for extended period of time without adding any preservatives in its natural environment.

Another objective of the present invention is to provide a method for preparing frozen coconuts comprising frozen young coconut water, untapped, untouched and preserved intact with coconut meat in its own confined coconut shell.

The invention provides a method according to claim <NUM>.

Embodiments in accordance with the present innovation disclose a method for preparing frozen coconuts using a shock freezing unit which is provided herein. Embodiments include harvesting <NUM> days old young coconuts having two layers of coconut meat and sorting of coconuts according to their sizes and quality. Further the method may include storing and resting of raw coconuts in ambient conditions for at least <NUM> days to reduce the inner pressure of coconuts. The embodiment further includes dehusking of outer green layer and fibrous husk of a raw coconut using a sharp edged weapon leaving the coconut shell without any or minimal amount of fibrous material on the outer surface of the dehusked coconut shell. The embodiment further include sorting of the coconut shell according to its size, thickness and weight. The embodiment further includes optionally polishing the outer hairs of the dehusked coconut using a polishing machine such as but not limited to a copper bristle polishing machine. The embodiment further includes optionally preventing of oxidation and contamination of the dehusked coconut shell surface and top husk cone by first immersing the dehusked coconut shell into one or several solutions, having antioxidant, anti-bug, anti-fungal and anti-mold properties, for preventing oxidation and contamination of the dehusked coconut shell surface and top husk cone. Said solutions can be organic or non-organic solutions such as but not limited to ascorbic acid solution or similar anti- browning solutions, the dehusked coconut shells are then taken out of one or several solutions and let get dry. The embodiment further includes weighing of the dehusked coconuts and moving the dehusked coconuts in a dry room until they lose more than <NUM>% of their initial weight. The embodiment further includes optionally sealing of dried dehusked coconut shell in vacuum bag using a vacuum sealing machine which make contact with the coconut shell and prevent any liquid leakage inside the bag by applying <NUM> even pressure around the dried dehusked coconut shell, which further prevents cracking of the dried dehusked coconut shell during further freezing process. The embodiment further includes placing the dried dehusked coconuts in a chilling room until the coconut water becomes partially slushy and inner pressure of the vacuum sealed coconut shell bag is further reduced to the levels at which the partially frozen vacuum sealed coconuts can then be completely frozen. The embodiment further includes placing the vacuum-sealed coconut shell bags containing the partially frozen coconuts in an individual container basket or coconut holding tray. The embodiment further includes flash freezing the partially frozen coconut so as to preserve its nutrients by either completely immersing the coconut holding tray in an insulated tub comprising cooling bath mixture for at least <NUM>-<NUM> minutes in between -<NUM> degree Celsius to -<NUM> degree Celsius depending on the batch size of partially frozen vacuum sealed coconut shell bags or by flash freezing the partially frozen coconut inside an air blast tunnel. The embodiment further includes storing the frozen coconut in a frozen storage unit having -<NUM> degree Celsius temperature, or -<NUM> degree Celsius, or -<NUM> degree Celsius, or any temperature at or below <NUM> degree Celsius.

In one embodiment in accordance with the present invention, the dehusked coconuts are rested for about three days in a dry room having less than <NUM> % humidity and over <NUM> degree Celsius temperature until they lost more than <NUM>% of their weight.

In one another embodiment in accordance with the present invention, the either vacuum sealed coconut shell bags or simply unpackaged dried dehusked coconuts are moved to a chilling room until the core temperature of the coconut reaches in between -<NUM> degree Celsius to -<NUM> degree Celsius for at least <NUM> days.

In one embodiment in accordance with the present invention, the coconut holding tray is immersed in an insulated tub containing cooling bath mixture for <NUM>-<NUM> minutes. The temperature range of cooling bath mixture is in between -<NUM> degree Celsius to -<NUM> degree Celsius. The cooling bath mixture is alcohol-based, and contains at least one of dry ice and liquid nitrogen, such as, but not limited to, mixtures of <NUM> % ethanol and dry ice, or mixtures of methanol and liquid nitrogen.

In one another embodiment in accordance with the present invention, the frozen coconuts are stored in a frozen storage having -<NUM> degree Celsius temperature, in another it is -<NUM> degree Celsius, in another it is -<NUM> degree Celsius, and in another it is any temperature at or below <NUM> degree Celsius. In one embodiment in accordance with the present invention, the shelf life of frozen coconut is more than one year.

