Methods and systems for upcycling sub-grade berries into shaped berry PURÉe

Abstract

A method and system for upcycling sub-grade berries into molded frozen puree products are disclosed. The process involves collecting B grade berries, preparing them, and processing them into a puree. The puree may then be molded into a shape the resembles a berry used in the puree, frozen, and packaged, resulting in a product that reduces food waste and provides a sustainable alternative to discarding sub-grade berries or using them for limited purposes.

Description

[0001]METHODS AND SYSTEMS FOR UPCYCLING SUB-GRADE BERRIES INTO SHAPED BERRY PURÉE Inventor: Robert F. Underwood RELATED APPLICATIONS This application claims benefit of and priority from U.S. Provisional Patent Application Nos. 63 / 682,125, filed August 12, 2024, and 63 / 770,579, filed March 12, 2025, which are hereby incorporated by reference in their entireties as if fully set forth herein, for all purposes. BACKGROUND The inventive subject matter disclosed herein (i.e., the one or more disclosed inventive concepts relates to the field of food processing and, more specifically, to a method and system for upcycling and processing natural, sub-grade berries into a reconstituted shape that resembles or mimics the shape of a natural berry. More particularly, the reconstituted berry is molded from a purée, with mold wells corresponding to the shape of a kind of berry from which the purée is made. The United States Department of Agriculture (USDA) sets forth standards for grading berries based on quality, size, ripeness, and freedom from defects. The grades range from U.S. No.1 (or A), which represents berries of good quality and condition, to lower grades like U.S. No.2 (or B), which includes berries that do not meet the criteria set for U.S. No.1 but are still suitable for consumption. The food industry often discards sub-grade berries that are subgrade, e.g., do not meet aesthetic standards for fresh market sales, despite their good nutritional value. There is a need for methods and systems that can transform subgrade berries into more valuable and useful products, reducing food waste and promoting sustainability. SUMMARY In a possible embodiment, the inventive subject matter addresses the aforementioned needs and others by providing methods and systems for processing berries of a grade below USDA grade 1, A or choice into more valuable and useful products. The berries may be any variety, including blackberries, raspberries, and blueberries. The berries are processed into or provided as a purée. The purée may then be molded into shapes resembling the original berries, frozen, and packaged for distribution. 1 Docket No. FBB2001PCT In a possible embodiment, the inventive subject matter provides methods and systems directed to the upcycling of sub-grade berries, specifically those not meeting a top USDA grade, into shaped berry purée products that mimic the appearance, size, and structure of natural berries. In certain embodiments, the inventive subject matter encompasses processing techniques involving (1) supplying a bulk quantity of whole berries or natural fruits that are below the highest USDA grade and converting these into a purée, and / or (2) providing a bulk quantity of purée wherein the constituent berries are of sub-grade quality. In a possible embodiment, the inventive subject matter further includes the step of forming the resulting purée into shaped berries, the shapes of which correspond to the kind of berry used in the purée, such that the final product holds its shape at least during frozen storage. In some embodiments, the purée is deposited into one or more molds with a plurality of wells, each well being configured in the shape of a berry used in the purée composition. To impart desirable characteristics to the purée, the inventive subject matter may encompass the addition of at least one additive distinct from berry material. In some aspects, this additive comprises date material, which is homogenized into the purée. The homogenization process may include subjecting the purée combined with dates to a heating step of at least 100 degrees Fahrenheit (37.8 degrees Celsius) for a minimum of 2.5 minutes. The dates may be present in the purée in an amount ranging from 10% to 30% by weight. In a possible embodiment, the inventive subject matter also contemplates freezing the purée within the molds, such that shaped, frozen berries are formed. In further embodiments, the purée processing, molding, and freezing steps may be accomplished in a continuous in-line process that utilizes a plurality of processing stations. For example, a moving belt may transport the molds to one or more processing stations, and purée from an inline batch tank may be pumped into the molds at a dedicated molding station. After molding and freezing, the shaped berries are released from the molds and packaged into commercial packaging. In a possible embodiment, the inventive subject matter includes maintaining these packaged berries in a frozen condition to preserve their shape and quality. The berries processed according to the inventive subject matter may include, independently or in combination, blackberries, raspberries, blueberries, and currants. 2 Docket No. FBB2001PCT In a possible embodiment, the inventive subject matter further provides for fruit-based products comprising shaped berries that mimic a selected kind of berry, wherein the formed berry comprises a frozen fruit purée with a dominant berry material corresponding to the selected berry type. The purée may further include a natural fruit-based sweetener additive (such as date material) other than a refined or artificial sweetener, and this additive serves to raise the melting point of the purée. In certain embodiments, the additive comprises homogenized dates blended into the purée, with the dates present at 10% to 30% by weight. The resulting shaped berry product may be formulated to take at least 60 minutes to completely melt at room temperature, which enhances product stability and consumer utility. In a possible embodiment, the inventive subject matter also contemplates that the purée is derived from a sub-grade dominant berry, and may include two or more berry varieties, such as blackberries, raspberries, blueberries, and currants, in any combination. In further embodiments, the inventive subject matter provides that the purée may possess a viscosity of at least 60 centipoises (cP) at room temperature, thereby supporting molding fidelity and product stability. The method may further comprise the step of homogenizing dates into the purée during processing, wherein the heating step may be carried out at not less than 90 degrees Fahrenheit (32.2 degrees Celsius) for a duration of at least 2.5 minutes. In summary, the inventive subject matter encompasses methods, systems, and products for upcycling sub-grade berries into shaped berry purée products. The following is a detailed description of various embodiments under the inventive subject matter. The appended claims, as originally filed in this document, or as subsequently amended, are hereby incorporated into this Summary section as if written directly in. The foregoing is not intended to be an exhaustive list of embodiments and features of the inventive subject matter. Persons skilled in the art can appreciate other embodiments and features from the following detailed description and Figures. BRIEF DESCRIPTION OF THE DRAWINGS The appended figures show embodiments according to the inventive subject matter, unless noted as showing prior art. FIG.1 shows representative frozen shaped fruits consisting of certain berry types. 3 Docket No. FBB2001PCT FIG.2 shows a close-up view of a berry type from FIG.1. FIG.3 shows a mold with plurality of wells for molding the kind of berry shown in FIG.2. FIGs.4-5 are examples of known processes and flow for pureeing fruit. FIG.6 shows process and flow steps for producing a frozen shaped fruit. FIG.7 is a table that indicates how dates added to different berry purées can significantly increase viscosity, as measured in centipoises (cP). FIG.8 shows a test in the way of a date table and corresponding images of shaped berry made of purées with and without dates were compared over 20 minutes after removal from a freezer in a frozen state. DETAILED DESCRIPTION. Representative embodiments according to the inventive subject matter are shown in Figs.1-8. In general, the inventive subject matter provides methods and systems for upcycling and processing natural, sub-grade berries into a reconstituted shape that resembles or mimics the shape of the kind of berry that is processed. As used herein, “mimic” means that the shaped berry to a casual observer is a fair facsimile of the natural berry in terms of shape, size and color but a close observer may note differences and not believe it is an actual berry just as ornamental wax fruit may appear real at a distance but not to a closer observer. More particularly, the reconstituted berry is molded from a purée, with mold wells corresponding to the shape of a kind of berry from which the purée is made. While the inventive subject advantageously may allow for recycling of subgrade berries, it can be used with any grade of berry. The inventive subject matter may apply to other types of fruits or to vegetables, but berries will be used herein as the principal example. A subgrade berry or other fruit or vegetable refers to a set of berries that are found to be below a higher United States Department of Agriculture (USDA) standard, with standards referenced herein being those in effect as of the filing date of this application. The standard may be that of the whole fruits or vegetables or to a composition processed from a set of whole fruits or vegetables assigned a particular USDA grade or grades below a higher standard. For example, a purée formed from berries of grade 2 or B would be considered a grade 2 or B purée. Some background on USDA grading follows. 