Patent Description:
There has been an increasing emphasis on the production of healthy food products primarily derived from vegetables and other organic plant-based products. For instance, various food manufacturers have produced dips, sauces, and other food products using nuts or cauliflower as the base component. However, these existing food products may exhibit one or more deficiencies, such as poor taste, inadequate texture, allergy risks, high production costs, and overall unhealthy formulations. Thus, there still is a need to identify and efficiently produce a healthy food product from plant-based sources. Examples of methods known in the art are disclosed in <CIT> and <CIT>.

One or more embodiments generally concern a method for making a liquid potato product. Generally, the method comprises: (a) providing an initial potato feed comprising a potato component; (b) at least partially gelatinizing said initial potato feed by blanching to thereby form a gelatinized potato feed; (c) adding water and at least one oil to said gelatinized potato feed to thereby form a treated potato feed; (d) shearing at least a portion of said treated potato feed at a temperature of less than <NUM> to thereby form a sheared potato product comprising an average particle size on a volume basis in the range of <NUM> to <NUM> as measured by a Microtrac Bluewave Particle Size Analyser, wherein the shearing occurs in a high shear milling device; and (e) heating said sheared potato product to at least <NUM> to thereby form said liquid potato product.

One or more embodiments generally concern a liquid potato product for producing a food product. Generally, the liquid potato product comprises: an average particle size in the range of <NUM> to <NUM> as measured by a Microtrac Bluewave Particle Size Analyser and exhibits two or more of the following rheological properties as measured at <NUM>:.

Furthermore, "Y" refers to shear stress in dynes per centimeter squared (dynes/cm<NUM>) and subscript values used with "Y" are shear rates or shear rate ranges per second (<NUM>/s) at which the shear stress "Y" is measured. Additionally, the rheological properties are measured <NUM> minutes after forming the liquid potato product.

Embodiments of the present invention are described herein with reference to the following drawing figures, wherein:.

The present invention is generally related to the production of Liquid P, which is a liquid product at least partially derived from potatoes, and the use of Liquid P to produce various food products. Certain embodiments of the present invention may include a potato liquefaction system for converting potatoes and other root vegetables into a useful liquid product, such as Liquid P. As discussed below in greater detail, it has been observed that the system described herein is capable of creating a unique liquid potato product, i.e., Liquid P, which can be used to produce various types of food products that exhibit one or more desirable traits.

As used herein, the term "Liquid P" may be used interchangeably with "liquid potato product" and both refer to a substance containing at least <NUM> weight percent potato and having a dynamic viscosity in the range of <NUM> to <NUM>,<NUM> cP at a shear rate of <NUM> <NUM>/s and at a temperature in the range of <NUM> to <NUM>.

As discussed below in greater detail, a method of making the liquid potato product, i.e., Liquid P, is provided herein.

Generally, the production method utilizes an initial potato feed comprising a raw diced or cubed potato component. This potato feed is pretreated by blanching to thereby eliminate any enzyme activity and at least partially gelatinize the potato feed. Furthermore, in various embodiments, the initial potato feed may also be chemically treated using chelating agents to eliminate the possibility of subsequent non-enzymic browning. However, for the production process described herein, it may not be necessary to chelate the initial potato feed.

Furthermore, the initial potato feed is mixed with water and at least one oil, in a defined ratio. This mixture may be pre-milled at a temperature of around <NUM> to <NUM> so as to produce a coarse slurry wherein the potato pieces, and the oil are easily maintained in suspension through stirring. Typically, if the potato pieces are small enough in the initial potato feed, the pre-milling step may be skipped and omitted from the process. Alternatively, in various embodiments, if the process is carried out in a batch basis, then there may be no need to maintain the potato pieces in suspension as all material enters the next step together.

The potato mixture comprising potato, water, and oil is then processed in a high shear milling device, such as an Urschel Comitrol or a Tetra Laval <NUM> High Pressure Homogenizer, where the pieces of potato are broken down into finer particle sizes, generally in the range of <NUM> to <NUM>, as measured by a Microtrac Bluewave Particle Size Analyser.

An advantage of using the high shear milling devices described herein is that each element of the potato mixture may pass through the high shear region only once and for a relatively short time. This may result in a very efficient application of mechanical energy for comminuting, which may cause a very low temperature rise (typically only a few degrees centigrade) in the sheared product. With this cold milling process, it is possible to maintain the milling temperature well below the gelatinization temperature of potato starch, which is believed to begin at <NUM> and be completed at <NUM>. Consequently, the resulting milled product does not automatically thicken upon being milled.