Embodiments in accordance with the present innovation disclose a method for preparing frozen coconuts using slow freezing unit is provided herein. The embodiment includes harvesting <NUM> days old young coconuts having two layers of coconut meat and sorting of coconuts according to their sizes and quality. Further the embodiment may include storing and resting of coconuts in ambient conditions for at least <NUM> days to reduce the inner pressure of coconuts. The embodiment further includes dehusking of the outer green layer and the fibrous husk of a raw coconut using a sharp edged weapon leaving the coconut shell without any or minimal amount of fibrous material on the outer surface of dehusked coconut shell. The embodiment further includes optionally polishing the outer hairs of the dehusked coconut using a polishing machine such as but not limited to a copper bristle polishing machine. The embodiment may further include sorting of the coconut shell according to its size, weight and thickness. The embodiment further includes optionally preventing of oxidation and contamination of the dehusked coconut shell surface and top husk cone by first immersing the dehusked coconut shell into one or several solutions, having anti-oxidant, anti-bug, anti-fungal and anti-mold properties, for preventing oxidation and contamination of the dehusked and polished coconut shell surface and top husk cone. Said solutions can be organic or non-organic solutions such as but not limited to ascorbic acid solution or similar anti- browning solutions, the dehusked coconut shells are then taken out of one or several solutions and let get dry. The embodiment further includes weighing of the dehusked coconuts and moving the dehusked coconuts in a dry room for about three days until they lose more than <NUM>% of their weight and the dehusked coconut shell becomes dry. The embodiment further includes optionally sealing of dried dehusked coconut shell in vacuum bag using a vacuum sealing machine which make contact with the coconut shell and prevent any liquid leakage inside the bag by applying <NUM> even pressure around the dried dehusked coconut shell, which further prevents cracking of the dried dehusked coconut shell during further freezing process. The embodiment may further include placing the dried dehusked coconuts in a chilling room until the coconut water becomes partially slushy and inner pressure of the vacuum sealed coconut shell bag is further reduced to the levels at which the partially frozen vacuum sealed coconuts can then be completely frozen in a freezing unit. The embodiment may further include placing the vacuum sealed coconut shell bags containing the partially frozen coconuts in an individual container basket or coconut holding tray. The embodiment may further include placing the partially frozen coconuts in plastic trays having air-holes allowing airflow within the freezer unit. The embodiment may further include placing the trays containing partially frozen coconuts in a standard freezer for at least <NUM> hours at -<NUM> degree Celsius temperature depending on the batch size of coconuts. The embodiment may further include storing the frozen coconut shell in a freezer or frozen storage unit having -<NUM> degree Celsius temperature.

In another embodiment in accordance with the present invention, the either vacuum sealed coconut shell bags or simply unpackaged dried dehusked coconuts are moved to a chilling room until the core temperature of the coconut reaches in between -<NUM> degree Celsius to -<NUM> degree Celsius for at least <NUM> days.

In one embodiment in accordance with the present invention, the partially frozen coconut is either contained in a vacuum sealed coconut shell bag or is a partially frozen coconut without any packaging.

In one another embodiment of the present invention, the frozen coconuts are stored in frozen storage having -<NUM> degree Celsius temperature. In one yet another embodiment in accordance with the present invention, the shelf life of frozen coconut is more than year.

The preceding is a simplified summary to provide an understanding of some aspects of embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, wherein: <FIG>, <FIG>, <FIG>, <FIG> are not according to the invention and are present for illustration purposes only.

To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.

As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words "include", "including", and "includes" mean including but not limited to.

The phrases "at least one", "one or more", and "and/ or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C" and "A, B, and/ or C" means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

The term "automatic" and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be "material".

<FIG> illustrates a schematic representation of system and a method for preparing frozen coconuts from raw coconuts up to getting frozen coconuts.

The system comprises a sorting and dehusking unit whereby the harvested coconuts are being dehusked. The dehusked coconuts are formed by firstly sorting and resting the raw coconuts in green husk for two days so to allow a first reduction of pressure inside the coconut before dehusking the coconut. The dehusked coconuts can optionally be polished using polishing machines. The dehusked and optionally polished coconuts are stored in a drying unit until the dehusked coconuts loose at least <NUM>% of their weight. The dried coconuts are then optionally sealed in vacuum bags using a vacuum-sealing machine. Vacuum bags apply uniform pressure around the dried dehusked coconut. Alternatively the dried dehusked coconuts may be left unpackaged. The system further comprises a chilling room having -<NUM> degree Celsius temperature for partially freezing the content of dried dehusked (and optionally vacuum sealed) coconuts and a freezing unit for completely freezing the partially frozen coconuts and forming frozen coconuts enclosing entire coconut water and coconut meat within itself. The system further comprises a freezing unit where the partially frozen (optionally vacuum sealed) coconuts are moved for completely freezing the partially frozen coconuts. The freezing unit either freezes the partially frozen coconut shell by a shock freezing method or by a slow freezing method, forming a frozen coconut enclosing entire coconut water and coconut meat within its own hard shell.