4 Docket No. FBB2001PCT The grade of berries and other agricultural products is typically determined by USDA-licensed inspectors or graders. These inspectors are trained and authorized by the USDA's Agricultural Marketing Service (AMS) to evaluate products according to the official USDA grading standards. But the standards herein may be applied by others familiar with berry production and the standards. Process for Determining the Grade: 1. Sampling: Inspectors take samples from the lot or batch of berries to evaluate. The sample size and method of selection are designed to represent the entire batch accurately. 2. Inspection: The inspectors assess the berries based on the specific criteria outlined in the USDA grading standards. This includes evaluating factors like size, color, firmness, and the presence of any defects (e.g., mold, decay, or physical damage). 3. Classification: After evaluation, the inspectors classify the berries into the appropriate grade category (e.g., U.S. No.1, U.S. No.2) based on how well they meet the standards. 4. Documentation: Once the grade is determined, it is documented, and the grade can be used for marketing and selling the berries. The grade often appears on packaging or in marketing materials to inform buyers of the quality level. Number Grades (e.g., U.S. No.1, U.S. No.2): Number-based grading is commonly applied to fresh fruits and vegetables, including whole berries. Number grades classify products based on specific quality criteria such as size, color, firmness, and absence of defects. • U.S. No.1: Represents the highest standard, typically for fresh produce that meets all quality criteria. • U.S. No.2: Allows for more minor imperfections and less uniformity but still meets acceptable standards for sale. Letter Grades (e.g., Grade A, Grade B): Letter grades are often applied to processed products, including frozen or canned fruits and vegetables, but sometimes also fresh produce. Letter grades evaluate overall quality, with Grade A typically representing the highest quality. 5 Docket No. FBB2001PCT • Grade A (or Fancy): Indicates the product is of top quality, with excellent color, shape, and flavor. For berries, this would mean they are uniform in size and appearance, and free from defects. • Grade B (or Choice): Represents good quality but with more leniency for imperfections in appearance, size, or flavor. • Grade C (or Standard): Acceptable quality, often used for processing where appearance is less important. Descriptive Terms (e.g., Choice, Select, Fancy): Descriptive terms apply to various food products, including fresh and processed fruits and vegetables. These terms describe the quality more subjectively and are often used with other grading systems. • Choice: Often signifies a mid-range quality, below Fancy but still of good quality. • Fancy: Indicates the highest quality, often associated with the best appearance, flavor, and texture. • Standard or Utility: Lower quality, often used for processing rather than fresh consumption. Relationship and Differences: The grading terms are used depending on the type of product and whether it is fresh or processed. Fresh berries are more likely to be graded with number grades (U.S. No.1, U.S. No. 2), while processed or frozen berries might be graded with letter grades (Grade A, B, C) or descriptive terms (Fancy, Choice). Sometimes, the terms can be interchangeable in their meaning. For example, "Grade A" and "U.S. No.1" might both refer to the highest quality of a product, but the specific grading system used will depend on the product and its intended market. Letter and descriptive grades (like Grade A or Fancy) are often more consumer-friendly and easier to understand, while number grades (like U.S. No.1) are more technical and specific to industry standards. In summary, while the different grading systems serve the same purpose— classifying product quality—they are applied differently based on the product type and context, with some overlap in meaning. (Persons skilled in the art will appreciate that the use of USDA grading standards disclosed herein can be applied in any jurisdiction by such a person and are not meant to imply that in a jurisdiction not subject to USDA standards that another standard should apply.) Introduction to Berry Varieties 6 Docket No. FBB2001PCT The term “berry” encompasses a variety of fruits with different characteristics and grading standards. Blackberries and raspberries are known as brambles, belonging to the genus Rubus. These fruits are aggregate fruits, composed of smaller units called drupelets. Blueberries, on the other hand, are true berries from the genus Vaccinium. Fruits from the genus Ribes may also be considered berries. This genus includes currants and gooseberries. Plants in this genus produce small, round berries and are typically shrubs. Examples include blackcurrants (Ribes nigrum), redcurrants (Ribes rubrum), and gooseberries (Ribes uva-crispa). Upcycling Subgrade Berries into Purée The inventive subject matter is directed to the use of a bulk fruit material to produce shaped berries. The bulk material can be the berries themselves or a bulk amount of purée from a bulk source of berries. The bulk material may be provided in a container like a tote, box, or large bag. It will typically weigh at least 400 lbs (181 kilograms) or have a volume of 55 gallons (208 liters). The bulk material may also be provided directly or indirectly from farm harvesting or storage equipment into processing systems, e.g., hoppers or vats of an industrial scale for batch operations. Batch operations contemplate at least 400 lbs (181 kilograms) or have a volume of 55 gallons (208 cubic meters) for a batch process. In some embodiments, the inventive subject is directed at processing a bulk supply of subgrade berries and does not include the steps of collecting or pureeing the berries. In other aspects, the inventive subject matter may include any number or combination of the steps defined herein leading to the production of shaped berries. As used herein, "purée" refers to one or more natural fruits or vegetables that have been blended, mashed, or strained to create a smooth, viscous or creamy consistency. The material being processed may or may not be heated in the processing steps. Other ingredients or additives may be added to a purée to impart desired characteristics, but the starting bulk fruit or vegetable will be the major component. In considering the following process steps, it will be appreciated that not all are required to produce a shaped berry. For example, while removal of seeds is desirable, it is not essential to create a shaped berry. It will also be appreciated that any two, three, four, five, six or more of the following steps may be connected by belt, conveyor, and / or pump system systems for uninterrupted sequential processing. 7 Docket No. FBB2001PCT Figs.4-6 are schematics of processing and flow steps and known equipment that may be used in the inventive subject matter. Figs.4-5 are examples of known processes and flow for pureeing fruit. Fig.6 shows process and flow steps for producing a frozen shaped fruit. The process and flows of Figs.4-6 may be used to produce purées that are then integrated into the process and flow of Fig.6. It will be appreciated that not all process and flow steps are required to produce a shaped fruit. For example, magnetic detection while desirable for quality control, is not a required step to produce an end-product. Here follows a set of steps that may generally be used to produce a packaged end-product. Step 1: Collection and Sorting Berries that are below a USDA standard grade are collected into a bulk amount. This, for example, may include B grade blackberries, raspberries, and blueberries that are overripe, misshapen, or slightly bruised but free from mold and decay. Step 2: Cleaning The collected berries may be washed with care to remove any dirt or residues, to help ensure the purity of the purée without causing further damage to the fruits. Step 3: Preparation The berries may be prepared by removing cores, stems, and leaves. Step 4: Berry Compositions & Pureeing The selected berries along with any other ingredients are processed into a purée. The berries used in the purée may be of single type or a mix of types, at least one type being a bulk amount of subgrade berries. In some cases, a mix of berry types will be based on a primary berry, whose flavor and / or appearance are dominating characteristic in the resulting purée and whose shape is mimicked or resembled in the end-product, shaped berry. In some cases, the major berry component will be a subgrade berry. In some cases, the subgrade berry component will represent 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or more of a purée will be of subgrade berries. Other ingredients or additives optionally may be included in a berry purée. They may include other natural or manufactured ingredients that enhance properties of a purée like viscosity, texture, flavor, sweetness, shelf-life, melting point, nutritional, health, and well-being 8 Docket No. FBB2001PCT supplements. Various ingredients can be used that are plant-derived to enhance product characteristics. Various plant-derived ingredients can be