A process for producing pre-cooked rice in block form and pre-cooked rice in block form.

Abstract

This invention describes a process for producing a food product, more specifically, pre-cooked rice in block form that can be reconstituted (made ready to cook) with a unique crispy texture and sensory appeal in a reduced preparation time, either by cooking in a conventional pot or heating in a microwave oven. This process comprises the steps of measuring and dosing the rice grains into individual portions; continuous cooking in a two-compartment tunnel with continuous water exchange; molding and compression into blocks; dehydration by frying; and cooling and packaging.

Description

[0001] PROCESS FOR PRODUCING INSTANT BLOCK RICE AND INSTANT BLOCK RICE FIELD OF APPLICATION

[0001] The present invention discloses a process for producing a food product, more specifically a process for producing ready-to-eat cooking rice with reduced preparation time. It also relates to the rice obtained by this process. DESCRIPTION OF THE STATE OF THE ART

[0002] Rice is a primary food source for more than two-thirds of the global population and is the second most-produced cereal in the world. Its nutritional properties are valued for their protein, carbohydrate, and vitamin content. For some countries, rice production plays a strategic social and economic role, such as Brazil, the largest producer of this grain, and where rice is part of the population's daily diet.

[0003] Due to the sociocultural and economic changes that are occurring in the daily lives of people in modern society regarding food consumption, there is an increase in the demand for ready-to-prepare food products, or instant foods, and among the many types of instant foods is instant rice, also known as quick-cooking rice or QCR (Quick Cooking Rice).

[0004] Instant rice is generally natural rice that has been pre-cooked to a maximum moisture content of 15%, then dehydrated in a commercial oven and packaged. Preparing instant rice requires only a few minutes of rehydration and cooking before the product is ready to eat. Some examples of instant rice are available in the state of the art.

[0005] Patent document KR20130094156 (GO MEE SEON) refers to instant foods designed to shorten cooking times, using a variety of colorants, such as natural powder, and adding nutrients from brown rice, with excellent texture and digestibility. The document reveals a method of manufacturing rice by steaming soaked rice in water, drying the edible rice and grinding it into grains, then spitting the grains in oil and recovering the oil-fried grains. The rice grains in this state are mixed with an edible powder (rice bran) so that the edible powder is evenly coated and colored on their surface. Although this rice presents an easy-to-cook rice, this document reveals the crushing of the rice grains, making the sensory experience of eating this rice far removed from that of eating rice prepared in the traditional way.

[0006] Patent US6509053 (ARROCERIAS HERBA SA) discloses a process for the industrial preparation of vacuum-packed cooked rice, comprising the steps of cleaning, blanching, cooling, draining, drying, frying, mixing with sauces and / or solids, packaging, soaking, cooking, and sterilization. As noted, this document presents a rice soaking process that, like the previously mentioned document, alters the sensory experience. Another important point is that the rice produced is vacuum-packed, which limits its use and application.

[0007] Patent document CA1047831 and the corresponding US patent US4166868 (ANDO MOMOFUKU) refer to a process for manufacturing ready-to-eat rice. The process consists of soaking the rice grains in water for 15 hours, gelatinizing the soaked rice grains by cooking them in a pan for 25 minutes under steam pressure, drying them under a jet of hot air until they reach a moisture content of 18-35%, followed by rolling the grains through forced passage through rollers with slits of 0.1-1 mm. After rolling, a second hot air drying is performed to reduce the moisture content to 13%. Finally, the rice is quickly fried in oil at temperatures of approximately 190°C.

[0008] In contrast, the present invention describes a new process for manufacturing ready-to-eat rice that overcomes the limitations of Canadian patent CA1047831.

[0009] The process of the present invention eliminates the need for long periods of soaking rice grains in water, reducing preparation time, speeding up production, and eliminating microbiological risks due to the grain's prolonged exposure to water during the soaking stage. Furthermore, the gelatinization of the grains is achieved more efficiently and in a controlled manner, through a continuous cooking process with controlled time and temperature.

[0010] A significant difference compared to patent CA1047831 is the absence of grain rolling, a technique that can cause grain deformation, compromising their integrity and natural appearance after rehydration. This step was omitted in this process, thus preserving the original shape and texture of the rice grains.