IB illustrates a schematic representation of a raw coconut from getting harvested, stored and dehusked up to getting further dried into a drying unit, according to an embodiment of the present invention.

In the system <NUM>, the raw coconuts <NUM> after they are collected and picked up by farmers are taken to an inspection facility for different kinds of inspections. The raw coconut <NUM> is being inspected for any visible outside damage, weighed via scale to ensure it meets minimum weight requirement for purchase and so on. An applied water bucket test (to determine the maturity of the coconut) is also performed to guarantee that the raw coconut <NUM> contains exactly two layers of coconut meat inside its inner shell. The raw coconuts <NUM> after passing all the quality inspections are stored in a room <NUM> having ambient temperature and away from direct sunlight for at least <NUM> days for reducing the inside pressure of the coconut before being dehusked.

The raw coconut <NUM> after getting dehusked completely by skilled hands wielding machetes turn in to a dehusked coconut <NUM>. The outer green layer (exocarp) and the fibrous husk (mesocarp) of the raw coconut <NUM> are removed, leaving the shell of the dehusked coconut <NUM> without or minimal amount of the fibrous material that surrounds it. All the husk is removed optionally excluding a piece of protective cone shaped husk atop the coconut. The remaining husk covers two closed holes and the spore of the shell of the dehusked coconut <NUM>, shielding the delicate opening on top.

The dehusked coconut <NUM> is then weighed and measured for height and circumference. The dehusked coconut <NUM> is then separated according to its size which can be small, medium or large. All this information gets updated in the inventory system and tagged accordingly on their mesh bag. The dehusked coconut <NUM> then waits for optional polishing.

The hair around the shell of the dehusked coconut <NUM> is optionally removed with a polishing machine such as but not limited to copper bristle polishing machine, similar to that of a shoe shiner. Holding the shell tightly, a worker slowly turns the shell underneath rotating bristles that gently remove the coir without bothering the cone, leaving a smooth shell surface. The shell of the dehusked coconut <NUM> after getting polished turns into a dehusked and polished coconut <NUM>.

The dehusked and polished coconut <NUM> after being polished is then placed in a bucket or successive buckets containing one or several organic or non-organic solutions with anti-oxidation, anti-bug, anti-mold or anti-fungal properties including for example but not limited an ascorbic acid solution that prevents oxidation of the surface and top husk cone of the dehusked and polished coconut <NUM> shell. After a brief period of time, the dehusked coconut <NUM> is taken out of the one or several solutions and placed in their respected numbered mesh bags and left to dry for further processing.

The dehusked and polished coconut <NUM> (or simply the dehusked coconut <NUM>) is moved into a drying unit such as a dry room <NUM> having humidity less than <NUM> % and temperature above <NUM> degree Celsius until the dehusked and polished coconut <NUM> has lost more than <NUM> % of its initial inside coconut water weight. A dried dehusked coconut shell <NUM> is obtained.

<FIG> illustrates a schematic representation of system for preparing frozen coconuts from dried dehusked coconuts sealed in vacuum seal bags before being frozen in shock freezing unit, according to an embodiment of the present invention.

The system <NUM> (a) comprises a vacuum sealing machine <NUM> for sealing the dried dehusked coconut <NUM> in vacuum bag <NUM> which applies uniform pressure around the dried dehusked coconut shell <NUM> preventing it from breaking during freezing; a chilling unit such as a chilling room <NUM> for partially freezing the content of the coconuts and getting partially frozen coconuts <NUM>; and a freezing unit <NUM> for completely freezing the partially frozen coconuts and forming a completely frozen coconut <NUM> enclosing entire coconut water and coconut meat within itself.

A dried dehusked coconut <NUM> is sealed in vacuum bag using vacuum sealing machine <NUM>. Any locally available vacuum sealing machine can be used for sealing coconut shells. The vacuum bags used for sealing dried dehusked coconut <NUM> are K-nylon bags having <NUM> micron thickness which make contact with the coconut shell and prevent any liquid leakage inside the bag by applying <NUM> degree even pressure around the coconut shell and prevent it from rupturing during freezing process. The vacuum bags also protect the coconut shell from rupturing upon thawing.

