A FOOD PROCESSING APPARATUS AND METHOD, FOR PREPARING AND INCUBATING A FOOD PRODUCT

FIELD OF THE INVENTION

The present invention relates to a device and method for preparing and culturing food products. More particularly, the invention relates to an apparatus for facilitating the preparation and the culturing/fermentation of bean or nut products.

BACKGROUND OF THE INVENTION

Food culturing or fermentation has been used by humans since ancient times due to its benefits in terms of food safety, sensory quality, nutrient availability, and shelf- life. Different types of fermentation for different food products produce different results.

The preparation and fermentation of beans or nuts is particularly popular. For example, tempeh and oncom are traditional meat alternatives from Indonesia since the 1700s, which are commonly made using solid-state fermentation of soy beans, peanuts, or other bean curds. Tempeh and oncom fermentations transform the beans and legumes into a solid food with the help of fungi such as Rhizopus spp. and Neurospora spp.

This results in favorable properties as a food, for example meat-like texture, desirable unique taste, high protein content, high protein and fat digestibility, and elimination of anti-nutrient phytate which can interfere with iron absorption in the human body.

Thus, by fermenting affordable ingredients like soy beans into tempeh for example, a tastier, more versatile, safer, and healthier protein source can be obtained sustainably.

However, the process for making fermented food products of this type has been considered tedious, for example the overall process may require the steps of soaking, dehulling (or deshelling), rinsing, boiling, drying, inoculating, and incubating the raw food material. The process typically requires a full kitchen set of a stove, pots, strainers, masher, trays, paper towels, bowls, spoons, plastic bags or banana leaves, and a temperature- regulated room or space for the fermentation during the incubation stage. Devices have been developed to facilitate the process. The most common devices comprise an industrial dehulling machine and temperature-controlled incubation containers with fermentation trays.

However, these devices do not significantly solve the overall tediousness of the process, such as to enable simple tempeh or oncom production in the home. An industrial dehulling machine can replace the manual dehulling process, and temperature-controlled incubation containers with fermentation trays can replace the temperature-regulated room and need of plastic bags. However, there remain many other steps which still require a substantially full kitchen set as well as the tedious acts of repeatedly moving ingredients from one bulky container to another

There is therefore a need for a device with a simplified and more compact structure and which can additionally simplify the process for the user. Such a device could for example then be used in a domestic environment.

SUMMARY OF THE INVENTION

The invention is defined by the claims.

According to examples in accordance with an aspect of the invention, there is provided a food processing apparatus for preparing and incubating a food product, comprising:

a base comprising a motor;

a basket for mounting on the base, for rotation by the motor; a cover vessel for removable mounting over the base in an inverted orientation; and

a heater for heating the volume inside the cover vessel,

wherein the apparatus is configurable in:

a soaking mode for soaking the food product in water in the cover vessel, with the cover vessel separated from the base;

a heating mode for heating the food product in water in the cover vessel, with the cover vessel separated from the base, and the heater providing water heating; a centrifugal drying mode for centrifugal drying of the food product in the basket, with the basket mounted on the base and the inverted cover vessel mounted over the base; and

an incubation mode for incubating the food product.

This apparatus enables multiple food processing steps to be performed for preparing and incubating a food product. It is of particular interest for bean or nut products, such as soy beans for making tempeh or oncom. However, it may be used for the preparation of other bean or nut based products and indeed other food products generally, where soaking, heating (i.e. cooking), drying and incubation are needed.

The apparatus is compact and uses few components to enable multiple functions to be implemented. In particular, the cover vessel functions both a lid when inverted, so that it can form a closed chamber with the base, and as a standalone vessel when upright. The closed space formed when the vessel is used as a lid is used to prevent water spillage during centrifugal drying, and it may also be used to form a closed space to be used during air heating.

The inverted cover vessel for example fits over the basket in a first orientation and the basket can be suspended from the top of the upright cover vessel in a second orientation.

This feature means that the food product can be placed in the basket and then soaked and heated (with the basket suspended in the upright cover vessel), and also dried (with the inverted cover vessel over the basket) without needing to transfer the food product to a different vessel. The food product remains in the basket for all of these operations. This reduces the number of manual operations needed by the user.

One of the basket and cover vessel may comprise a set of tabs, and the other of the basket and cover vessel may then comprise a set of recesses, wherein the tabs and recesses are aligned in the first orientation and are non-aligned in the second orientation.