[0011] In summary, the present invention presents an innovative and improved process for producing ready-to-eat rice, distinguished by the simplicity and efficiency of a continuous process, and by preserving the natural characteristics of the rice grains. Therefore, the present process offers considerable advantages in terms of practicality, standardization, and quality of the final product.

[0012] Patent document GB1280436 (NISSIN SHOKUHIN KAISHA LTD) describes a conventional method of producing instant fried rice. This method involves cooking the rice in a pan for twenty minutes under pressure of 2 to 3 kg / cm². In this process, the cooked rice is subjected to a gradual drying process using hot air at a progressive temperature starting at 30°C and reaching the range of 90°C, reducing the moisture content to 10% to 20%. The rice grains are then fried at 210°C for approximately 15 seconds, resulting in rice grains with an apparent specific gravity between 0.17 and 0.18.

[0013] Comparing the GB1280436 process with the present invention, a rice cooking process is first disclosed that allows the formation of individual portions presented in the form of blocks. The shapes that divide the portion are used throughout the entire process, from cooking to cooling. This technique protects the product during the cooking stage, preventing grain deformation, as it is subjected to the appropriate water:rice ratio and the time of exposure to temperature, which was carefully designed to maintain the grain's originality. Comparing the present invention to that described in patent GB1280436, it is observed that cooking rice in a pressure vessel at the proposed parameters leads to grain deformation due to excessive exposure to pressure and heat. The resulting misshapen mass of rice from this process has a high level of moisture, requiring a long period of exposure to hot air to reach a moisture content of 10 to 20% under the aforementioned drying conditions.This limits the ability to operate at scale and significantly increases costs. Furthermore, the drying step is followed by frying at 210°C, which results in excessive expansion considering the apparent specific gravity reported in the document, similar to what happens to corn kernels when turned into popcorn, losing the kernel's original shape and texture. On the other hand, the current process results in an apparent specific gravity of 0.52, presenting the kernel's natural and original appearance.

[0014] In conclusion, the present invention reveals a simplified and continuous process flow, which allows highly productive scale production, providing economic viability for the consumer, especially considering the socioeconomic reality of most countries.

[0015] As noted, the prior art would benefit from a solution that presents a process for producing instant rice that maintains the physical integrity of the rice grains, thus ensuring that the sensory experience of tasting the rice is not affected. Additionally, the prior art would also benefit from a solution that presents a process for producing instant rice that is already portioned, easy to package and store, and has a long shelf life. OBJECTIVES OF THE INVENTION

[0016] The instant rice production process of the present invention aims to obtain a product with stability during its shelf life (room temperature) mitigating food oxidation, without going through the extrusion stage, thus preserving the shape and appearance of the rice grains, that is, preserving the naturalness and with a sensory experience equal to that of rice prepared in a traditional way.

[0017] This invention also aims to preserve the original shape and physical integrity of rice grains. To this end, innovative techniques and equipment were developed to efficiently and continuously optimize all aspects of production. These techniques maintain the natural characteristics of rice grains, ensuring that the product closely resembles the original grain and adds positive sensory attributes.

[0018] Another objective of the present invention is to offer a process for manufacturing instant rice in block form, involving a compaction step that preserves the original shape of the grains, ensuring that, when reconstituted, they maintain their natural appearance.

[0019] Furthermore, the present invention includes a dehydration step by frying the grains in oil, which promotes the maintenance of their physical and chemical properties, giving the rice the desired shelf-life stability. Furthermore, this approach prevents the risk of oxidation caused by the oxidizing enzymes naturally present in rice, which are notoriously resistant. SUMMARY OF THE INVENTION

[0020] The present invention relates to an innovative process for producing instant rice in block form, which comprises the steps of compressing cooked rice and the subsequent step of controlled dehydration by frying, which provides a quality product, preserving the original shape of the grains, crunchy texture, stability and convenience for the consumer.

[0021] Although conventional approaches to rice production exist, none of them encompass the precise combination of individual batching, continuous tunnel cooking, specialized molding, controlled dehydration, meticulous cooling, sensory customization and protective packaging as proposed in the process of the present invention.

[0022] During the specialized compression or molding stage, the rice grains achieve high density and internal cohesion, reducing voids. Next, the dehydration stage is carried out by frying, where hot oil permeates these voids, promoting an increase in local temperature and rapid expansion of the moisture present. This process results in reconstituted rice grains with a unique crunchy texture and sensory appeal.