incorporated into the process to enhance the flavor, texture, and nutritional profile of the shaped berries. For instance, natural fruit juices such as apple or orange juice can be added to boost sweetness and moisture in the purée while maintaining a health-conscious balance. Plant-based thickeners like pectin and guar gum may also be utilized to achieve the desired consistency, offering structural integrity to the shaped berries without introducing artificial or processed substances. Additionally, spices such as cinnamon or ginger can be included to enrich the flavor profile, adding depth and a subtle aromatic quality to the end product. Other examples include natural extracts like vanilla or almond, which can provide a hint of luxury to the flavor palette. These additives not only complement the primary berry components but also align well with the goal of creating a product that is both appealing and free from harmful refined sugars or synthetic sweeteners. By combining these natural options strategically, the final shaped berry can cater to diverse consumer preferences while upholding nutritional integrity. One example of an optional ingredient or additive, dates may be included in the purée to achieve certain advantages effects, as discussed in more detail below. Here follows some background information on dates. Also, important is what may be excluded from the shaped berries: refined sugars and sweeteners may be excluded. Refined sugars are processed forms of sugar that are extracted from natural sources such as sugarcane or sugar beets. During the refining process, these sugars are stripped of their natural nutrients, including vitamins and minerals, leaving behind pure sucrose. Common examples of refined sugars include white sugar, brown sugar, and powdered sugar. These sugars are widely used in processed foods, baked goods, and sugary drinks to enhance flavor and sweetness. Refined sugars are often labeled as unhealthy because they: • Lack Nutritional Value: They provide "empty calories," offering energy without beneficial nutrients such as fiber, vitamins, or minerals. • Contribute to Health Issues: Excessive consumption has been linked to obesity, diabetes, heart disease, and dental problems. 9 Docket No. FBB2001PCT • Cause Blood Sugar Spikes: Refined sugars are quickly absorbed into the bloodstream, causing rapid spikes and drops in blood sugar levels, which might lead to energy crashes and increased hunger. In addition to refined sugars, there are other forms of sweeteners that are considered harmful when consumed in excess or over time. These include: HFCS is a highly processed sweetener made from corn starch. It contains a high level of fructose, which is metabolized differently in the body compared to glucose. HFCS is commonly found in sodas, candies, and processed snacks. Excessive intake has been associated with obesity, fatty liver disease, and insulin resistance. Synthetic sweeteners such as aspartame, saccharin, and sucralose are often used as sugar substitutes in "sugar-free" or "diet" products. While they are low in calories, they have been linked to potential health risks, including impacts on gut health, headaches, and even long-term metabolic changes, though research in these areas is ongoing. Maltodextrin is a highly processed carbohydrate derived from starch. Although technically not a sugar, it has a high glycemic index and can cause blood sugar spikes similar to refined sugars. It is often used as a thickener or filler in processed foods. Marketed as a "natural" sweetener, agave nectar contains a high concentration of fructose, which can strain the liver and contribute to metabolic issues if consumed excessively. Since it is important to moderate the consumption of refined sugars and unhealthy sweeteners, replacing them with natural alternatives like dates, honey, or maple syrup, which retain more nutrients and provide additional health benefits. Dates have been found not only to be advantageous as sweeteners but also to provide other advantageous properties to the making of the inventive shaped fruits. Dates are the fruit of the date palm tree (Phoenix dactylifera). They are known for their rich, sweet flavor and high nutritional value, being a good source of fiber, vitamins, and minerals such as potassium, magnesium, and iron. Dates are rich in the following nutritional elements: • Sugars: Primarily glucose and fructose, making them a natural sweetener that can enhance the sweetness of a berry purée. • Dietary Fiber: Beneficial for digestive health. 10 Docket No. FBB2001PCT • Vitamins and Minerals: Especially potassium, magnesium, and iron. • Antioxidants: Such as flavonoids, carotenoids, and phenolic acid, which have anti- inflammatory and protective health effects. Blended dates offer a versatile and natural alternative to refined sugars and synthetic additives, making them a popular choice in health-conscious and clean-label products. When dates are blended, they can be transformed into a paste, purée, or syrup and homogenized with berries. As a purée, paste, or syrup, they can be added along with the berries into tank or other container for pureeing, or they can be separately processed into a desired form and then added into the tank with whole berries, or they can be mixed with already pureed berries to create a berry-date purée. Due to their high sugar content, they provide a sweet flavor without the need for refined sugars or artificial sweeteners. Blended dates can act as a binder, holding ingredients together due to their sticky texture. Dates are flavor enhancers and can add a rich, caramel-like sweetness to products. Dates can be added to products to boost their nutritional content, particularly fiber, minerals, and antioxidants. Dates can act as texture modifiers. The smooth, thick consistency of blended dates can be used to alter the texture of food products, providing a creamy or thickening effect in smoothies, for example. Blended dates can significantly affect the properties of purées and liquids, particularly in terms of viscosity and melting point due to their unique composition, which includes natural sugars, fiber, and other soluble solids. Dates can modify viscosity to improve the mouthiness of end products, e.g., to provide a sorbet texture. Viscosity refers to the thickness or resistance to flow in a liquid. It may be measured in centipoise (cP). Unless otherwise noted, it is measured at room temperature i.e., 20-25 degrees C. When blended dates are added to a liquid, they can increase the viscosity due to the following factors: • Fiber Content: Dates contain a high amount of dietary fiber, particularly soluble fiber like pectin and beta-glucan. When blended into a liquid, these fibers absorb water and swell, creating a gel-like consistency. This increases the thickness of the liquid, making it more viscous. • Sugar Concentration (Brix Level): Dates are rich in natural sugars (glucose and fructose), which can contribute to the viscosity of a liquid by creating a denser solution. The sugar molecules interact with water, reducing the free movement of water molecules and thus increasing viscosity. 11 Docket No. FBB2001PCT • Solid Particles: Blended dates are not completely dissolved in liquid but rather dispersed as fine particles. These suspended particles can add to the bulk and thickness of the liquid, further increasing its viscosity. Dates may be added to the bulk fruit material being processed into a purée or they may be added to a preexisting purée. The date material once added may be subject to heat to help it blend or homogenize into a purée material being processed. FIG.9 illustrates representative steps and parameters according to the inventive subject matter. The inventive subject matter is generally directed to adding whole or cut or otherwise segmented dates into a fluid plant-based material like a bulk of fruit or other plant material, a purée, or other processed plant material and causing the date material to release sugars and optionally fibers into the plant-based material to achieve desired properties. Process Overview The process begins with a step 10 of introducing fresh or frozen fruits and / or vegetables into a mechanically agitated vat, tank, or vessel. This initial step involves agitating the mixture until it becomes fluid enough to pump. The choice of fruit or vegetable can vary, including, for example, options like berries, apples, pears, citrus, cherries, celery, carrots, spinach, etc., each contributing unique flavors, colors, and nutritional benefits to the final product. Hereinafter, any such fluid fruit and / or vegetable material of one or more kinds of fruit or vegetable material shall be referred to as a Plant-Based Mixture or “PBM”. To ensure uniform mixing, high-shear mixers or vertical mixers can be employed. Regular cleaning and maintenance schedules may be essential to prevent clogging, especially when dealing with large or fibrous pieces. Additionally, temperature-controlled vats or tanks can help maintain the correct temperature during agitation, preventing spoilage or degradation of the product. Fluidization and Heating Once the PBM is adequately fluid, there is a step of pumping and heating 20 the PBM. Water has a very low viscosity, typically around 1 centipoise (cP) at a room temperature of 20 degrees C. This low viscosity allows it to flow easily and is often used as a reference point (at same temperature) when discussing the viscosity of other liquids. The choice of pump also depends on other factors such as the desired flow rate, the presence of particulates, and the shear sensitivity of the fluid. High-viscosity