The vacuum sealed coconut shell bag <NUM> is moved to a chilling room <NUM> having - <NUM> degree Celsius temperature to partially froze the content of coconut shell until core temperature of coconut shell reaches anywhere in between -<NUM> degree Celsius to -<NUM> degree Celsius. The chilling room helps reducing the inner pressure of the dried dehusked coconut <NUM> to the levels at which to the coconut may be further freezed without risk of coconut shell cracking during the freezing process.

The partially frozen vacuum sealed coconuts <NUM> are arranged on a coconut holding tray <NUM> (a) and moved to shock freezing unit <NUM>. Referring to <FIG>, each individual container basket holding only one partially frozen vacuum sealed coconut <NUM>. The coconut holding tray <NUM> (a) is immersed in shock freezing unit <NUM>.

The shock freezing unit <NUM> as shown in <FIG> and <FIG> comprises an insulated tub <NUM> for holding coconut holding tray <NUM> and cooling bath mixture <NUM> for completely freezing the coconut shell. The coconut holding tray <NUM> containing partially frozen vacuum sealed coconuts <NUM> is fully immersed in cooling bath mixture in temperature range -<NUM> degree Celsius to -<NUM> degree Celsius for <NUM>- <NUM> minutes depending on the batch size of coconuts. The cooling bath mixture is alcohol-based, and contains at least one of dry ice and liquid nitrogen, such as, but not limited to, mixtures of <NUM> % ethanol and dry ice, or mixtures of methanol and liquid nitrogen.

The completely frozen coconut shells <NUM> are stored in frozen storage <NUM> at - <NUM> degree Celsius. Alternatively, it could be stored at -<NUM> degree Celsius, -<NUM> degree Celsius, or at any temperature at or below <NUM> degree Celsius.

<FIG> illustrates a schematic representation of system and method for preparing frozen coconuts from dried dehusked coconuts optionally sealed in vacuum seal bags in slow freezing unit, according to an embodiment of the present invention.

In this system, the dried dehusked coconuts <NUM> are either vacuum sealed using vacuum sealing machine to form vacuum sealed coconuts <NUM> or used as dried dehusked coconuts without any packaging <NUM> for partially freezing the content and reducing the inner pressure of the dried dehusked coconuts <NUM>. The vacuum sealed coconuts <NUM> and the completely dried dehusked coconuts <NUM> are moved to a chilling unit such as a chilling room <NUM> for forming partially frozen vacuum sealed coconuts <NUM> and partially frozen coconuts without any packaging <NUM> respectively. Referring to <FIG>, the partially frozen coconuts without any packaging <NUM> and the partially frozen vacuum sealed coconuts <NUM> are arranged in a porous coconut holding tray <NUM> (b), <NUM> (c) respectively. The coconut holding tray <NUM> (b), <NUM> (c) are placed in slow freezing unit. The slow freezing unit <NUM>, referring to <FIG>, is a standard freezer having -<NUM> degree Celsius temperature. The coconut are kept for at least <NUM> hours depending on the batch size of coconut shells. This freezing unit <NUM> is used for freezing both partially frozen vacuum sealed coconuts <NUM> and partially frozen coconuts without any packaging <NUM>.

<FIG> illustrates a schematic representation of a coconut holding tray capable to hold partially frozen vacuum sealed or unpackaged coconuts to be completely frozen; not according to an embodiment of the present invention.

A coconut holding tray <NUM> (a) comprising a top cover <NUM>, a base <NUM>, a plurality of side casings <NUM>, <NUM>, at least one partitioned compartment <NUM>, <NUM>, <NUM> comprising individual container basket <NUM> for holding one partially frozen vacuum sealed coconut shell bag <NUM>. Each compartment <NUM>, <NUM>, <NUM> comprise at least one round shaped opening. The individual container basket <NUM> comprises partially frozen vacuum sealed coconut shell bag <NUM> (or an unpackaged coconut not shown in the figure). After loading the coconut holding tray <NUM> (a) with the partially frozen vacuum sealed coconut <NUM>, the top cover <NUM> is closed. In this situation the at least one partially frozen vacuum sealed coconut <NUM> is accessible only through the at least one round shaped opening which is located on the top cover <NUM> of the coconut holding tray <NUM> (a) which allows free liquid flow across the compartments but prevents partially frozen vacuum sealed coconuts <NUM> to touch other each other to prevent them from sticking together or from potential cracking of the vacuum bags sealing the vacuum sealed coconuts.