[0023] Controlled dehydration in a continuous frying tunnel was developed with the specific aim of providing stability to instant rice at room temperature and preventing oxidation caused by oxidizing enzymes naturally present in rice.

[0024] Thus, based on the aforementioned process flows, it was possible to develop solutions for obtaining an instant product, without going through the extrusion process, capable of preserving the natural characteristics of the rice grain, providing the consumer with a unique sensory experience, with practicality and convenience, without compromising the quality and naturalness of instant block rice. BRIEF DESCRIPTION OF THE FIGURES

[0025] The technical aspects of the subject matter of this invention will become fully clear from the detailed description provided on the basis of the figures listed below, in which: Figure 1 presents a general illustrative drawing of the processing line. Figure 2 presents an illustrative drawing of the molding stage. Figure 3 presents an illustrative drawing of the device for transferring the rice block to the demolding stage and the cooling conveyor belt. Figures 4a-f show illustrative photographs demonstrating the appearance of the rice grain at the different stages of the present process. DETAILED DESCRIPTION OF THE INVENTION

[0026] In accordance with the objectives presented above, the present invention “PROCESS FOR PRODUCTION OF INSTANTANEOUS BLOCK RICE”, which comprises the steps of dosing, cooking and molding, dehydration, and finally, cooling and packaging. Step of dosing the rice grains

[0027] In the initial stage of the process, the dosage of the rice grains plays a crucial role in maintaining the integrity and naturalness of the product. To achieve this, specialized dosing equipment is used, which allows the dosing of individual portions of rice in a continuous processing line.

[0028] The dosing equipment is composed of the following components: 1. a unique supply system that ensures a consistent and controlled flow of rice grains during the dosing process; and 2. a silo with multiple volumetric dosers. These dosers are strategically placed on top of a conveyor belt and are designed to accurately measure and dispense rice grains.

[0029] The dosing equipment also incorporates several control and safety features, including: - a separate electronic control panel, which is isolated from the rest of the processing line and incorporates safety relays and a safety contact; - a dosing system with human-machine interface (HMI) control. The dosing process is governed by an HMI control system, which allows precise adjustments and individual settings for each doser; and - an independent Programmable Logic Controller (PLC). A separate PLC ensures the efficient operation of the dosing system, working in conjunction with the HMI control.

[0030] Once measured, the rice grains are fed into specialized molds. These molds are designed to meet specific requirements, as described below: - Mesh: The mesh used in the molds is made of stainless steel, with 1.85 mm openings and a distribution of 6 openings per linear inch. This mesh provides the necessary permeability for water and oil during the cooking and frying stages; - Coating: To achieve the necessary level of nonstick properties and facilitate demolding while the product is still hot after the frying process, the molds are coated with two layers of polytetrafluoroethylene (PTFE). The PTFE coating is free of perfluorooctanoic acid (PFOA) and has a low coefficient of friction, as well as chemical and heat resistance suitable for process temperatures, reaching approximately 180°C.The coating thickness ranges from 22.5 to 43 micrometers and is food-grade; and - Shape: When designing the mold dimensions, several important factors were considered. In addition to accommodating the required volume of rice for a single serving, the shape also ensures a low coefficient of friction for easy demolding. As a result, the base of the mold has a 9-degree slope, with specific length and width measurements, providing a volume of 283,200 cubic millimeters, suitable for the desired portion size. Continuous Cooking and Molding Stage.

[0031] After dosing the rice into the molds, the grains pass through a cooking tunnel.

[0032] During the development of this stage of the process, special attention was paid to the risks of contamination of the rice used. Rice is known to be a significant source of the contaminant arsenic (As), present especially in crops in the Asian region. Research reveals that rice grains from these areas are frequently contaminated with inorganic arsenic (As), which is the most toxic form of this element. Ingestion of this inorganic arsenic (As) has been associated with several health concerns, such as skin, lung, and bladder cancers, as well as possible non-cancer adverse effects, including respiratory, cardiovascular, neurological, and metabolic diseases.

[0033] Due to the rapid expansion of global food trade, millions of consumers around the world are exposed to the risk of ingesting high levels of arsenic (As) through the consumption of imported rice and rice-based products.