fluids, such as thick sauces and 12 Docket No. FBB2001PCT pastes, require pumps that can handle the increased resistance to flow without damaging the product. This is particularly important for maintaining the quality and consistency of the juice during processing. For purposes of the inventive subject matter, any of the aforementioned forms of PBM and any pumpable PBM using known or to be developed industrial pump systems may be considered a fluid. Unless indicated otherwise, the term Plant-Based Material or PBM shall refer to a fluid material. The viscosity of dates after decomposition in hot water, as occurs in the processing of date sugars, can vary depending on factors such as the temperature, duration of heating, and the concentration of the date mixture. Generally, date syrup, which is a common product of this process, has a high viscosity. For example, date syrup typically has a viscosity ranging from 1,000 cP to 10,000 cP at room temperature for commercial grade syrups. Although the foregoing description refers to fruit PBMs, it is understood the analogous vegetable compositions will have the same or similar viscosity values. Here is a summary of typical viscosity values at room temperature ranges (20 -25 degrees C) for common commercial grade PBMs: Water: ~1 centipoise (cP) Clear Fruit Juices (e.g., apple, grape): 1 cP- 2 cP Nectar and Pulp-Containing Juices (e.g., orange juice with pulp, pear nectar): 10- 100 cP Concentrated Juices: Can exceed 100 cP Berry Purées (e.g., strawberry, blackberry): 10 cP - 1,000 cP Apple Sauce: 1,000cP - 10,000 cP Fruit Jams, Preserves, and Conserves: 1,000 cP -10,000 cP Date Syrup (Brix level 60-75): 1,000 cP - 10,000 cP 13 Docket No. FBB2001PCT These values are typical at room temperature, but viscosity can change with temperature and Brix level. For example, heating a fluid generally decreases its viscosity, making it flow more easily; while cooling it increases viscosity, making it thicker. In summary, the viscosity of the PBM may vary considerably and may range from 1.2 to 10,000 or more centipoise. (All viscosity values given herein are assumed to be the material at room temperature unless otherwise noted.) In some cases, a PBM may have a viscosity of at least 1.2 cP, or at least 2, or at least 4 cP or at least 6 cP, or at least 8 cP or at least 10, or at least 20 cP, or at least 50 cP, or at least 100 cP, or at least 1000 cP, or at least 2000, cP, or at least 4000 cP, or at least 6000 cP, or at least 8000 cP, or at least 10,000 cP. In one suitable embodiment, the viscosity of the PBM may be from 8 cP to 12 cP. In a representative embodiment, the PBM is pumped through a tube-in-tube heat exchanger. This equipment efficiently transfers heat to the product, ensuring it reaches a temperature range of 100-120 degrees Fahrenheit. The heat exchanger is designed to maintain consistent heating, using food-grade materials that resist corrosion. To address potential challenges such as fouling and scaling, regular cleaning protocols and anti-fouling coatings can be implemented. Advanced control systems, such as PID controllers, can help maintain consistent temperatures, while the heat exchanger can be designed to accommodate varying viscosities by optimizing flow rates and using appropriate materials. Optional, the heating may occur after adding the date material in step 30 below to the PBM. Addition of Dates At this point, under a step 30, whole or destoned dates, either chopped or diced, are added to the vessel with the PBM to form a Plant-Based Date Mixture or “PBDM”. (Hereinafter, any such whole or segmented date material that has not otherwise been processed to decompose or otherwise modify the natural structure of the date tissue shall be referred to herein as “date material”. For purposes of illustration, a date processed into, for instance, a syrup or sugar is not a “date material” as used herein because tissue structure has been lost in converting to a syrup or sugar. The percentage of dates added can be adjusted based on the desired texture, flavor, and sweetness of the final product. Automated dosing systems can ensure consistent addition of dates, while high-shear mixing systems can prevent clumping and ensure even distribution. The mixture, now containing dates, is heated to a sufficient temperature to cause the dates to 14 Docket No. FBB2001PCT decompose to release sugars and optionally fibers. This process continues until the dates break down and liquify into the purée / juice liquid medium, enhancing the PBM with their natural sweetness and texture. A suitable temperature range is 110-120 degrees F preferably with continuous mechanical agitation. However, higher or lower temperatures may be suitable and may accelerate or lengthen the time for the decomposition. Higher temperatures may also apply and may accelerate the decomposition process, but it could also lead to color and flavor degradation. Excessive could cause a burnt flavor. Lower temperatures may not be effective in breaking down the dates. Breakdown of Dates to Release Sugars The breakdown of dates in the heated PBM is a key step to release their natural sugars and achieve a desired Brix level. Mechanism of Sugar Release: Cell Wall Breakdown: Heat and mechanical agitation help break down the cell walls of the dates, releasing the sugars contained within the cells. Enzymatic Activity: Natural enzymes present in the dates or from other fruits, such as invertase, can further break down sucrose into glucose and fructose, enhancing the sweetness of the mixture. Achieving Different Brix Levels: Amount of Dates: By adjusting the amount of dates added to the mixture, the Brix level can be controlled. More dates will result in a higher Brix level, increasing the sweetness. Temperature and Time: While a temperature range of 75°F to 190°F, may be suitable for decomposition of date and other plant materials, maintaining the mixture at 110-120 degrees F may be a more optimal range. The mixture remains heated for sufficient time for the dates to break down facilitates sugar release. The duration of heating and agitation can be adjusted to achieve the desired Brix level. Complete decomposition of date material is about 5 minutes at a target 120 degrees. But in practice as date material is added, the actual temperature may fluctuate between 100-120 degrees during the 5 minutes of decomposition. Accordingly, it can be expected that withing such temperature range, substantial decomposition of date materials has occurred after at least 2.5 15 Docket No. FBB2001PCT minutes. Enzymatic Breakdown: Enzymes like pectinases and cellulases may be added to enhance breakdown. In summary, Brix levels are dependent on factors including the amount of date material added, processing temperature, agitation (time, intensity, mechanics duration), and / or enzymes. Benefits of Using PBM Instead of Water Using a fluid PBM instead of water for processing dates offers several advantages: Higher Sugar Concentration: By avoiding the addition of extra water, which can cause dilution, the sugar concentration remains higher, allowing for better control over the Brix level. Enhanced Flavor Integration: The natural flavors of the fruit or vegetable juice blend seamlessly with the dates, enhancing the overall taste profile of the final product. Nutritional Benefits: The juice provides additional vitamins and nutrients, contributing to the nutritional value of the final product. Improved Texture: The viscosity of the juice helps in achieving a smoother texture, as it aids in the even distribution of the dates and prevents clumping. Temperature Effects on Sugar and Fiber Release Temperature plays a crucial role in the release of sugars and fibers from dates: Sugar Release: Optimal Temperature Range: Heating the mixture to 110-120 degrees Fahrenheit helps in breaking down the cell walls of the dates, releasing the sugars contained within. This temperature range is optimal for enzymatic activity, which further breaks down complex sugars into simpler forms like glucose and fructose. Preventing Sugar Crystallization: Maintaining a consistent temperature prevents the crystallization of sugars, ensuring a smooth and homogenous mixture. Fiber Release: Softening of Fibers: The heat helps to soften the dietary fibers present in the dates, making them 16 Docket No. FBB2001PCT more soluble and easier to integrate into the mixture. Enhanced Nutrient Extraction: Higher temperatures facilitate the release of soluble fibers and other nutrients, enhancing the nutritional profile of the final product. Mechanical Size Reduction Following the breakdown of the dates, the next step 40 that may be applied to the entire PBDM may a series of mechanical size reduction steps. This step may involve equipment such as grinders, mills, purée finishers, juice extractors, or homogenizers, which remove seeds and pits while homogenizing the product to achieve the desired texture and consistency. The degree of size reduction can be tailored to produce either a smooth or more textured final product. Multi- stage size reduction equipment can help achieve consistent particle size, while cooling systems or water jackets can dissipate heat generated during the process. Holding Tanks and Packaging Finally, the processed PBDM may be transferred to holding tank(s) in step 50 or to an inline station for further processing or handling. A holding tank may be equipped with temperature regulation capabilities, e.g., cooling or heating capabilities, maintain the mixture at the desired temperature until it is ready for packaging. The cooling may be passive or active. They may also