This tab and recess design provides a simple way enable the basket to fit wholly inside the cover vessel or to be able to be suspended from the top of the cover vessel.

The soaking mode is for example for soaking the food product in the basket suspended in the cover vessel, and the heating mode is for heating the food product in the basket suspended in the cover vessel. Thus, there is no need to change the configuration of the apparatus between soaking and heating.

The heater is for example provided at a base of the cover vessel, beneath the basket when the basket is suspended from the top of the cover vessel.

The suspended basket thus keeps the food product away from the heater, which can then function as a water immersion heater, without the food product making contact with the heater.

The base may comprise a bottom container for collecting water during the centrifugal drying mode. This ensures that water can be removed from the food product during the drying stage.

The apparatus may further comprise an incubation vessel, wherein the incubation mode is for incubating the food product in the incubation vessel.

By providing a dedicated incubation vessel (rather than only using the cover vessel or the basket) the incubation performance may be optimized.

The incubation vessel for example fits in the basket or the basket fits in the incubation vessel, and the incubation mode is for incubating the food product with the incubation vessel coupled to the basket.

This provides a compact arrangement. In particular, the incubation vessel can be stowed in the basket (or vice versa) when the apparatus is stored. Preferably, all components fit within the space formed by the base and the inverted cover vessel. It also means the incubation vessel can be formed without removing the food product from the basket.

The incubation vessel for example has an open bottom and fits inside the basket, flush with an inner wall of the basket. The incubation vessel can thus be slid into the basket without removing the food product from the basket.

There is preferably also a lid for the incubation vessel, having a set of openings. The lid is then designed specifically for the incubation performance. The lid may be an integral part of the incubation vessel.

The apparatus may further comprise a support for the incubation vessel having a handle which extends through the lid, defining a base of the incubation vessel, and for assisting moving of the incubation vessel in and out of the basket. This simplifies the assembly and disassembly of the different components. The incubation may take place in the a room, if the ambient temperature is suitable. In such a case, the incubation vessel is all that is used. However, the incubation mode may for example be for incubating the food product with the inverted cover vessel over the basket, the basket connected to the base, and the heater providing air heating.

This alternative option makes use of the heater to provide the required temperature. The cover vessel in this case functions as an air heater, with a closed air chamber formed by connecting the inverted cover vessel to the base. The heater is at the top of the air chamber, above the incubation vessel.

The apparatus may further comprise a temperature regulating arrangement for controlling the heater to provide regulated temperature control.

This may be used to regulate water heating and air heating, in the different modes of operation.

The invention also provides a method of preparing a food product using the apparatus as defined above, the method comprising:

soaking the food product in water in the cover vessel, with the cover vessel separated from the base;

heating the food product in water in the cover vessel, with the cover vessel in an upright orientation separated from the base, and using the heater to provide water heating;

centrifugally drying the food product in the basket, with the cover vessel mounted over the base; and

incubating the food product.

This method defines the processing steps performed when using the apparatus defined above.

The incubating for example comprises storing the food product in an incubation vessel in the basket, and using a heater to provide air heating.

These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings, in which:

Figure 1 shows one example of a food processing apparatus for preparing and incubating a food product;

Figure 2A shows a side view of the apparatus of Figure 1;

Figure 2B shows a cross section through line A- A.

Figure 3 shows an exploded view of the various components of the apparatus of Figure 1;

Figure 4 shows the base support and motor;

Figure 5A shows the bottom container from beneath;

Figure 5B shows the bottom container mounted on the base support;

Figure 6A shows the basket rotation plate mounted over the motor;

Figure 6B shows a side view of the base support, motor and basket rotation plate coupled together;

Figure 7A shows in side view how the basket sits on the basket rotation plate;

Figure 7B shows a cross section through line B-B in Figure 7A;

Figure 8 shows the support for the incubation vessel positioned in the basket, in perspective view;

Figure 9A shows the support for the incubation vessel positioned in the basket, in side view;

Figure 9B shows a cross section through C-C in Figure 9A;

Figure 10A shows the incubation vessel and its lid;

Figure 10B shows that the incubation vessel is received inside the basket;

Figure 11 A shows the incubation vessel in the basket in side view;

Figure 1 IB shows a cross section through D-D in Figure 11 A;

Figure 12 shows the apparatus configuration for soaking and for heating;