[0034] With this concern in mind, the present invention was carefully developed to incorporate a specific phase during the cooking stage, with the aim of reducing arsenic (As) levels if there is any variation in the raw material used in the product's manufacture. In the following lines, we will describe this specific phase in detail.

[0035] The cooking stage consists of a tunnel with two separate compartments. The first compartment continuously washes the beans, significantly removing contaminants. This involves a constant water exchange, and the beans are held in this compartment for 4 to 6 minutes. These beans are then submerged in circulating water at a temperature of 90 to 98°C, which allows the element to be carried away.

[0036] Scientific studies show that cooking rice with high arsenic levels, when using excess water, is an effective method for significantly reducing this contaminant. For example, Raab et al. (2019) demonstrated that a 6:1 ratio (water: rice) resulted in a 35% and 45% reduction in arsenic concentration in two rice varieties, when compared to raw rice. Gray et al. (2016) found that rice cooked in water free of inorganic contaminants, in a 10:1 ratio (water: rice), reduced the content of inorganic arsenic (the most toxic) by up to 60%, depending on the variety. Another study by Carey et al. (2015) demonstrated that a 12:1 ratio (water: rice) resulted in a 57% reduction in inorganic arsenic.

[0037] In the process of the present invention, the first cooking phase developed to reduce arsenic contamination in rice employed a water-to-rice ratio of 12.8:1. Furthermore, a water flow rate equivalent to 3 to 4 total water changes per hour was implemented, meaning all the water in the tank is changed every 15 to 20 minutes. This process achieved a contaminant reduction of approximately 75% to 88%.

[0038] Surprisingly, the promising results demonstrated a significant reduction in the presence of arsenic, which represents a significant impact on food safety and public health, providing an effective method to minimize exposure to this dangerous contaminant.

[0039] In conclusion, the results obtained revealed a significant reduction in the presence of arsenic in rice when employing a specific water:rice ratio and an adequate water renewal rate.

[0040] In the second compartment, the grain retention time also varies from 4 to 6 minutes, and the temperature ranges from 90 to 98°C, completing the rice cooking process. At this stage, the water is renewed to remove excess starch released from the rice, preventing oversaturation of the cooking water. The water renewal rate varies from 30% to 100% of the circulating volume, and water renewal occurs continuously, maintaining a maximum solids level in the cooking water of 0.6%. This represents 50% renewal every hour.

[0041] At the end of the cooking tunnel, the molding station is inserted. At this point in the process, the cooked rice completely fills the mold and requires compaction to form a compact block, while preserving the natural characteristics of the grains, which can be seen in the product.

[0042] The molding stage is a novelty due to the specific nature of the process. This stage ensures that: - the force applied for compaction is sufficient to group the grains without causing deformation; - the tool used to apply the force does not affect the integrity of the mold's lining; and - there is no physical contamination of the mold's base material with the food.

[0043] The compaction step is performed by a plunger coated with a nonstick, sanitary material, which prevents product buildup and does not damage the mold's lining. A pressure of 1.0 to 1.2 kgf / cm is applied to the plunger. 2for compaction. To correctly position the plunger in relation to the molds, the upper conveyor belt is mechanically synchronized with the mold belt. The plunger only presses the cooked rice volume when it is 100% vertical, while the smaller rollers inside the conveyor belt maintain the pressure on the plungers during horizontal movement. At the end of the compaction belt, the lower roller raises the plunger vertically before returning to the upper part of the conveyor belt, to avoid damaging the mold lining.

[0044] This process allows the block, after the frying dehydration stage, to acquire the following characteristics: - shape of a compact rectangular block; - the compacted rectangular block with a reduction in rice volume of 5 to 10% after cooking; - dense characteristic in its dry form (after frying), but permeable to water during the reconstitution stage at the time of consumption; - after reconstituted, it allows the rice grains to be seen in their natural form; and - in its preparation, it can be reconstituted on the stove or in the microwave, providing great practicality.

[0045] Therefore, the rice presents unique and innovative sensory attributes, such as crunchiness, texture, flavor, aroma, and color, being manufactured by the process of the present invention. Dehydration Stage

[0046] The dehydration process takes place in a continuous frying tunnel, with the oil maintained at a temperature of 150 to 180°C for a holding time of 10 to 12 minutes. During this stage, heat is transferred from the oil to evaporate the water present in the block. Some of the used oil is incorporated into the product, giving the consumer a distinctive flavor after preparation.