include agitation or mixing mechanisms to maintain the mixture in a homogenized or suspension form that is free of separation or sedimentation. The cooling process may be facilitated using methods like jacketed tanks with cooling fluids or refrigeration units or tube-in- tube or plate and frame heat exchangers. The PBDM from a holding tank can be transferred to a packaging station for packaging in various forms, ranging from large-scale industrial containers to small, convenient packages for individual use. Or prior to packaging, the PBDM can be transferred to other tanks or stations for further processing, for example, concentration or condensing, or addition of further ingredients. Filtration media or settling tanks can be used along with the foregoing steps to remove fibers, if desired. EXEMPLARY EQUIPMENT AND HARDWARE To execute the inventive subject matter, various items of known or to be developed equipment, hardware, sensors, and software may be used. The following is a non-limiting example of a system including such items. The processing of date, e.g., whole or sectioned dates, begins with the preparation of a plant- 17 Docket No. FBB2001PCT based mixture (PBM), consisting of fruits or vegetables processed into a fluid state. This mixture is combined with date material to form a PBM-date mixture (PBDM). The PBDM is heated in a specialized tank or vessel equipped with a temperature control system capable of reaching the desired range, such as 75°F to 190°F. The heating process continues for a specified duration, ensuring the date material decomposes sufficiently to release the desired level of date sugars. Throughout the heating process, temperature sensors, such as thermocouples or Resistance Temperature Detector (RTD), may monitor the temperature to maintain precise control. Additionally, inline refractometers may continuously measure the sugar levels in the PBDM, ensuring the heating is discontinued once the desired sugar level is achieved. Once the heating process is complete, the PBDM may be transferred to a second tank or vessel designed for cooling. This vessel may be equipped with active cooling systems, such as refrigeration units or cooling jackets, tube-in tube or plate and frame heat exchangers, or passive cooling methods like ambient air or water baths. The cooling process may be monitored to ensure the mixture reaches the appropriate temperature to discontinue the date decomposition process. To maintain the uniformity of the mixture during heating and cooling, high-shear mixers and agitators may be employed. These devices help ensure the PBM and date material are thoroughly homogenized, resulting in a consistent final product. The viscosity of the PBM may be a monitored parameter, and viscometers are used to measure it, ensuring it falls within a desired range. This helps ensure, for example, the mixture has the desired consistency for further processing. In addition to the heating and cooling steps, the process may involve molding a PBDM purée into shaped berries. This may be achieved using molds configured in the shape of the berries used in the purée. Once molded, the purée is frozen using specialized freezing units, ensuring the shaped berries hold their form. The entire process may be controlled and monitored using advanced software systems. Supervisory Control and Data Acquisition (SCADA) systems may oversee the process, providing real-time monitoring and control of temperature, viscosity, and Brix levels. A SCADA system is a known tool for monitoring and controlling complex industrial processes. Generally, the system includes a network of sensors and instruments spread across a facility, each measuring parameters like temperature, pressure, and flow rate. These sensors may 18 Docket No. FBB2001PCT constantly gather real-time data for such in-process parameter. The data is then transmitted to Remote Terminal Units (RTUs), which act as intermediaries, collecting information from the sensors and sending it to the central SCADA system. Alongside RTUs, Programmable Logic Controllers (PLCs) are used to process data and manage and automate process parameters. All data and information may be conveyed over a digital communication network, which can include wired, wireless, or even satellite connections, ensuring that data flows seamlessly from the field to the central hub. The SCADA system includes a central computer or server for processing the incoming data, providing operators with a real-time information of the entire operation. Through a user interface, operators can monitor some or all aspects of the process, from the smallest sensor reading to the overall system performance. The SCADA system is not just about monitoring; it also empowers operators to take control. If an abnormal condition or alarm is detected, operators can remotely adjust settings, start or stop equipment, and make informed decisions to keep the process on track. The system also stores historical data, allowing for detailed analysis and reporting. This data can be used to identify trends, optimize processes, and ensure regulatory compliance. Data logging features may be used to help ensure all process parameters are recorded for quality control and traceability. Automation software, such as PLC systems, automates the heating, cooling, and mixing processes, while recipe management software stores and executes specific process parameters for different batches. Quality control may be maintained through statistical process control (SPC) software, which analyzes process data to ensure consistency and quality. A comprehensive setup that includes SCADA systems and quality control may best help ensure the efficient and consistent production of a sweetened plant-based mixture with date sugars, adhering to the inventive subject matter. Looking more particularly at Fig.4-6’s representative steps: Product Flow lines depict the movement of materials during processing and in some cases packaging materials. The following section details manufacturing processes depicted in Figures 4, 5, and 6. These descriptions characterize the sequence of steps, material handling, critical control points, and storage conditions as represented in the respective flow diagrams. Critical control points (CCPs) are processing points where a desirable but not necessarily essential processing step occurs that 19 Docket No. FBB2001PCT might help improve product safety or quality, depending on various risk factors that persons skilled in the art will appreciate. Process Flow According to Figure 4 (Fruit Purée / Ingredient Processing) This process (Fig.4) comprises steps for converting raw fruit and ingredients into a finished, packaged product, incorporating possible critical control points (CCPs) that may be used and storage limitations. 1. Ingredient Receiving: Processing commences with the receipt of materials. Raw fruit and wet ingredients (Purée Stock) are received at a temperature not exceeding 40°F (approximately 4.4°C) (Step 1a). Dry ingredients are received separately (Step 1b). Packaging materials may be received if required (Step 3). The receiving steps may in include a storage step where materials are stored before introduction into a downstream step processing step. 2. Initial Preparation: Raw fruit may be transferred into drums (Step 4) before being processed in a Chopper / Worm Tank (Step 5). Water is introduced (Step 6). An In-Use Magnet actively removes any ferrous metal contaminants (Step 6b). The material is passed through a screen or goes through a turbo extractor (Step 7). Waste material, specifically noted as seedless, is output (Step 7a). The raw batch undergoes Quality Testing (Step 9a), and additional water may be added (Step 9b). 3. Intermediate Storage: The prepared raw batch is held in storage tanks (Step 8). A critical operational parameter imposes a maximum storage duration of twelve (12) hours within these tanks. 4. Critical Safety Processing: The raw batch is subjected to Pasteurization, designated as a Critical Control Point (CCP). This step requires maintaining the product at a temperature not less than 160°F (approximately 71.1°C) for a duration of twenty (20) seconds (Step 10). Subsequently, the pasteurized product undergoes Metal Detection, also designated as a CCP (Step 11). 5. Finishing and Packaging: The processed product is collected in a Finished Product Hopper (Step 12). Composite Sampling is performed (Step 13). Packaging and Weighing occur, utilizing packaging materials stored per Step 3, with final containers comprising Pails with Lids, Cases, or Food-Safe (FS) Lined Drums (Step 14). 6. Release and Distribution: Packaged product undergoes Pre-Shipment Inspection and formal Product Release (Step 15) prior to Shipping (Step 16). 