Figure 13 shows the apparatus configuration for drying; and

Figure 14 shows a method of preparing a food product using the apparatus. DETAILED DESCRIPTION OF THE EMBODIMENTS

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term“and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms“a”,“an”, and“the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms“comprises” and/or“comprising”, when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

The invention provides a food processing apparatus which has a set of components which may be used in different configurations to implement a soaking mode, a heating mode, a centrifugal drying mode and an incubation mode. The re-use of different components in the different modes provides a compact apparatus, and the overall process requires a reduced number of user steps. Figure 1 shows one example of a food processing apparatus 10 for preparing and incubating a food product. It is shown with all of the component parts contained with the device. This is the way the apparatus is stored.

The apparatus 10 comprises a base 20 and a cover vessel 30 over the base. The cover vessel 30 has a heater 32 for heating the volume inside the cover vessel. The heater has an external power input for receiving a power cord. The cover vessel has a closed base and an open top, and it can thus function as a heating pot In Figure 1, the cover vessel is used as a lid, and hence it is in an inverted orientation compared to the orientation in which it can be used as a pot. The terms base and top are used with reference to the orientation when used as a pot.

The cover vessel 30 screws onto the base 20 by mating screw threads 34 to from a closed internal chamber.

A basket 38 is mounted on the base 20, for rotation by a motor within the base.

The apparatus also includes an incubation vessel which sits within the basket 38. Only a lid 40 of the incubation vessel is seen in Figure 1 as well as the top of a handle 42 for lifting the incubation vessel out of the basket 38.

Figure 2A shows a side view of the apparatus of Figure 1 and Figure 2B shows a cross section through line A- A.

The cross sectional view of Figure 2B shows the motor 50 in the base, mounted on a base support 52. It also shows that the incubation vessel 54 is formed as a liner on the inside of the basket 38. The base of the incubation vessel 54 is defined by a support 41 from which the handle 42 extends upwardly through an opening in the lid 40.

The apparatus is configurable in various modes, which will be described in more detail below after the components are shown in more detail.

Figure 3 shows an exploded view of the various components of the apparatus of Figure 1.

It shows that the motor 50 is coupled to a basket rotation plate 56.

Figure 4 shows the base support 52 and motor 50. The motor receives power from a power input terminal 60 when the apparatus is turned on by a switch 62. The motor 50 has a rotational output shaft 64. The base support has alignment features 66, in particular a set of projecting pins, for alignment of the base support 52 with the bottom container 21.

Figure 5 A shows the bottom container 21 from beneath, and shows corresponding alignment features 70, in particular a set of recesses for receiving the projecting pins 66 of the base support.

Figure 5B shows the bottom container 21 mounted on the base support 52.

Figure 6A shows the basket rotation plate 56 mounted over the motor. It engages with the output shaft 64 of the motor so that they are rotationally coupled. The basket rotation plate has a set of projections 80 for driving the rotation of the basket.

Figure 6B shows a side view of the base support 52, motor 50 and basket rotation plate 56 coupled together.

Figure 7A shows in side view how the basket 38 sits on the basket rotation plate 56, and Figure 7B shows a cross section through line B-B in Figure 7A. It shows that the projections 80 of the basket rotation plate 56 engage with openings in the base of the basket.

Figure 8 shows the support 41 for the incubation vessel positioned in the basket, in perspective view. The support 41 has an upwardly projecting handle 42 which extends above the top of the basket.

Figure 8 also shows more clearly that the basket 38 has a set of tabs 82 which extend radially outwardly from an upper rim of the basket. These tabs define the largest radial dimension of the basket, and in the example shown there are diametrically opposed pairs of tabs. There may be only one pair of tabs, but two pairs are shown. There may instead be any other polygonal arrangement of tabs, such as a set of three. The purpose of these tabs is to enable the basket 38 to be suspended from the top of the cover vessel, when the cover vessel is in its upright orientation (i.e. functioning as a pot).

Figure 9A shows the support 41 for the incubation vessel positioned in the basket, in side view, and Figure 9B shows a cross section through C-C in Figure 9A. The bottom of the support 41 comprises a base 90. It has notches which sit over the projections 80 of the base rotation plate (which extend all the way through the bottom of the basket) which set the position of the support 41. The support 41 is thus coupled to rotate with the basket. Figure 10A shows the incubation vessel 54 and its lid 40. The vessel 54 is a cylinder with an open bottom end and a top end closed by the lid.