[0047] This step is extremely important for the process, however, it can have negative effects, such as: a. decreased product shelf life due to the Lipid Oxidation reaction; and b. decreased product shelf life due to the Hydrolytic Oxidation reaction.

[0048] Based on these two aspects, the preventive measures covered by the process are described below: (iii) lipid rancidity: this phenomenon occurs when fats and oils come into contact with oxygen in the air, which is accelerated by heat and the presence of catalytic metals. Oxidation begins with the formation of free radicals in the unsaturated fatty acids present in the oil or fat, triggering a chain reaction that accelerates the rancidity process of the food, significantly reducing its shelf life. During the oxidation process, several byproducts are formed, imparting an unpleasant rancid flavor to the product.

[0049] The process developed includes two containment measures, one physical and one chemical: - Physical measures: (i) The process was designed so that water vapors resulting from the dehydration process, which accumulate in the upper part of the tunnel, are controlledly eliminated, forming a protective layer that reduces the entry of oxygen into the frying dehydration zone. This layer acts as an insulating physical barrier, preventing fat oxidation. To achieve controlled vapor elimination and the formation of the protective layer, a minimum pressure of approximately 30 mm of water column was maintained in the dehydration chamber, preventing or hindering the entry of ambient air.This was achieved using a pressure gauge, interlocked with an exhaust valve to ensure adequate steam volume during the dehydration process; (ii) another measure adopted in the process development was the presence of a heat exchanger used to cool the fat during line shutdowns. When this occurs, the fat present in the tunnel, which is at a temperature between 150 and 180°C, is transferred to a buffer tank, passing through a filter screen to remove any particles that may have passed from the product to the medium. The fat then passes through the heat exchanger, which reduces its temperature to between 50 and 60°C.avoiding slow cooling that would accelerate oxidative reactions, and finally storing it in the buffer tank at a maximum temperature of 60°C; (iii) the line also has filters through which the processed fat passes continuously as it is pumped to the heat exchanger used to recover the medium temperature. These filters remove product fragments that could contaminate the fat, thus preventing these fragments from burning in the heat exchanger piping and, consequently, fat polymerization. Fat polymerization leads to the undesirable formation of deposits on the equipment walls, which, in addition to clogging the equipment, promote fat oxidation, resulting in the formation of byproducts that impart a rancid flavor to the product.In this flow, the fat passes through two filters: the first is a perforated mesh filter, which retains larger particles, and the second is a polishing filter, which captures smaller particles, keeping the frying medium clean and free of unwanted particles. 2.5 kgf / cm pressure gauges are installed at the inlet and outlet of these filters. 3, which indicate filter saturation by particles, providing a warning that cleaning is necessary; (iv) the line has two sets of these filters that operate in compensation mode to avoid interrupting the process for filter cleaning; - chemical measure: chemical prevention to provide greater oxidative stability is related to the frying medium. To this end, a formulation composed of oils high in monounsaturated fatty acids was developed, combined with a blend of antioxidants that includes a mixture of tocopherols (alpha, beta, gamma, and delta), ascorbyl palmitate, rosemary extract, TBHQ, and citric acid. The components of the formulation have the following functionality and quantity: 1. Tocopherols (alpha, beta, gamma, and delta): Tocopherols are a group of compounds belonging to the vitamin E family.They act as antioxidants, neutralizing and preventing the formation of harmful free radicals, which can lead to lipid oxidation. Participation in the mixture is 300 mg / kg. 2. Ascorbyl palmitate: Also known as vitamin C ester, ascorbyl palmitate is a fat-soluble form of vitamin C. It acts as an antioxidant, inhibiting lipid oxidation and preserving their quality. Participation in the mixture is 100 mg / kg. 3. Rosemary extract: Rosemary extract contains several phenolic compounds, such as rosmarinic acid and carnosic acid, which exhibit strong antioxidant properties. These compounds help protect fats from oxidation and extend their shelf life. Participation in the mixture is 30 mg / kg. 4. TBHQ (tert-butylhydroquinone): TBHQ works by inhibiting the formation of free radicals and interfering with the lipid oxidation process. Mixture participation is 70 mg / kg 5.Citric acid: Although primarily used as an acidity regulator, citric acid also has antioxidant properties. It helps prevent lipid oxidation by chelating metal ions that can catalyze oxidation reactions. The blended dose is 200 mg / kg. By combining these different antioxidants, the aim was to significantly improve the overall oxidative stability of fats, and surprisingly, the result was an extended shelf life and preservation of product quality.