20 Docket No. FBB2001PCT Process Flow According to Figure 5 (Enhanced Fruit Processing with Ozone) This process (Fig.5) details an alternative flow for fruit / purée processing, featuring distinct receiving requirements, explicit storage segregation, ozone treatment, and flexible finished goods handling, alongside possible CCPs that may be used: 1. Ingredient Receiving: Processing commences with the receipt of materials. Raw fruit and wet ingredients (Purée Stock) are received at a temperature not exceeding 40°F (approximately 4.4°C) (Step 1a). Dry ingredients are received separately (Step 1b). Packaging materials may be received if required (Step 3). The receiving steps may in include a storage step where materials are stored before introduction into a downstream step processing step. 2. Preparation and Initial Processing: Ingredients are Staged, and frozen ingredients undergo Slacking (controlled thawing) (Step 9). Processing occurs in a Chopper / Worm Tank (Step 10) with Water addition (Step 11). Approved Rework material may be reintroduced (Step 12). An In- Line Magnet removes any ferrous metal contaminants (Step 13). The mixture is refined via Finisher Screens 1 & 2 and a Turbo Extractor (Step 14), followed by placement of material in a storage tank (15) and Quality Testing (Step 15a). Water may be added (Step 16) to the storage tank for blending with product that also introduced into the tank. Water is optional and may be used as a processing aid (not to dilute) where heat alone is not sufficient to breakdown the bulk fruit that is being processed. If water added, it may be subject to Ozone Treatment (Step 16a) prior to Pasteurization. Pasteurization is designated as a CCP, requiring a temperature not less than 160°F (approximately 71.1°C) for twenty (20) seconds (Step 17). Metal Detection, also designated as a CCP, follows (Step 18). 4. Finishing, Packaging, and Release: The finished product is held in a Finished Product Hopper (Step 19). Composite Sampling is conducted (Step 20). Packaging and Weighing utilize materials from storage (Step 21). Packaged product undergoes Pre-Shipment Inspection and formal Product Release (Step 22). 5. Finished Product Handling and Distribution: Released product may be routed directly to Shipping (Step 24) or may optionally enter Frozen Storage (Step 23) prior to Shipping (Step 24). 21 Docket No. FBB2001PCT In this and other figures, product flow lines are solid lines with arrowheads. Non-Product Flow lines are dashed lines with arrowheads. They depict the movement of packaging materials or product quality assurance steps. Shaded boxes indicate optional steps. Process Flow According to Figure 6 (Molded Frozen Product Manufacturing) Fig.6 outlines the manufacture of molded frozen product, relying on freezing as a key preservation step and featuring metal detection as one possible CCP: 1. Material Receiving and Storage: Raw Material is received at a temperature not exceeding 40°F (approximately 4.4°C) (Step 1). Packaging Materials are received separately (Step 2). Raw Material is held in Frozen Storage (Step 3). Packaging Materials are held in Packaging Storage (Step 4). 2. Thawing, Molding, and Freezing: Frozen raw material undergoes Staging and Slacking (controlled thawing) (Step 5) to achieve suitable consistency for Molding (Step 6). Approved Rework material may be reintroduced (Step 7). The molded product is subjected to Freezing (Step 8) and subsequently Unmolded (Step 9). 3. Safety and Quality Assurance: The unmolded frozen product passes through Metal Detection, designated as a Critical Control Point (CCP) (Step 10a), followed by Quality Testing (Step 10b). 4. Packaging and Release: Packaging materials flow from storage to the packaging operation. The frozen product is packaged. Packaged product undergoes Pre-Shipment Inspection, including a possible step of metal detections for each packaged unit, and formal Product Release (Step 12). 5. Finished Product Storage and Distribution: Released product may be routed directly to Shipping (Step 14) or may optionally enter Frozen Storage (Step 13) prior to Shipping (Step 14). The processing flows of Figs.4-6 are intended to be representative and not limiting. Persons skilled in the art will appreciate that fewer or more steps may be included and that process parameters may be varied depending on various factors, including the materials being processed, end results desired, regulatory requirements, etc. Fig.7 is a table that indicates how dates added to different berry purées can significantly increase viscosity, as measured in centipoises (cP) at or about 60º F (15.56º C). Dates were added to a 22 Docket No. FBB2001PCT PBM by weight percentage at or about 12.5%. The data show that addition of dates to raspberry purée, blueberry purée, and an ANTIOX berry blend resulted in substantial increases in the viscosity of the purée for each berry or berry blend type. The blend indicated by “ANTIOX” was a blend of black raspberry, blueberry, black currant, and dates. Viscosity increases 230% for Raspberry, 140% for blueberry, and 390% for ANTIOX. By varying the weight percentage of dates to sufficient amount, it can be expected that viscosity increases of 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, 125%, 150%, 175%, 200%, 250%, 300%, 400%, 500%, 600%, 700%, 800%, 1000% or more are attainable. A sufficient viscosity increase is believed to help a shaped frozen berry retain its shape even above its melt temperature. It is believed that an exponential increase in viscosity may occur with an increase in date materials to a certain level. Fiber and sugar components from dates are also believed to contribute to the shape preservation above melting points and at temperatures of use, namely around room temperature or higher. Frozen shaped berries formed from a purée that includes dates offers all the advantages of the unfrozen purée itself but in natural, whole-berry shape. The frozen berries can be added to food products like shake and smoothies just like natural whole berries (fresh or frozen). However, unlike natural whole berries, the shaped berries according to the inventive subject matter can be tuned with an additive like date purée to give more advantageous properties to a smoothie, shake or other liquid or solid food product they are mixed into or otherwise added to. For example, in smoothies, shakes, and frozen snacks the shaped berries with dates or other desired additives may increase the thickness or improve the texture of such beverages, e.g., create a smoother, creamier mouthfeel. However, if dates are heated too much, they may breakdown and lose their ability to thicken or improve texture. In general, dates should be processed below 165 degrees F (74 degrees C) to preserve their ability to thicken and improve texture. While blended dates themselves do not have a specific melting point (since they are not a pure substance), their addition to liquids might affect the overall melting point of a frozen shaped berry that includes processed dates. Fig.8 shows a test where shaped berries made of (1) 69% blueberry, 13% black raspberry, 12% date, and 6% black currant (“BBBR”), and (2) a black raspberry purée without dates (“BR00”). The viscosity of the purée forming the frozen BBBR shaped berry was 109.3, and the viscosity of the purée forming the frozen BR00 shaped berry was 24.68. After removal from a freezer in a frozen state, the BBBR and BR00 shaped berries were compared at 10-minute intervals over 50-60 minutes. Both shaped berries were formed in the same kind of mold so that they were initially of identical size and shape. As seen in the time- progression images, the BBBR shaped berry, showed slower melting. At 60 minutes, a substantial portion of the berry continued to hold shape. In contrast, the BB00 shaped berry was 23 Docket No. FBB2001PCT mostly melted at about 50 minutes, with only an insubstantial remnant remaining. Since the starting purée (BBBR) is mostly blueberry and, but for the presence of the dates, it would have a lower viscosity than the black raspberry control purée (BR00), it can be said that the addition of the dates substantially modified the viscosity of BBBR to a relatively higher level than it would have without dates. That upscaling of the viscosity (alone or with other rheological changes from the date material) therefore correlates with longer shape retention. (As used herein, the term “melting point” with respect to a shaped frozen berry, is the temperature where the shaped berry collapses into a puddle, no longer retaining its shape, with no substantial non-liquid portion remaining, i.e., 10%, 5%, 3%, 2 %, 1 % or less of its initial 3D volume visibly remaining.) Accordingly, a shaped berry of a berry-date blend offers advantages in retail and consumer applications where it is desirable to present the intact berry shape as long as possible, e.g., as a topping. It is to be understood that the foregoing test is not a scientific study but is to illustrate general principles that apply when a berry purée is infused with dates. The study should therefore be considered a prophetic example. The inventive subject matter contemplates that date weight percentages of at least 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13% 14%, 15%, 16%, 17%, 18%, 19%, 20%, 22%, 24%, 26%, 28%, 30%, 32%, 34%, 36%, 38%, 40%, 42%, 44%, 46% 48%, 50% will allow for significant shape preservation while still allowing a berry or blend of berries to dominant the blend in terms of at least flavor to mimic the appearance of a berry. The dates that are added are processed as contemplated elsewhere in this disclosure to decompose them to an appropriate form that provides the desired effects. Blended dates may have other effects on a purée. The fiber and natural sugars in blended dates can help stabilize emulsions, where oil and water are mixed. This can prevent separation in dairy-based products, e.g., in shakes or smoothies that include dairy products like cream or yogurt. Believed Principles of Operation While not intended to be bound by a particular theory of operation, it is believed the advantages of using date materials to achieve benefits is based on the following principles. The main parts of the dates that contribute to the change in structure of the purée are believed to be Pectin, polysaccharides like Galactan, Glucan, and Mannans. Pectin forms bonds with sucrose (sugar), in a medium with an acidic pH (between 2.5-3.5) which provides a gelling effect by binding 24 Docket No. FBB2001PCT