Figure 10B shows that the incubation vessel 54 is received inside the basket 38. The lid 40 has a central opening 100 through which the handle 42 projects. The handle enables the base 90 to be lifted out of the basket, and this carries the incubation vessel 54 with it. Thus, the bottom of the incubation vessel is formed by the separate base 90.

The lid 40 therefore can be integral with the cylindrical side wall of the incubation vessel (as is shown in the cross section of Figure 1 IB), but equally the lid may be separate.

Figure 11 A shows the incubation vessel in the basket in side view and Figure 1 IB shows a cross section through D-D in Figure 11 A.

The way the apparatus is used will now be described.

The apparatus in particular enables at least a soaking mode for soaking the food product in water in the cover vessel, a heating mode for heating the food product in water in the cover vessel, a centrifugal drying mode for centrifugal drying of the food product in the basket and an incubation mode for incubating the food product.

This apparatus thus enables multiple food processing steps to be performed for preparing and incubating the food product. These steps will now be described with reference to the processing of soy beans for making tempeh.

T _ Bean soaking

The apparatus is configured as shown in Figure 12.

The basket 38 is suspended in the cover vessel 30 by the tabs 82. The cover vessel functions as a water container. The open end of the cover vessel has slots 110 which allow the tabs 82 to pass, and supporting portions on which the tabs can rest. Thus, in Figure 12, there are supporting portions beneath the tabs (which cannot be seen), which support the basket 38. This also means the bottom of the basket 38 is raised above the heater 32.

The support of the incubation vessel is in place (only the handle 42 is visible), but the incubation vessel is not in place. The base is not used during soaking.

The beans are placed in the basket and the basket is suspended in the upright cover vessel 30 as shown. The cover vessel is filled with water and the beans are soaked. The soaking for example is carried out at room temperature, so the heater is not used during soaking. Soaking may be appropriate for 8 to 24 hours by way of example, but this will depend on the bean or other food type. Pre-soaked beans will of course not need the soaking step. Even longer soaking times may be used.

2, _ Dehulling

The version of the apparatus shown is based on the processing of already de-hulled beans, which are commercially available. Thus, no de-hulling is required.

However, the apparatus can be used with beans which are not dehulled. In such a case, the beans are removed after soaking and subjected to a separate dehulling process. This may for example involve crushing and stirring the beans (while still in water), which causes the hulls to detach and float to the surface. The water and hulls may then be poured off to remove the hulls.

3, _ Heating/cooking

The beans are then heated (with fresh water). The apparatus has the same configuration as in Figure 12. The beans do not need to be removed from the basket (assuming a separate dehulling device is not being used).

The beans are heated in the basket, again with the basket suspended in the upright cover vessel. This may be achieved simply by plugging in power. Thus, operation of the heater may simply involve plugging it in.

It is of course instead possible to have a user interface to enable timing control, temperature control, and an automatic turn off function after a set or default time period.

The basket may simply sit on the supports (between the recesses), which supports may also prevent angular rotation of the basket because of side walls of the supports. Alternatively, the basket may lock more rigidly into the cover vessel. The heater is used as a water immersion heater. The base is again not used for this part of the process.

The heating comprises boiling, for example for a period of 45 minutes, but again the duration will depend on the type and/or quantity of food material. The volume of the basket is for example around 1 liter, such as between 500ml and 2 liters. For example, the diameter and the height of the cover vessel are each in the range 10 cm to 20 cm.

4 _ Drying

The basket is then removed from the cover vessel 30, and the water stays behind. The water is tipped away. The basket is then mounted on the basket rotation plate 56 above the base 20. The cover vessel 30 is then inverted to function as a lid. The cover vessel is then screwed over the base resulting in the configuration shown in Figure 13.

When the cover vessel is fitted over the basket, the slots 110 are aligned with the tabs 82 so that the cover vessel fits entirely over the basket. Thus, the basket is now beneath rather than above the heater.

The basket may thus be positioned with one angular orientation to align the tabs with the slots and other angular orientation to align the tabs with support surfaces.

Again, the beans do not need to be removed from the basket.

The motor is then operated to provide a centrifugal drying operation. This may be implemented simply by operating the switch 62 in the base. There is a limited amount of water to be removed. However, any remaining water which comes off during drying is collected in the bottom container 21.