[0050] These physical and chemical preventive measures were implemented in the process to ensure the quality and stability of the frying medium, thus preventing oxidative reactions and the formation of undesirable flavors in the product. Cooling and Final Packaging Stage

[0051] After the frying stage is completed, the rice block is unmolded and transferred from the molds to a conveyor belt at the entrance to the cooling stage.

[0052] Transfer between conveyors: The demolding system and the transfer between the frying exit and the cooling stage are carried out smoothly, aiming to preserve the integrity of the rice block. This helps reduce grain loss due to small breakages, in addition to maintaining the net weight as described on the packaging. Small forks are used to perform this transfer. They receive the fried block at the incline of the tray, carefully carrying it to the dryer conveyor.

[0053] The demolding process was fully developed by the inventors so that the transfer occurs without breaking the product, which after the frying process becomes extremely friable and therefore very sensitive to any mechanical action, no matter how gentle.

[0054] After transfer, the molds used return to the beginning of the production line through the lower part of the frying stage, where, on the return journey, they undergo a cleaning process to remove residual oil.

[0055] Cooling the rice block: The cooling step plays a key role in reducing the temperature of the rice block to below 40°C (104°F) to prevent condensation from forming in the final packaging. This condensation could lead to microbiological deterioration of the product over its shelf life. Additionally, during this step, a sachet containing the product's flavoring seasonings is added, completing the final product, which consists of the rice block and the flavoring sachet. Sensory Experience

[0056] The distinctive characteristic of the rice resulting from the process of the present invention is its crunchy texture when consumed. This characteristic derives, in particular, from the compaction and dehydration steps through frying.

[0057] The process involves compacting cooked rice into a mold using compressive forces that result in a denser, more cohesive structure. Compaction reduces the voids between the grains, increasing the interaction between the starch molecules present in the rice.

[0058] During frying, when compacted rice is submerged in hot oil, a phenomenon called diffusion occurs. According to the laws of thermodynamics, heat from the oil is transferred to the rice, increasing the local temperature and causing the moisture contained in the compacted grains to rapidly expand. This expansion creates voids in the rice's internal structure.

[0059] Based on the second law of thermodynamics, we know that systems tend to seek thermodynamic equilibrium. In this case, the hot oil, which is hotter than the rice, permeates these empty spaces through a process called mass transport, driven by the temperature gradient between the rice and the oil. The oil fills the empty spaces, establishing thermal equilibrium through heat conduction.

[0060] During frying, a complex reaction called the Maillard reaction occurs, involving the caramelization of sugars in the rice, the fragmentation of proteins, and the formation of aromatic compounds. This reaction contributes to the formation of the crispy layer on the surface of the rice. The compounds resulting from the Maillard reaction add flavor and texture, unique characteristics of the product.

[0061] The process of this invention combines precise dosing, rice compaction, and frying in hot oil, and features a complex interaction between the physical and chemical properties of the components involved. The development of this innovative process results in a block of instant rice with a unique, sensorially appealing crunchy texture, which stands out from other options available on the market and provides consumers with a unique culinary experience.

[0062] In view of the above, the process and the product obtained, instant block rice, provide a solution to the state of the art by enabling the production of perfectly dosed instant rice, while maintaining the integrity of the grains, which allows for a differentiated sensory experience, in a block with optimized shelf life.

[0063] The following examples show the results of the production process tests (Example 1), determination of the frying temperature curve (Example 2), identification of the tolerance limit of the starch level in the cooking water (Example 3), comparative analytical data on physical-chemical composition (Example 4), evidence proving the naturalness of the grains after the compaction stage (Example 5) and shelf life (Example 6).

[0064] Example 1: Testing the production process

[0065] The uncooked rice was divided into individual portions and placed into 50 molds. The molds were then baked at 98°C for 10 minutes to allow the starch in the rice to gelatinize. This process resulted in a 240% increase in mass due to water absorption during cooking.

[0066] After the cooking stage, the blocks were subjected to compression, with each one receiving a compression force of 1.2 kgf / cm2. The blocks were then subjected to dehydration by frying, being exposed to temperatures between 140 and 160°C for 10 minutes.