<FIG> illustrate a schematic representation of a coconut holding tray <NUM> capable of holding partially frozen vacuum sealed coconuts <NUM> or partially frozen coconut shell without any packaging <NUM> for producing completely frozen coconut shell <NUM>, not according to an embodiment of the present invention.

A coconut holding tray <NUM> (b), <NUM> (c) comprising porous air holes <NUM>, peripheral side-walls <NUM>, and space <NUM> for holding coconut shell. The porous air holes <NUM> in the coconut holding tray allows good air flow inside freezing unit.

<FIG> and <FIG> illustrate a schematic representation of top and side view of shock freezing unit comprising insulated tub for holding coconut holding tray and cooling bath mixture for completely freezing the partially frozen vacuum sealed coconuts and producing frozen coconuts, not according to the invention.

The shock freezing unit <NUM> (as shown in <FIG>) comprises an insulated tub <NUM> for holding coconut holding tray <NUM> and cooling bath mixture <NUM> for completely freezing the partially frozen vacuum sealed coconuts <NUM>.

<FIG> illustrate a schematic representation of a slow freezing unit <NUM> comprising coconut holding tray containing partially frozen coconuts and standard freezer for freezing the partially frozen vacuum sealed coconuts <NUM> or partially frozen unpackaged coconut <NUM> and producing frozen coconuts respectively, not according to the invention.

The slow freezing unit <NUM> is a standard freezer having -<NUM> degree Celsius temperature for completely freezing the partially frozen coconut shell bag. This freezing unit <NUM> is used for freezing both partially frozen vacuum sealed coconut shell bag <NUM> and partially frozen coconut shell without any packaging <NUM>.

<FIG> illustrates an exemplary flowchart <NUM> illustrating a method of preparing the frozen coconuts using a shock freezing unit, according to an embodiment of the present invention.

Initially at step <NUM>, the raw coconuts after having been harvested preferably in the afternoon and after <NUM> days so that they have preferably two layers of coconut meat, and after inspection, are stored for at least two days in a storage room having ambient temperature and away from direct sunlight for reducing the inner pressure of raw coconuts.

At step <NUM>, the outer green layer and the fibrous husk of raw coconuts are dehusked leaving the coconut shells without any or minimal amount of fibrous material surrounding the coconut shells.

At step <NUM>, the dehusked coconut shells are sorted according to their sizes, weight and thickness.

At step <NUM>, the outer hairs of the dehusked coconut shells are optionally polished using a polishing machine such as copper bristle polishing machine.

At step <NUM>, to prevent oxidation and contamination by mold or fungus of the dehusked and polished coconut shells surfaces and top husk cones, the coconut shells are optionally put into one or several organic or non-organic solutions such as an ascorbic acid solution, and then taken out of the solution to get dry.

At step <NUM>, the dehusked (and optionally polished) coconut shells are weighed and moved into a dry room having humidity less than <NUM> % and temperature more than <NUM> degree Celsius and kept there until the coconuts lose more than <NUM>% of their initial weight prior to drying.

At step <NUM>, the dried dehusked coconut shells can be optionally sealed in vacuum bags using a vacuum sealing machine.

At step <NUM>, the either vacuum sealed coconuts or unpackaged coconuts are moved into a cold storage unit such as a chilling room having -<NUM> degree Celsius temperature for at least <NUM>-<NUM> days until the coconut water in the coconut shell becomes partially slushy and with a core temperature of -<NUM> degree Celsius to -<NUM> degree Celsius and inner pressure inside the partially frozen coconut has decreased.

At step <NUM>, the partially frozen vacuum sealed or unpackaged coconuts are placed in individual container basket of coconut holding tray.

At step <NUM>, the coconut holding tray containing partially frozen vacuum sealed or unpackaged coconuts proceeds to a shock freezing unit. The coconut holding tray can for example be immersed in insulated tub filled with cooling bath mixture for <NUM> -<NUM> minutes at -<NUM> degree to -<NUM> degree Celsius depending on the batch size of coconut shells or be processed through an air blast flash freezing tunnel.

At step <NUM>, after the shock freezing unit, the frozen coconuts are brought to frozen storage and stored at -<NUM> degree Celsius. Alternatively, they could be stored at -<NUM> degree Celsius, -<NUM> degree Celsius, or at any temperature at or below <NUM> degree Celsius.