As used herein, the terms "milling" and "shearing" may be used interchangeably and both terms refer to a mechanical treatment that induces a shear rate through the liquid which changes the underlying micro-structure. Thus, for example, shearing and milling may include particle comminution.

Once the potato mixture has been milled, it can then be mixed with other ingredients, such as tomato pieces, spices, beans, root vegetables, etc., and then heated to a point wherein the potato starch will thicken. Generally, this may occur once the starch gelatinization temperature (i.e., above <NUM>) is reached.

<FIG> depicts an exemplary Liquid P production system <NUM> that may be employed to at least partially convert one or more potato-containing feeds into Liquid P and food products containing Liquid P. It should be understood that the Liquid P production system <NUM> shown in <FIG> is just one example of a system within which the present invention can be embodied. Thus, the present invention may find application in a wide variety of other systems where it is desirable to efficiently and effectively produce liquid potato products. As described below, the system <NUM> depicted in <FIG> may be used to carry out the Cold Milling Liquid Potato (CMLP) process. The exemplary system <NUM> illustrated in <FIG> will now be described in greater detail.

Turning to <FIG>, an initial potato feed <NUM> is provided to the system. Generally, in various embodiments, the initial potato feed <NUM> may comprise diced potatoes that have been diced into pieces having average widths of at least <NUM>, <NUM>, <NUM>, or <NUM> inches and/or less than <NUM>, <NUM>, or <NUM> inches. Furthermore, in various embodiments, the diced potatoes in the initial potato feed <NUM> may be peeled and/or unpeeled.

In various embodiments, the potato feed <NUM> comprises, consists essentially of, or consists of potatoes. Generally, in various embodiments, the potatoes can comprise of any variety of Solanum tuberosum. Exemplary potato varieties can include, for example, Shepody potatoes, Bintje potatoes, American Blue potatoes, Royal potatoes, Innate Potatoes, Maris Piper potatoes, Focus potatoes, Yukon Gold potatoes, Lady Balfour potatoes, Kennebec potatoes, Colette potatoes, Chieftain potatoes, Innovator potatoes, Russet Burbank potatoes, purple potatoes, Russet potatoes, Bamberg potatoes, or combinations thereof.

Although the following description is based on the use of potatoes (i.e., Solanum tuberosum) as the principal component in the potato feed <NUM>, it is envisioned that potatoes may be replaced partially or entirely with other forms of starchy, tuberous roots, such as sweet potatoes (i.e., Ipomoea batatas). Thus, in any of the following embodiments, it is envisioned that the potato component may be formed from sweet potatoes (i.e., Ipomoea batatas) as opposed to potatoes (i.e., Solanum tuberosum).

In various embodiments, the potato feed <NUM> can comprise at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of one or more potatoes, based on the total weight of the feed stream.

The potatoes in the initial potato feed <NUM> may come from any conventional potato source. For example, the potato source can be, for example, a hopper, storage bin, railcar, trailer, or any other device that may hold or store potatoes and other types of vegetables.

In certain embodiments, the initial potato feed <NUM> may comprise one or more other root vegetables, such as parsnips, celery root, sweet potatoes, onions, red beets, carrots, or combinations thereof. As used herein, the term "root vegetable" refers to an edible underground plant part, other than potatoes, that comprises a higher fiber content relative to peeled potatoes.

In various embodiments, the potato feed <NUM> can comprise at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of one or more root vegetables, based on the total weight of the potato feed.

Turning again to <FIG>, the potato feed <NUM> is sent to a pretreatment system <NUM> for further processing before any subsequent milling and cooking steps. While in the pretreatment unit <NUM>, the potato feed <NUM> can go undergo one or more treatments including, for example, washing, peeling, mashing, water bath, microwave heating, radio frequency heating, magnetic heating, electric field pulse heating, cubing, dicing, or combinations thereof.

While in the optional pretreatment system <NUM>, the pretreatment system <NUM> comprises any system or device capable of subjecting the potato feed <NUM> to a blanching.

Generally, in various embodiments, the blanching process can involve: (i) contacting the potato feed <NUM> with hot water and/or steam and (ii) subsequently contacting the heated potato feed with an aqueous solution to thereby form the gelatinized feed <NUM>. In certain embodiments, the aqueous solution can comprise one or more chelating agents and/or pH-modifying agents, such as citric acid, EDTA, sodium acid pyrophosphate, a phosphate compound, or a combination thereof.