[0067] After dehydration, the blocks were removed from the molds and cooled. The resulting blocks had a moisture content of 1.2% and a fat content of 14%, as shown in the table below.

[0002]

[0068] Example 2: Tests to determine the frying temperature curve

[0069] Based on several successive tests, it was possible to determine the temperature ranges required for the dehydration process, ensuring adequate moisture reduction in the compacted block. These moisture levels are essential to ensure the microbiological stability of the product.

[0070] The temperature of the dehydrating medium was measured during the drying cycle to achieve a reduction in the moisture content of the compacted block, which ranges from 60 to 66%, to a final moisture content of no more than 5%. After careful analysis, the following temperature ranges were developed over time and process, as represented in the table below. Time (minutes) Temperature Range (°C) 1 to 2 140 to 1492 to 3 122 to 1443 to 3 122 to 1234 to 5 123 to 1245 to 6 125 to 1276 to 7 128 to 1367 to 8 138 to 1508 to 9 152 to 1569 to 10 159 to 160

[0071] These data are important in developing an efficient dehydration process, providing the necessary microbiological stability for the final product.

[0072] Example 3: Tests to identify the tolerance limit of starch levels in cooking water

[0073] Consecutive cooking tests were conducted to determine the maximum tolerated starch concentration in the cooking water, i.e., the solids content of the cooking medium, without affecting the performance of subsequent process steps. These tests were repeated in duplicate, totaling five experiments.

[0074] The results demonstrate that the maximum limit is reached after two cooking cycles, when the moisture content of the dehydrated block exceeds the acceptable limit. A moisture level of up to 5% is considered acceptable. It was noted that the results presented values ​​above this limit when the starch concentration in the cooking medium was greater than 0.6%. The table below displays the results obtained and provides data to establish the cooking water renewal rate at this stage of the process.

[0075] Example 4: Comparative analytical tests of physical and chemical composition

[0076] Physicochemical analyses of the raw rice and the final product confirm that there is no significant nutrient loss. The percentage reduction in protein and carbohydrates observed in the analyses is a result of the increased fat content, resulting from absorption during the dehydration process through frying. Likewise, the increase in caloric value is explained by the increased energy content of the food.

[0077] The table below presents the results of the analyses. The data in the table demonstrate that the process described does not compromise the nutritional composition of the rice, since the reductions in protein and carbohydrate content are offset by the increase in fat content, offering a tastier and higher-calorie option. Nutrient Raw Rice % Final Product % Caloric Value Total 351 463 Protein 6.7 6.5 Fat 0.4 14.1 Carbohydrates 80.1 77.5 Moisture 12.0 1.1 Fiber 0.30 0.29 Ash 0.50 0.48

[0078] Example 5: Evidence proving the naturalness of the grains after the compaction stage

[0079] The behavior of the rice grains during the process was analyzed by comparing their physical characteristics, such as the appearance of the rice grain in the different stages: raw (figure 4A), after the cooking process (figure 4B), after compaction (figure 4C), after dehydration by frying (figure 4D) and finally in its reconstitution without flavoring (figure 4E) and with the addition of flavoring (figure 4F).

[0080] These photos demonstrate the physical changes the rice undergoes during the process, providing a clear and comparative view of the transformations. The final result demonstrates the quality of the product in terms of the grain's characteristics, demonstrating the maintenance of its natural appearance throughout the process. Furthermore, such visual evidence reinforces this innovative invention and the product's competitive differentiation in the food market.

[0081] Example 6: Shelf life testing

[0082] Product shelf life testing was carefully conducted to determine the shelf life of instant rice. Accelerated tests were conducted in a dedicated climate chamber, properly calibrated at a temperature of 40°C and a relative humidity of 75%. These conditions were selected to obtain results that accurately reflect the product's behavior over time.

[0083] The table below presents the detailed results of the tests performed.

[0003] Product Instant Rice Block Test Type Accelerated - Climatic Chamber at 40°C - 75% RH Fat Type Vegetable Fat Type Polyester Laminated Film with Polyethylene Results

[0084] Based on the detailed results presented in the table above, it can be seen that the control parameters remain within stability limits during accelerated testing conditions. These results provide evidence that the product has an adequate shelf life and meets the required stability requirements.

[0085] This information is important and necessary for the protection of innovation and the commercial success of the product, confirming its quality and durability.