This avoids the need for any paper towel drying of the beans, again reducing the amount of manual manipulation needed of the beans.

The heater is not used during the centrifugal drying. The drying is for example performed at 6000 rpm and only lasts for a few seconds, such as 3 seconds.

Note that the presence of the heater gives the option of a heated drying process if desired.

5, _ Inoculation

The basket is removed from the device. This gives the configuration shown in Figure 8.

The user adds a specific amount of a suitable starter culture (known as a tempeh starter) to the beans. The beans are then mixed to distribute the tempeh starter. It is also possible to purchase already inoculated beans, in which case this step is not needed.

6, _ Incubation

The incubation vessel 54 is then applied. It is slid down the inner wall of the basket (which is possible as it has an open bottom) so again does not require removal of the beans from the basket. The lid may be an integral part or it may be applied on top.

The resulting configuration is shown in Figure 10B. The rest of the apparatus is not used.

The basket is for example left overnight in at a temperature of 30 to 32 degrees Celsius. This promotes bacterial growth. The holes in the lid enable inspection of the incubation process as well as providing venting.

If the user does not have a suitable place for the incubation (e.g. an airing cupboard) or during winter months, the heater may be used for the incubation.

The configuration of the apparatus is then as shown in Figure 1. The heater may be used to regulate the temperature at around 30 degrees, for example overnight.

It will be understood from the description above that the heater can function as a water immersion heater or an air heater. Separate heaters may instead be provided.

As explained above, the basket may be fitted inside the cover vessel or it may be suspended from the top lip of the cover vessel, by virtue of the tabs and slots. However, any other arrangement may be used, such as an additional support ring to be positioned over the cover vessel to support the basket, or removed to allow the cover vessel to slide over the basket. Thus, other designs are possible.

The example above has the incubation vessel inside the basket. This gives the vessel a smooth inner surface, which is desired to facilitate stirring. It is equally possible for the basket to sit inside the incubation vessel.

The example above shows a screw fitting between the cover vessel and the base. Any other connection is possible. It is preferably water tight to prevent escape of water during drying, but this is not essential given the small volume of water to be collected during drying.

The example above involves soaking and heating (boiling) in the basket, so that no transfer of the food product to the basket is needed before the centrifugal drying. This is the preferred option, but of course the food product may be soaked and heated in the cover vessel alone, for example if it has a hidden heating element. Similarly, the example above enables the transition to the incubation configuration without removing the beans from the basket. Again, this is preferred, but of course the food product may be transferred to a separate incubation vessel.

The materials used in the design are able to withstand greater than the 100 degree boiling temperature, e g. 150 degrees. Suitable plastics may be used for this purpose, although metals or other materials may be used.

A most simple control system for the base is simply an on-off switch for the centrifuge operation (which then runs for a fixed time).

The cover vessel may have its own switch for the heater or the heater may simply be plugged in to operate.

The heater may be used for water heating (when the cover vessel is removed from the base) or for incubation heating (when the cover vessel is attached to the base). This requires regulation at a different temperature such as 30 degrees Celsius. A sensor may be used for the detection of the connection state to determine whether to perform heating regulated at 100 degrees (water) or at 30 degrees (air) when the power is connected to the heater. Of course, there may instead be an input for setting the heating mode for the user. A temperature regulation system is used for this purpose, with a temperature sensor for detecting the temperature in the cover vessel.

Other user interface designs are possible, including systems enabling programming of the different steps (temperature, times etc.) depending on the type of food product being processed.

The apparatus is described above as used for processing beans, in particular soy beans, for making tempeh. However, it may be used for the preparation of other bean or nut products and indeed other food products generally, where soaking, heating (e.g. cooking), drying and incubation are needed.

Figure 14 shows a method of preparing a food product using the apparatus as defined above, the method comprising:

in step 140, soaking the food product in water in the cover vessel, with the cover vessel separated from the base; in step 142, heating the food product in water in the cover vessel, with the cover vessel in an upright orientation separated from the base, and using the heater to provide water heating;

in step 144, centrifugally drying the food product in the basket, with the cover vessel mounted over the base; and

in step 146 incubating the food product.

There is an optional step 143 of dehulling, if beans are used which have not been de-hulled.

There is also an optional step 145 of inoculating, if beans are used which have not been previously inoculated.

Variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure and the appended claims. Any reference signs in the claims should not be construed as limiting the scope.