In certain embodiments, the first step of the blanching process can comprise contacting the potato feed <NUM> with heated water over a time period of at least <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> minutes and/or less than <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> minutes. In such embodiments, this water heat treatment can occur at around atmospheric pressures and at a temperature of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Additionally or alternatively, in various embodiments, the water heat treatment can occur at a temperature of less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>.

In certain embodiments, the first step of the blanching process can comprise contacting the potato feed <NUM> with pressurized steam over a time period of at least <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> minutes and/or less than <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> minutes. In such embodiments, this steam treatment can occur at a gauge pressure of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> psig and/or less than <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> psig and at temperature of at least <NUM>, <NUM>, or <NUM> and/or less than <NUM>, <NUM>, <NUM>, or <NUM>.

In certain embodiments, the second step of the blanching process can occur at a temperature of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Additionally or alternatively, in various embodiments, the second step of the blanching process can occur over a time period of less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> minutes.

In certain embodiments, the blanching process will remove very little water and/or solids from the potato feed <NUM>. Unlike prior art blanching techniques that partially dehydrate the potato feeds, the blanching techniques of the present disclosure may attempt to retain much of the water, moisture, and solids naturally present in the potatoes. For example, in various embodiments, the moisture content (by weight) of the at least partially gelatinized potato feed <NUM> may be less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent lower than the moisture content of the potato feed <NUM>. In other words, the moisture content of the gelatinized potato feed <NUM> may be at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent of the moisture content of the potato feed <NUM>.

The blanching conditions at least partially gelatinize the starch in the potatoes as well as denaturing any enzymes. From an economic perspective, it may be desirable to subject the potato feed <NUM> to minimal blanching as some blanching techniques can cause a loss of potato solids and, therefore, result in a reduced yield. Additionally, as discussed above, the pretreatment may also include submersion in an aqueous chelating solution (e.g., citric acid or sodium acid pyrophosphate) to prevent non-enzymic browning happening. Typically, the blanching and chelation conditions may be driven by the size of the incoming potato feed <NUM>.

Upon leaving the pretreatment system <NUM>, the pretreated potato feed <NUM> may be introduced into an optional pre-milling system <NUM>. While in the pre-milling system <NUM>, the pretreated potato feed <NUM> can be pre-milled by a coarse cutting device, such as a bowl chopper (e.g., a Karl Schnell F-type blender) or fine dicing machine, at a temperature of around <NUM> to <NUM>. The purpose of the pre-milling system <NUM> is to help produce a consistent slurry feed <NUM> prior to being fed into the high shear milling treatment <NUM>. However, in certain embodiments, the pre-milling system <NUM> may be excluded if the potato feed is already of a sufficiently small size so as to make a slurry.

After pre-milling, the potato feed <NUM> is then transferred to a mixing/holding tank <NUM> where water, at least one oil, and other ingredients are added to the potato feed <NUM> prior to the high shear milling treatment. Additionally or alternatively, in various embodiments, water, at least one oil, and other ingredients are added during the pre-milling step in the pre-milling system <NUM>. In such embodiments, the mixing/holding tank <NUM> may be optional.

When an oil ingredient is added at either of these stages, then the oil droplet size may also be reduced during the subsequent high shear milling treatment and may be less prone to separation than if added after the high shear treatment. Exemplary oils can include, for example, vegetable oil, peanut oil, sunflower oil, canola oil, coconut oil, palm oil, corn oil, avocado oil, walnut oil, soybean oil, sesame oil, or combinations thereof. These oils and water can be useful in modifying the viscosity of the Liquid P and may also enhance certain taste and textural properties of the resulting Liquid P.

Exemplary other ingredients that may be added at this stage include, for example, root vegetables, optional flavorants, optional additives, and/or other types of vegetables (i.e., non-root vegetables) and/or fruits.

Exemplary flavorants can include, for example, spices, meat, cheese, herbs, or combinations thereof. Exemplary additives that may be added may include, for example, protein supplements (e.g., whey protein, chickpeas, soy, or combinations thereof), dietary fiber supplements, vitamins, minerals, or combinations thereof. The other vegetables and fruits that may be added at this stage can include, for example, Capsicum peppers (including sweet peppers and hot peppers), onions, spinach, kale, mushrooms, mango, artichokes, legumes, corn, olives, tomatoes, or combinations thereof.