[0086] It should be understood that the present description does not limit the application to the details described herein and that the invention is capable of other embodiments and of being practiced or executed in a variety of ways, within the scope of the claims. Although specific terms have been used, such terms should be interpreted in a generic and descriptive sense, and not for the purpose of limitation.

Claims

1 / 3 CLAIMS 1. PROCESS FOR PRODUCING INSTANTANEOUS RICE IN BLOCKS, characterized by the fact that it comprises the steps of: a) dosing the rice grains into individual portions; b) continuous cooking in a two-compartment tunnel with constant water exchange; c) molding and compacting into a block; d) dehydration by frying; and e) cooling and packaging.

2. PROCESS, according to claim 1, characterized by the fact that the rice grains from the dosing step are directed to forms that comprise a permeable mesh and that promotes containment of the rice. 3.PROCESS, according to one of claims 1 or 2, characterized by the fact that the cooking takes place in a tunnel with two separate compartments, in which - the first compartment performs a continuous washing of the grains, with constant water exchange with a water renewal rate every 15 to 20 minutes, in a water:rice ratio of the order of 12.8:1, and the grain retention time of 4 to 6 minutes, in which the grains are submerged in circulating water at a temperature of 90 to 98 °C; - the second compartment performs the completion of the cooking continuously with a retention time of 4 to 6 minutes with a water renewal rate of 50%, in which the grains are submerged in water at a temperature of 90 to 98 °C.

4. PROCESS, according to any one of claims 1 to 3, characterized by the fact that the compaction of the rice into blocks is carried out by a piston, in which the piston compresses the rice block with a pressure of 1.0 to 1.2 kg / cm2. 2 / 3 5. PROCESS, according to claim 4, characterized by the fact that the plunger is coated with non-stick material.

6. PROCESS, according to any one of claims 4 to 5, characterized by the fact that during the compaction of the rice in blocks it is ensured that: - the force applied for compaction is sufficient to group the grains without causing deformation.

7. PROCESS, according to any one of claims 1 to 6, characterized by the fact that the dehydration step takes place in a continuous frying tunnel, with the oil maintained at a temperature of 140 to 160 °C throughout the entire process, in which the initial temperature is adjusted to 150 to 180 °C, and with a retention time of 10 minutes.

8. PROCESS, according to claim 7, characterized by the fact that heat is transferred from the oil to the evaporation of the water present in the block, part of the oil being incorporated into the product. 9.PROCESS, according to claim 8, characterized by the fact that physical and chemical procedures for containing lipid oxidation and hydrolytic oxidation are performed.

10. PROCESS, according to claim 9, characterized by the fact that the physical procedures are: - controlled elimination of water vapors resulting from the dehydration stage, accumulated in the upper part of the tunnel; - use of a heat exchanger to cool the fat during line stops; - transfer of the fat present in the tunnel to a buffer tank, passing through a filter screen to remove particles; - passage of the fat through the heat exchanger; and - storage of the fat in the buffer tank. 3 / 3 11. PROCESS, according to claim 10, characterized by the fact that the dehydration stage line has two sets of filters that operate in compensation mode, in which the fat in process passes continuously as it is pumped to the heat exchanger, which is used in the recovery of the temperature of the medium.

12. PROCESS, according to claim 9, characterized by the fact that the chemical procedure uses a composition of oils with a high content of monounsaturated fatty acids and antioxidants.

13. PROCESS, according to any one of claims 1 to 12, characterized by the fact that the fried rice block is demolded and transferred from the molds to a conveyor belt at the entrance to the cooling and packaging stage. 14.OXIDATION CONTAINMENT COMPOSITION, characterized by the fact that the composition comprises: Mixture of alpha, beta, gamma and delta Tocopherols - 300 mg / kg Ascorbyl Palmitate - 100 mg / kg Rosemary Extract - 30 mg / kg TBHQ - 70 mg / kg Citric Acid - 200 mg / kg.

15. PROCESS, according to any one of claims 1 to 13, characterized by the fact that the cooling step reduces the temperature of the rice block to below 40 °C and subsequently a sachet containing the flavoring seasonings of the instant rice in block is added.

16. INSTANTANEOUS RICE IN BLOCK, characterized by the fact that the rice is obtained according to the process defined in any one of claims 1 to 13.