water within the pectin-sucrose matrix. Galactan is known for gelation of liquids in cells. Glucan, specifically Beta-glucan is another known gelling agent and a water-resistant starch. Mannans, in this case Glucomannan and Galactomannans, are water insoluble fibers. Both are used as natural food thickeners and stabilizers. It is believed that all these components are acting together synergistically to both thicken and gel the beyond berries are what give the inventive shaped berries such different melting behavior from a typical fruit juice or purée. It is believed that the reason for observing a slower melting of the inventive shaped berries is because the thickened purée gels harder as it gets colder, due to all the polysaccharides in the mixture, so thawing it takes significantly longer. It is worth noting that the water in the shaped berries is still freezing and thawing at the temperatures expected of ~16 brix solution, but the structure is being maintained like a Jell-O® gelatin, but not as stable. Basically, the starch in the dates happens to be like those that are used in commercial food thickeners. When used in the specific application of the shaped berries, they provide an excellent structure that allows them to hold shape for longer than an un-modified liquid. It is reasonable to extrapolate that shaped berry stability increases with increasing percent of date materials. The composition of dates was determined using this table, sourced from the International Journal of Molecular Sciences – ISSN 1422-0067 Article: Palm Date Fibers – Analysis and Enzymatic Hydrolysis by Marzieh Shafiei, Keikhosro Karimi, and Mohammad J. Taherzadeh. Published November 2010. 25 Docket No. FBB2001PCT Berry-Date Blends Blended dates can add a natural caramel-like sweetness to liquids, which might slightly modify the perceived flavor profile and the mouthfeel of the liquid, making it seem richer or more full- bodied. Here are some example blends (all weight percentages), with the heading indicating the primary berry in the mix: Black Raspberry 69% blueberry, 13% black raspberry, 12% date, and 6% black currant. Blueberry 44% blueberry, 44% red raspberry, and 12% date. Raspberry 88% red raspberry and 12% date. Black Raspberry: 64% blueberry, 20% date, 11% black raspberry, 5% black currant. Red Raspberry 80% red raspberry, 20% date. Blueberry 40% blueberry, 40% red raspberry, 20% date. In general, a berry present in at least 50% would be a dominant berry, and the shaped berry could be characterized as such. However, for a berry to impart a dominant flavor, it is not required for the dominating berry to be present in a particular minimum percentage as some berries have such strong flavor profiles that they need not be a major component. Step 5: Straining The purée may be strained to remove seeds and impurities. 26 Docket No. FBB2001PCT Step 6: Homogenization The purée is homogenized to achieve a uniform texture. Step 7: Pasteurization The purée may be pasteurized or subject to other forms of microbial load reduction for safety and shelf-life extension. Step 8: Shaping of Purée The purée is shaped to mimic or resemble a berry or other fruit. Typically, the shape may be of a primary, dominant berry type used in the blend. However, the inventive subject contemplates that the purée may represent other berries or fruits. Berries may be shaped using a mold with wells having a desired berry or fruit shape. Fig.1 shows from left to right sets of fruits formed from frozen purée: (1) blackberries, (2) blueberries, and (3) raspberries. Fig.2 shows a closer view of the blackberries. Fig.3 shows a tray with mold wells or cells which can be filled with purée to create a molded berry shape. The mold has a tray form with multiple wells. A tray mold could have any number of wells, but for industrial scale production it would have 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 200, 300, 400, or more wells, depending on size of tray and wells. The mold may be formed of a flexible silicone material. A biocompatible mold release agent may be used to facilitate release of the individual molded berries. A filler or ejector system may be used to fill wells individually or on an entire tray basis, with excess purée extending between wells removed by drainage apertures, squeegee system or other means of removal. The purée added into molds may be from bulk batch tanks configured in an in-line process and pumped to the filler or ejector system. Step 9: Freezing The purée in the mold wells is preferably rapidly frozen in a freezing station. In some embodiments, a belt system may be used to move the trays to processing points. For example, a series of mold trays may be placed on a moving belt that passes the trays through a cryogenic freezer to freeze the purée into a desired shape. 27 Docket No. FBB2001PCT Step 10: Packaging The frozen molds are released to showcase the individual berry shapes. The individual berries may then be conveyed to a bagging machine and packaged into a container. The belt system may be used to move the trays and shaped berries from the freezing station to the packaging or other points downstream from the freezing station. The packaging may be any bag or other kind of container suitable for frozen fruits or vegetables. The packaged bags may be placed in a case (e.g., 12 units per case) and kept in a freezer until shipment. Step 11: Storage The packaged products are stored frozen until distribution. Step 12: Use The packaged shaped berries are provided to an end-user and used. For example, they may be provided to a retail food service facility that displays the shaped berry when making or offering beverage or food products. The packaged berries may also be sold directly to consumers in grocery stores or other retail outlets. They may be used by makers of smoothies, shakes who blend them with other ingredients. They may be used as toppings for frozen and unfrozen dishes. Advantageously, the packaging, may show pictures or accurate illustrations of the shaped berries to represent and promote their realistic nature. A package, e.g., a poly bag, could include a clear window to display contents. Example intended uses of the shaped berries include as additions to water and non-alcoholic or alcoholic beverages; bakery items; dairy and nondairy products such as yogurt, ice cream, cottage cheese and sour cream. They may also be used as flavor and color enhancers. Any such use may be indicated on packaging. Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of the inventive subject matter, and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein. All patent and non-patent literature cited herein is hereby incorporated by references in its entirety for all purposes. 28 Docket No. FBB2001PCT As used herein, “and / or” means “and” or "or", as well as “and” and “or.” Moreover, any and all patent and non-patent literature cited herein is hereby incorporated by references in its entirety for all purposes. The principles described above in connection with any particular example can be combined with the principles described in connection with any one or more of the other examples. Accordingly, this detailed description shall not be construed in a limiting sense, and following a review of this disclosure, those of ordinary skill in the art will appreciate the wide variety of systems that can be devised using the various concepts described herein. Moreover, those of ordinary skill in the art will appreciate that the exemplary embodiments disclosed herein can be adapted to various configurations without departing from the disclosed principles. The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the disclosed innovations. Various modifications to those embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of this disclosure. Thus, the claimed inventions are not intended to be limited to the embodiments shown herein but are to be accorded the full scope consistent with the language of the claims, wherein reference to an element in the singular, such as by use of the article "a" or "an" is not intended to mean "one and only one" unless specifically so stated, but rather "one or more". Any and all structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the features described and claimed herein. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed as “a means plus function” claim under US patent law, unless the element is expressly recited using the phrase "means for" or "step for". In addition, all ranges disclosed herein are to be understood to encompass any and any and all subranges subsumed therein. For example, a stated ranges of “1.0 to 10.0” should be considered to include any and all subranges beginning with a minimum value of 1.0 or more and ending with a maximum value of 10.0 or less, e.g., 1.0 to 5.3, or 4.7 to 10.4, or 3.6 to 7.9. Any and all ranges disclosed herein are also to be considered to include the end points of the range, unless expressly stated otherwise. For example, a range of “between 5 and 10” should generally be considered to include the end points 5 and 10. 29 Docket No. FBB2001PCT Further, any use of the phrase “up to” is used in connection with an amount or quantity, it is to be understood that the amount is at least a detectable amount or quantity. For example, a material present in an amount “up to” a specified amount can be present from a detectable amount and up to and including the specified amount. The inventor reserves all rights to the subject matter disclosed herein, including the right to claim all that comes within the scope and spirit of this disclosure. 30 Docket No. FBB2001PCT