Upon leaving the mixing/holding tank <NUM>, at least a portion of the potato feed <NUM> is introduced into a high shear milling device <NUM>. While in the high shear milling device <NUM>, the potato feed <NUM> passes once through the high shear zone of the milling device where it is subjected to high lateral and rotational shear forces, which substantially reduce the particle size of the potato slurry <NUM> in a very efficient way Although it will depend on the flowrate and power input into the high shear milling device <NUM>, there is generally no appreciable temperature rise during the milling process. The milling in the high shear milling device <NUM> takes place at a low enough temperature to avoid potato starch gelatinization, which is believed to begin at <NUM> and be complete at <NUM>. Consequently, the resulting milled potato feed <NUM> is very liquid-like and pumpable.

In various embodiments, the particle size of the milled potato feed <NUM> exiting the high shear milling device <NUM> is in the range of <NUM> to <NUM>. For example, the milled potato feed <NUM> exiting the high shear milling device <NUM> may comprise an average particle size on a volume basis of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> and/or not more than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>, as measured by a Microtrac Bluewave Particle Size Analyser.

In various embodiments, the sheared potato mixture may comprise a D10 particle size of at least <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>, as measured by a Microtrac Bluewave Particle Size Analyser. As used herein, the "D10 particle size" indicates that <NUM> percent measured particles (on a volume basis) have a size not more than the recited size.

In various embodiments, the sheared potato mixture may comprise a D50 particle size of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>, as measured by a Microtrac Bluewave Particle Size Analyser. As used herein, the "D50 particle size" indicates that <NUM> percent the measured particles (on a volume basis) have a size not more than the recited size. For example, a D50 particle size range of <NUM> would indicate that <NUM> percent of the measured particles (on a volume basis) have a diameter not more than <NUM>. The D50 particle size may also refer to the median particle size within the measured particles.

In various embodiments, the sheared potato mixture may comprise a D90 particle size of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> and/or less than <NUM>, <NUM>, <NUM>, or <NUM>, as measured by a Microtrac Bluewave Particle Size Analyser. As used herein, the "D90 particle size" indicates that <NUM> percent of the measured particles (on a volume basis) have a size not more than the recited size. For example, a D90 particle size range of <NUM> would indicate that <NUM> percent of the measured particles (on a volume basis) have a size not more than <NUM>.

The particle size ranges described herein are determined using microscope imaging with a Lugol staining solution and/or a Microtrac Bluewave Particle Size Analyser (in Bluewave mode). A microscope image, such as those depicted in <FIG> and <FIG>, or a separate sample of the material is analyzed by the Microtrac Bluewave Particle Size Analyser. The Microtrac Bluewave Particle Size Analyser uses laser diffraction to approximate equivalent sphere size distributions for the particles in the sample and thereby provides a particle size distribution range on a volume basis.

If the desired particle size can not be achieved in a single pass within the high shear milling device <NUM>, it is possible for the milled potato steam <NUM> to be recycled back to the mixing/holding tank <NUM> for reprocessing through the high shear milling device <NUM> until the desired particle size is achieved.

The high shear milling device <NUM> comprises any shearing device known in the art capable of providing the high shear necessary to produce the milled potato stream <NUM>. Exemplary shearing devices include, for example, an Urschel Comitrol or a Tetra Laval <NUM> High Pressure Homogenizer. Other generic types of high shear devices that may be used may include, for example, ball mills or hammer mills. Some high shear milling devices, such as the HPH, may require that the potato slurry <NUM> be pumpable. Thus, in such embodiments, water is added to the pre-milled potato feed <NUM> to ensure that the potato feed is sufficiently pumpable. Alternatively, in various embodiments, other high shear milling devices, such as the Urschel Comitrol, the pre-milled potato feed <NUM> can be fed via gravity into the high shear milling device <NUM> through an inlet funnel and, therefore, does not need to be pumpable; rather, the feed just needs to be fluid enough to enter the milling chamber.

In various embodiments, the shearing step in the high shear milling device <NUM> can occur at a temperature of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Additionally or alternatively, in various embodiments, the shearing step in the high shear milling device <NUM> occurs at a temperature of less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. It should be noted that these temperature ranges include and compensate for any heat produced by the shearing conditions.

In various embodiments, the shearing step in the high shear milling device <NUM> can occur over a time period of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> seconds and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> seconds. Thus, because the potato feed spends a relatively short time (seconds) in the high shear milling device <NUM>, the CMLP process is considerable quicker than a hot milling process with a high shear mixer, which usually takes minutes.

Additionally or alternatively, in various embodiments, the shearing step in the high shear milling device <NUM> can occur at a pressure of at least <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> psig and/or less than <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> psig.

