Frozen Food Product

Abstract

The present invention provides a process for the manufacture of frozen instant cooking pasta from elongated dried pasta products that substantially retains the pre-processing length of the dried pasta comprising the steps of: (i) dividing an elongated dried pasta products into one or more portions, each portion having a desired mass; (ii) loading each portion of pasta into one of a plurality of separate dosing devices; (iii) re-hydrating each portion of pasta within a dosing device; (iv) quenching the re-hydrated pasta resulting from step (iii); (v) freezing. Further embodiments are directed to the apparatus that is necessary for carrying out this process and the frozen product achieved.

Description

[0001] The invention relates to the field of re-heatable frozen pasta products and particularly to frozen nests of elongated pasta products, such as spaghetti, linguine tagliatelle, bucatini. BACKGROUND TO THE INVENTION [0002] The technology for the formation of dried elongated pasta has long been available wherein fresh pasta strands are shaped commonly into a nest shape and exposed to high temperature drying conditions. The resultant dried nests are unsuitable for inclusion in re-heatable frozen meals as the shape is inevitably lost when the pasta is re-hydrated during pre-cooking. Consequently subsequent portioning steps prior to freezing necessitate the undesirable cutting of the pasta lengths. [0003] The prior art further describes frozen pasta formed by a process wherein a fresh pasta sheet is cut into strips and portioned by directly filling a mould. These bundles of pasta are subsequently cooked within the mould and may then be frozen. [0004] The portioning of fresh pasta pr...

AI Technical Summary

Benefits of technology

[0013] The Applicants have developed a process to produce instantly re-heatable frozen bundles of elongated pasta products which retain an ‘al dente’ texture by virtue of them being formed from dried pasta and also substantially retain the pre-processing length of the pasta by the avoidance of cutting as a means of dividing once re-hydrated.

[0021] The exposure of pasta dough to high temperatures during drying procedures has considerable effects on the compositional structure of the dough which serve to improve the perceived texture when cooked.

[0022] Gluten denaturation occurs from 60 to 80° C. and results in the formation of a protein lattice structure which entraps starch particles and helps to prevent starch loss to the cooking water during re-hydration. Although there are a number of techniques which would be suitable for the drying of pasta dough for the purpose of the invention, it is preferable that the pasta dough undergoes a High Temperature Short Time (HTST) drying procedure.

[0023] A high quality flour with a high gluten content, for example Durham wheat derived semolina flour, is preferably used in the dough since this will give rise to a dense lattice structure when dried. Consequently yielding a higher quality product with better textural properties when re-hydrated.

Problems solved by technology

The resultant dried nests are unsuitable for inclusion in re-heatable frozen meals as the shape is inevitably lost when the pasta is re-hydrated during pre-cooking.

Consequently subsequent portioning steps prior to freezing necessitate the undesirable cutting of the pasta lengths.

The flexible nature of fresh pasta lends itself well to portioning prior to cooking however it is not possible to achieve an ‘al dente’ texture from the fresh pasta and so the essence of a traditionally cooked Italian meal cannot be achieved by this route.

Methods known in the prior art for the production of frozen pasta in which re-hydrated dried pasta has been used are predominantly limited to those wherein short pasta products such as penne, fuselli etc. undergo cooking and freezing.

The inflexible and fragile nature of elongated dried pasta products presents considerable technical difficulties.

Such products are particularly difficult to portion on an industrial scale when re-hydrated and clearly cannot be molded into nests when in their dried form.

Previous attempts to prepare frozen elongated pasta products have involved the horizontal cooking of pasta lengths in a large vessel then straining and portioning, however known techniques for portioning of the entangled lengths of pasta have not allowed the cutting of the pasta to be avoided.

Consequently the product quality is considerably compromised by the presence of short pasta lengths.

Reducing the mass of pasta in each portion to give a shorter re-heating time while providing a desirable nest shape has been found to present further technical problems.

Using only a small amount of pasta it is particularly difficult to form and retain an appealing nest shape.

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