Claims

CURRENTLY CLAIMED INVENTIONS:

1. A method for processing sub-grade berries into a frozen purée, comprising the steps of: purée processing comprising (1) providing a bulk amount of whole berries or other natural fruits that are below a top USDA grade and processing them into a purée and / or (2) providing a bulk amount of purée; wherein the berries in the purée comprise subgrade berries; and forming the purée resulting from the purée processing into shaped berries that mimic the size and appearance of a natural kind of berry which hold their shape at least while frozen.

2. The method of claim 1 wherein the purée is placed into one or more molds having a plurality of wells configured in the shape of a berry used in the purée.

3. The method of claim 1 wherein the purée includes an additive other than a berry material to impart desired characteristics to the purée.

4. The method of claim 3 wherein the additive to the purée includes date material 5. The method of claim 4 wherein in the purée processing the dates are homogenized into the purée including by subjecting the purée with dates to a heating step of at least 100 degrees F (37.8 degrees C) for at least 2.5 minutes.

6. The method of claim 5 wherein the dates are present at 10%-30% by weight of the purée.

7. The method of claim 2 further comprising freezing the purée in the molds.

8. The method of claim 2 wherein the purée processing, molding and freezing are part of a continuous in line process that includes a plurality of processing stations.

9. The method of claim 8 wherein a moving belt transports the molds to two more stations for processing.

10. The method of claim 8 wherein purée from an inline batch tank is pumped into molds at a molding station.

11. The method of claim 2 further comprising packaging the shaped berries released from the molds into commercial packaging.31 Docket No. FBB2001PCT12. The method of claim 11 further comprising maintaining packaged berries in a frozen condition to preserve their shapes.

13. The method of claim 1, wherein the berries include two or more of blackberries, raspberries, blueberries and currants.

14. A shaped berry mimicking a select kind of berry and comprising a frozen fruit purée, the purée including a dominant berry material representing the selected berry, the shaped berry including a natural fruit-based sweetener additive other than a refined or artificial sweetener, the additive raising the melting point of the purée.

15. The shaped berry of claim 14 wherein the additive comprises homogenized dates that are blended into the purée.

16. The shaped berry of claim 15 wherein the dates are present at 10%-30% by weight of the purée when added into the purée processing step.

17. The shaped berry of claim 14 wherein the shaped berry has melting point such that at room temperature takes at least 60 minutes to completely melt.

18. The shaped berry of claim 14 wherein the purée is formed from a subgrade dominant berry.

19. The shaped berry of claim 18 wherein the purée include two or more of blackberries, raspberries, blueberries and currants 20. The method of claim 1 wherein the purée has viscosity of at least 60 cP at room temperature.

21. A method for processing sub-grade berries into a frozen purée, comprising the steps of: purée processing comprising (1) providing a bulk amount of whole berries or other natural fruits and processing them into a purée and / or (2) providing a bulk amount of purée; wherein the berries in the purée comprise subgrade berries; wherein in the purée processing, the dates are homogenized into the purée including by subjecting the purée with dates to a heating step of at least 90 degrees F (32.2 degrees C) for at least 2.5 minutes; and forming the purée resulting from the purée processing into shaped berries that mimic the size and appearance of natural kind of berry which hold their shape at least while frozen.32 Docket No. FBB2001PCT22. The method of claim 21 wherein the dates are present at 10%-30% by weight of the purée when added in the purée processing step.33 Docket No. FBB2001PCT

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