Turning again to <FIG>, the resulting sheared potato feed <NUM> may be sent to a mixing/holding tank <NUM> where additional ingredients and additives may be added thereto. Exemplary other ingredients that may be added at this stage include, for example, root vegetables, optional flavorants, optional additives, and/or other types of vegetables (i.e., non-root vegetables) and/or fruits. It should be noted that other root vegetables may be added at this stage as long as such vegetables are of sufficiently small particle size (e.g., are finely chopped or in the form of a slurry).

The resulting sheared potato feed <NUM> may form a useful base material to which other ingredients may be added. The sheared potato feed <NUM> may be stored in the mixing/holding tank <NUM> for a length of time; although, from a processing and food safety perspective, it may not be practical to store the uncooked sheared potato feed <NUM> for an extended period of time. Generally, the sheared potato feed <NUM> has a low viscosity that is much easier to pump and mix compared to a potato feed that has already been gelatinized though a hot milling process (i.e., a milling process occurring at or above the starch gelatinization temperatures). Thus, the sheared potato feed <NUM> may be easier to transport relative to potato feeds treated via hot milling processes.

Afterwards, as shown in <FIG>, the sheared potato feed <NUM> is into a cooking device <NUM>, where it is subjected to temperatures so as to increase the temperature of the potato feed to at least <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> to thereby form the Liquid P. In various embodiments, it may be desirable to heat the sheared potato feed <NUM> to a temperature that will fully gelatinize the starch therein. It has been shown that at least <NUM> days can pass between the high shear milling treatment and the cooking step, where the starch is gelatinized, without any apparent adverse impact on the development texture in the Liquid P product. Although, from a processing and food safety perspective, it may not be practical to store uncooked sheared potato product for that length of time.

In various embodiments, the cooking step occurs at a temperature of at least <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>, and/or less than <NUM>, <NUM>, or <NUM> and at atmospheric pressure.

In certain embodiments, the final texture and rheological properties of the Liquid P may not develop until <NUM> hours after cooking and may continue to develop for up to several days thereafter. It has been observed that a low shear viscosity may develop over time along with a pronounced hysteresis (below a shear rate of <NUM> <NUM>/s), while high shear viscosity may decline.

The various characteristics and properties of the Liquid P are described below. It should be noted that, while all of the following characteristics and properties may be listed separately, it is envisioned that each of the following characteristics and/or properties of the Liquid P are not mutually exclusive and may be combined and present in any combination, as long as such combination does not conflict. It should be noted that all weight percentages associated with the Liquid P formulations are based on the total weight of the Liquid P formulation, unless otherwise noted.

In various embodiments, the Liquid P comprises at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of a potato component originally derived from the potatoes in the initial potato feed, based on the total weight of the Liquid P composition.

In various embodiments, the Liquid P can include up to <NUM> weight percent of one or more additional complex carbohydrate materials, other than potatoes. In certain embodiments, the additional complex carbohydrate materials used to make the Liquid P can have a higher fiber content than the potatoes used to make the Liquid P. Examples of additional complex carbohydrate materials suitable for use in Liquid P include root vegetables, such as parsnips, celery root, sweet potatoes, onions, red beets, carrots, or combinations thereof. For example, in various embodiments, the Liquid P comprises at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of one or more root vegetables originally present in the initial potato feed, based on the total weight of the Liquid P composition. In certain embodiments, the Liquid P comprises a weight ratio of potato to root vegetables of at least <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM> and/or less than <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM>.

In various embodiments, at least one oil is added in sufficient quantities so that the Liquid P comprises at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of the oil, based on the total weight of the Liquid P composition. In certain embodiments, the Liquid P comprises a weight ratio of potato to oil of at least <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM> and/or less than <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM>.

In various embodiments, water is added in sufficient quantities so that the Liquid P comprises at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of the added water, based on the total weight of the Liquid P composition. It should be noted that this added water refers to water added during the production of the Liquid P and does not encompass the moisture originally present in the potato.

In various embodiments, the flavorants, additives, other non-root vegetables, and/or fruits are added in sufficient quantities so that the Liquid P comprises at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent and/or less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of flavorants, additives, other non-root vegetables, and/or fruits, based on the total weight of the Liquid P composition.

Due to the unique shearing process described herein, the Liquid P can be in the form of a viscous, flowable liquid that has a shiny and smooth appearance.