<FIG> depicts an exemplary flowchart illustrating a method of preparing frozen coconuts using a slow freezing unit, according to an embodiment of the present invention.

At step <NUM>, the outer green layer and the fibrous husk of raw coconuts are dehusked using a sharp edged weapon leaving the coconut shells without any fibrous material surrounding it.

At step <NUM>, to prevent oxidation and contamination by mold or fungus of the dehusked (and optionally polished) coconut shells surfaces and top husk cones, the coconut shells are optionally put into one or several organic or non-organic solutions such as an ascorbic acid solution, and then taken out of the solution to dry.

At step <NUM>, the dried dehusked coconuts without any packaging are moved into a cold storage having -<NUM> degree Celsius temperature for at least <NUM>-<NUM> days until the coconut water in the coconut becomes partially slushy forming partially frozen coconut and with a core temperature of -<NUM> degree Celsius to -<NUM> degree Celsius and inner pressure inside the partially frozen coconut has decreased.

At step <NUM>, the partially frozen coconuts without any packaging are arranged in porous plastic coconut holding tray.

At step <NUM>, the coconut holding tray containing partially frozen coconuts without any packaging is kept in a freezer having -<NUM> degree Celsius temperature for at least <NUM> hours depending on the batch size of coconuts.

At step <NUM>, the dried dehusked coconut is sealed in vacuum bag using vacuum sealing machine. In this step, the vacuum sealed coconuts are moved to into a cold storage having -<NUM> degree Celsius temperature for at least <NUM>-<NUM> days until the coconut water in the coconut shell becomes partially slushy forming partially frozen vacuum sealed coconuts with a core temperature of -<NUM> degree Celsius to -<NUM> degree Celsius and inner pressure inside the partially frozen coconut has decreased.

At step <NUM>, the partially frozen vacuum sealed coconuts are arranged in porous plastic coconut holding tray.

At step <NUM>, the coconut holding tray containing partially frozen vacuum sealed coconuts is kept in a freezer having -<NUM> degree Celsius temperature for at least <NUM> hours depending on the batch size of coconuts.

At step <NUM>, the frozen coconuts are brought to frozen storage and stored at - <NUM> degree Celsius. Alternatively, they could be stored at -<NUM> degree Celsius, -<NUM> degree Celsius, or at any temperature at or below <NUM> degree Celsius.

The following example is illustrative of the present invention, however, it will be understood that the invention is not limited to the specific details set forth in the example:.

One hundred forty four raw coconuts were harvested; quality-checked and was stored in a store room having ambient temperature and away from direct sunlight to reduce the inner pressure of the raw coconuts for <NUM> days. The raw coconuts were dehusked, sorted, polished to get dehusked and polished coconut shells. The dehusked and polished coconuts were weighed and stored in a dry room having humidity less than <NUM> percent and temperature above <NUM> degree Celsius until they lost more than <NUM>% of their initial weight before drying. The dried dehusked and polished coconuts were sealed in <NUM> micron thick K Nylon vacuum bags using vacuum sealing machine to apply <NUM> pressure on the outer coconut shell. The vacuum sealed coconuts were moved to a chilling room having -<NUM> degree Celsius temperature for <NUM>- <NUM> days until the core temperature of coconuts reaches in range - <NUM> degree Celsius to -<NUM> degree Celsius temperature. Now, a partially frozen vacuum sealed coconut was placed in an individual container basket of coconut holding tray and <NUM> such partially frozen vacuum sealed coconut shell bags were arranged in single coconut holding tray. Four such coconut holding trays were fully immersed at the same time in shock freezing unit comprising insulated tub filled with mixture of <NUM> % pure ethanol and dry ice at the same time. The temperature of cooling bath was -<NUM> degree Celsius to -<NUM> degree Celsius. More dry ice was added to maintain temperature of the cooling bath. The coconut holding trays were left in insulated tub containing mixture of <NUM> % pure ethanol and dry ice for <NUM>-<NUM> minutes and taken out at the same time. Frozen coconuts were further stored in the frozen storage and can be used for more than a year.

Claim 1:
A method for preparing frozen coconut containing frozen coconut meat and frozen coconut water, in which the entire coconut shell is preserved intact with coconut meat and coconut water inside the coconut shell, the method comprising:
a. dehusking a coconut to remove an outer green layer and at least a majority portion of a fibrous husk thereof;
b. drying said dehusked coconut until it weighs at least <NUM>% less than its weight prior to drying; and
c. freezing the coconut in an environment at or below <NUM> degrees Celsius.