Preservative-Free Hummus Packaging with Nitrogen Atmosphere
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Solution Overview
Problem
Current methods for extending the shelf life of preservative-free hummus, such as using extreme temperatures or pressures, are inefficient and costly, and lack a continuous process for pasteurizing chickpea products in the same cooking vessel.
Innovation Solution
A continuous single pot method is employed to cook and pasteurize chickpeas, maintaining a temperature range of 70° C. to 85° C. for 5 to 20 minutes, followed by cooling and packaging in a nitrogen-rich atmosphere, ensuring a 28-day shelf life without preservatives and low microbial counts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If extreme thermal or pressure conditions are used to extend shelf life, then shelf life is extended to many months, but processing complexity and cost increase
Solution Approach 1:
The patent combines the cooking and pasteurization steps into a single continuous process in one vessel. The chickpeas are cooked and then immediately pasteurized without transfer, merging two separate thermal processing operations into one integrated system, thereby reducing equipment complexity while maintaining extended shelf life
Solution Approach 2:
The cooking vessel is designed to serve multiple functions: it acts as both the cooking chamber and the pasteurization chamber. The same vessel that cooks the chickpeas at elevated temperatures also performs the pasteurization function, eliminating the need for separate dedicated pasteurization equipment
2Reliability
If separate pasteurization equipment is used, then pasteurization is effective, but process continuity and efficiency decrease
Solution Approach 1:
The patent merges the cooking and pasteurization operations into a single continuous process within one vessel, eliminating interruptions for transfer between equipment. This maintains pasteurization effectiveness while achieving continuous processing and improved productivity
Solution Approach 2:
The process maintains continuous thermal action on the chickpeas without interruption. The chickpeas remain in the vessel throughout both cooking and pasteurization phases, with the thermal processing continuing uninterrupted, thereby achieving both effective pasteurization and continuous operation
3Duration of action of stationary object
If preservatives are added to extend shelf life, then shelf life is extended, but product quality and consumer preference deteriorate
Solution Approach 1:
The patent converts the naturally occurring chickpeas into a preservative-free product with extended shelf life through proper thermal processing. The pasteurization step eliminates spoilage microorganisms without requiring any chemical preservatives, thereby maintaining product quality while achieving the desired shelf life extension
Solution Approach 2:
The patent achieves preservative-free shelf life extension by carefully controlling thermal processing parameters. The pasteurization is performed at specific temperature and time conditions that are sufficient to eliminate spoilage organisms but gentle enough to preserve the sensory and nutritional quality of the chickpea product
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides a cost-efficient and continuous process for producing preservative-free hummus with extended shelf life, maintaining low microbial counts and avoiding the need for extreme processing conditions, resulting in a product with negligible vegetative flora when stored at 2° C. to 8° C.
Implementation Method 1
cooking and pasteurize chickpeas, maintaining a temperature range of 70° C. to 85° C. for 5 to 20 minutes
Implementation Method 2
packaging in a nitrogen-rich atmosphere, ensuring a 28-day shelf life without preservatives and low microbial counts
Data Source
AI summary
A food package comprising a container having a sealed top layer and comprising a fresh, preservative-free food product comprising chickpeas, such as hummus, which includes no preservatives and exhibits a total yeast and mold counts of less than 10 CFU/g at 28 days after production when stored at 2° C. to 8° C. The package includes a headspace between the fresh hummus and the top sealing layer, the headspace comprising a modified atmosphere which is nitrogen rich, such as 70% N2:30% CO2.