The Liquid P described herein can exhibit desirable rheological profiles without the need for thickening agents, such as starches, gums, flour, etc., which can be considered undesirable additives by many consumers. For example, the Liquid P may comprise less than <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of at least one thickening agent, based on the total weight of the Liquid P formulation.

It has been observed that the thickening effect of a cold-milled liquid potato product is different to a potato product made through either a conventional mashing process or a liquid potato product made through a hot milling process, particular in the lower shear region (i.e., below a shear rate of <NUM> <NUM>/s). It has also been observed that substantially less potato can be used to produce the cold-milled Liquid P described herein. Consequently, this has both economic as well as potentially nutritional (for those avoiding carbohydrates) advantages.

In various embodiments, the resulting Liquid P can exhibit a viscosity at <NUM> or <NUM> of at least <NUM>, <NUM>, <NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, or <NUM>,<NUM> cP and/or less than <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, <NUM>,<NUM>, or <NUM>,<NUM> cP.

Although not wishing to be bound by theory, it is believed that the shearing conditions used in the production of the Liquid P helps form its unique rheological profile. In one or more embodiments, the Liquid P is a non-Newtonian fluid having a non-linear relationship between shear stress and shear rate.

In various embodiments, the Liquid P may exhibit a shear stress at <NUM> of at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> dynes/cm<NUM> at a shear rate of <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> per second ("<NUM>/s"). Additionally or alternatively, in various embodiments, the Liquid P may exhibit a shear stress at <NUM> of less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> dynes/cm<NUM> at a shear rate of <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> <NUM>/s. It should be noted that these above rheological measurements may be applicable to the Liquid P immediately after its production (e.g., tested <NUM> minutes after its production) or after it has been stored for <NUM> hours ("Day <NUM>"), <NUM> hours ("Day <NUM>"), or <NUM> hours ("Day <NUM>") at <NUM>.

It has been observed that the presence of a complex carbohydrate material, such as fiber and other root vegetables, in the Liquid P formulation may influence the rheological properties of the composition. As used herein, a "complex carbohydrate material" comprises a higher complex carbohydrate content relative to peeled potatoes. As noted above, a complex carbohydrate material may include other root vegetables (i.e., root vegetables that are not potatoes). In various embodiments, the Liquid P can include up to <NUM> weight percent of one or more additional complex carbohydrates, other than potatoes.

In various embodiments, the Liquid P may exhibit one of the following shear stress profiles at <NUM> immediately after forming the Liquid P (e.g., <NUM> minutes after it has been formed) and/or after storing the Liquid P for <NUM> hours ("Day <NUM>"), <NUM> hours ("Day <NUM>"), or <NUM> hours ("Day <NUM>") at <NUM>:.

In various embodiments, the Liquid P exhibits at least <NUM> of the following rheological properties:.

As used herein, "Y" is shear stress in dynes per centimeter squared (dynes/cm<NUM>) and subscript values used with "Y" are shear rates or shear rate ranges per second (<NUM>/s) at which the shear stress "Y" is measured. For example, "Y<NUM>," "Y<NUM>," "Y<NUM>," "Y<NUM>," "Y<NUM>," "Y<NUM>," and "Y<NUM>" refer to the shear stress values (dynes/cm<NUM>) of Liquid P at <NUM> at shear rates of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> <NUM>/s, respectively. Furthermore, as used herein, "Y<NUM>-<NUM>," "Y<NUM>-<NUM>," "Y<NUM>-<NUM>," "Y<NUM>-<NUM>," "Y<NUM>-<NUM>," "Y<NUM>-<NUM>," "Y<NUM>-<NUM>," and Y<NUM>-<NUM>" refer to the change in shear stress values between Y<NUM> and Y<NUM>, Y<NUM> and Y<NUM>, Y<NUM> and Y<NUM>, Y<NUM> and Y<NUM>, Y<NUM> and Y<NUM>, Y<NUM> and Y<NUM>, Y<NUM> and Y<NUM>, and Y<NUM> and Y<NUM>, respectively.

It should be noted that these above rheological measurements are applicable to the Liquid P <NUM> minutes after it has been formed. Furthermore, the above rheological properties are measured at <NUM>.

The resulting Liquid P can be used to produce various food products. Exemplary food products that the Liquid P can be used to produce include, for example, dips, sauces, dressings, soups, imitation dairy products, spreads, confectionaries, beverages, and any other food product incorporating liquid and/or semi-solid components. In certain embodiments, the food product comprises a dip.

In various embodiments, the food products produced with the Liquid P can comprise at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of the Liquid P, based on the total weight of the food product. Additionally or alternatively, in various embodiments, the food products produced with the Liquid P can comprise less than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> weight percent of the Liquid P, based on the total weight of the food product.

This invention can be further illustrated by the following examples of embodiments thereof.

Four different processes for comminuting potato products to a pumpable liquid were compared: two CMLP processes (one using an Urschel Comitrol and a second using an HPH), a hot milled liquid potato process (i.e., a high-shearing with a shearing temperature rising above <NUM>), and a conventional low shear process. All four processes used the same formulation, which is outlined in TABLE <NUM>, below.

Thawed diced ¾ potato cubes, which had been pre-blanched and treated with a citric acid chelating solution, were pre-milled with an Urschel Comitrol <NUM> fitted with a Dio Cut impeller and a <NUM> <NUM>300U head at a rotational speed of <NUM> rpm. This produced a coarsely granulated raw potato mash. The granulated potato mash was then mixed with the water and oil in the proportions indicated in TABLE <NUM>.

The potato, water, and oil slurry was then milled at high shear by processing it in a single pass through an Urschel Comitrol <NUM> fitted with a Veri Cut HD <NUM> impeller and a <NUM> head at a rotational speed of <NUM> rpm. The inlet temperature was <NUM> and the exit temperature was <NUM>. The resulting liquid potato cold-milled product was measured on a grind fineness gauge, which showed an average particle size of <NUM> with the largest size being <NUM>. These particle sizes were later confirmed by microscopy. The material was then stored under refrigeration.

<FIG> depicts a microscope image taken using an Olympus BX53 compound microscope in Bright-field mode with an LED powered Kohler illuminator (un-polarized). Samples of the potato product were diluted with distilled water and stained with Lugol solution. Image capture and particle sizing was carried out with the associated Olympus cellScan software.

After <NUM> days in cold storage, the liquid potato cold-milled product was cooked to <NUM> and then allowed to cool to room temperature. A portion was then transferred to the rheometer sample chamber (Brookfield DV3TRVTJ with small sample adaptor kit using a SC4-<NUM> spindle and TC-<NUM> AP controller water bath), where it was placed in the temperature-controlled water bath (set at <NUM>). Subsequently, the rheometer spindle was positioned in the product.

Once the sample had reached a temperature of <NUM>, the rheometer ran through a prescribed program. During this program, the spindle was spun at a defined rpm which, together with the wall-to-wall distance between the spindle and the chamber, created a defined shear rate in the sample. Consequently, the corresponding torque can be measured, which directly translated to the experienced shear stress (dynes/cm<NUM>). The program stepped through a series of rotational speeds at <NUM> second intervals to create a shear rate range covering <NUM> to <NUM> <NUM>/s. Once the maximum shear rate of <NUM> <NUM>/s was reached, the program reduced the rotational speed of the spindle in <NUM> second intervals back down to zero. This resulted in two sets of data - one "up" and one "down. " plotted together as one curve where any hysteresis effects are then noticeable.

Thawed diced ¾ potato cubes, which had been pre-blanched and treated with a citric acid chelating solution, were pre-milled with a Karl Schnell F-Series blender. This produced a coarsely granulated raw potato mash. The granulated potato mash was then mixed with the water and oil in the proportions indicated in TABLE <NUM>.

The potato, water, and oil slurry was then milled at high shear by processing it in a single pass through a Tetra Laval High Pressure Homogenizer at a pressure of <NUM> psig. The inlet temperature was <NUM> and the outlet temperature was <NUM>. The resulting liquid potato cold-milled product was measured by microscopy, which showed an average particle size of <NUM> with a particle size range of <NUM> to <NUM>. The material was then stored under refrigeration.

After five days the liquid potato cold-milled product was cooked to <NUM> and then allowed to cool to room temperature. A portion was then transferred to the rheometer sample chamber (Brookfield DV3TRVTJ with small sample adaptor kit using a SC4-<NUM> spindle and TC-<NUM> AP controller water bath), where it was placed in the temperature-controlled water bath (set at <NUM>). Subsequently, the rheometer spindle was positioned in the product.

TABLE <NUM>, below, provides the Day <NUM>, Day <NUM>, and Day <NUM> rheological profiles of the tested sample.

<FIG> provides a chart showing the rheological properties of the tested sample at Day <NUM>, Day <NUM>, and Day <NUM>.

Thawed diced ¾ potato cubes, which had been pre-blanched and treated with a citric acid chelating solution, were mixed with the oil and water according to the recipe in TABLE <NUM> and poured into a Vitamix mixer (Vitamix <NUM> model VM0103 <NUM> amp 110v with variable speed). It was at this point that the conventional low-shear method and the hot-milled liquid potato process described herein began to differ.

For the conventional method, the Vitamix was ran at a low speed setting (<NUM>-<NUM> on dial) for <NUM> to <NUM> minutes until a consistent, homogeneous puree was achieved. The shear treatment was gentle enough to ensure that there was no appreciable temperature increase. The product was then heated in the microwave with stirring to achieve a temperature of <NUM> to <NUM> °F (<NUM> to <NUM>).

For the Hot-milled Liquid Potato process, the Vitamix was run at a high speed setting (<NUM> on dial) for <NUM> to <NUM> minutes until there was a characteristic appearance change where the product became glossy with a distinct sheen and the power draw for the motor noticeably rose. With the amount of mechanical work being applied to the product there was a temperature increase to around <NUM> to <NUM> °F (<NUM> to <NUM>) by the end of the shear treatment.

For both methods, the finished product was allowed to stand for <NUM> minutes at room temperature and a portion was then transferred to the rheometer sample chamber (Brookfield DV3TRVTJ with small sample adaptor kit using a SC4-<NUM> spindle and TC-<NUM> AP controller water bath), where it was placed in the temperature-controlled water bath (set at <NUM>). Subsequently, the rheometer spindle was positioned in the product. This represented the "Day <NUM>" product.

Once the sample had reached a temperature of <NUM>, the rheometer ran through a prescribed program. During this program, the spindle was spun at a defined rpm which, together with the wall-to-wall distance between the spindle and the chamber, created a defined shear rate in the sample. Consequently, the corresponding torque can be measured, which directly translated to the experienced shear stress (dynes/cm<NUM>). The program stepped through a series of rotational speeds at <NUM> second intervals to create a shear rate range covering <NUM> to <NUM> <NUM>/s. Once the maximum shear rate of <NUM> <NUM>/s was reached, the program reduced the rotational speed of the spindle in <NUM> second intervals back down to zero. Thus, this resulted in two sets of data - one "up" and one "down. " plotted together as one curve where any hysteresis effects are then noticeable.

TABLE <NUM>, below, provides the Day <NUM> rheological profiles at <NUM> of the samples from Examples <NUM>-<NUM>.

Furthermore, it is possible to directly compare the rheology of the products at Day <NUM> from each of the four methods with a curve plot of shear rate (<NUM>/s) against shear stress (dynes/cm<NUM>). <FIG> is a graph that compares the rheological profiles at Day <NUM> of the liquid potato product produced in Example <NUM> with the hot-milled product and conventional products produced in Comparative Examples <NUM> and <NUM>.

<FIG> is a graph that compares the rheological profiles at Day <NUM> of the liquid potato product produced in Example <NUM> with the hot-milled product and conventional products produced in Comparative Examples <NUM> and <NUM>.

As shown in <FIG> and <FIG>, both of the cold-milled products produced in Examples <NUM> and <NUM> are substantially thicker (more viscous) than both the hot-milled product and conventional product of Comparative Examples <NUM> and <NUM>.

It should be understood that the following is not intended to be an exclusive list of defined terms. Other definitions may be provided in the foregoing description, such as, for example, when accompanying the use of a defined term in context.

As used herein, the terms "a," "an," and "the" mean one or more.

As used herein, the term "and/or," when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination, B and C in combination; or A, B, and C in combination.

As used herein, the terms "comprising," "comprises," and "comprise" are open-ended transition terms used to transition from a subject recited before the term to one or more elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up the subject.

As used herein, the terms "having," "has," and "have" have the same open-ended meaning as "comprising," "comprises," and "comprise" provided above.

Claim 1:
A method of making a liquid potato product, the method comprising:
(a) providing an initial potato feed comprising a potato component;
(b) at least partially gelatinizing said initial potato feed by blanching to thereby form a gelatinized potato feed;
(c) adding water and at least one oil to said gelatinized potato feed to thereby form a treated potato feed;
(d) shearing at least a portion of said treated potato feed at a temperature of less than <NUM> to thereby form a sheared potato product comprising an average particle size on a volume basis in the range of <NUM> to <NUM> as measured by a Microtrac Bluewave Particle Size Analyser, wherein the shearing occurs in a high shear milling device;
(e) heating said sheared potato product to at least <NUM> to thereby form said liquid potato product.