TITLE

PACKAGING SYSTEM FOR READY-TO-COOK FERMENTED BATTER

TECHNICAL FIELD

[0001] The present invention is in the technical field of preservation and packaging of fermented food products. More particularly, the present invention is in the technical field of a packaging system for fermented batter (e.g. idli, vada, dhokala, dosa).

BACKGROUND

[0002] Indigenous fermented foods have been prepared and consumed for thousands of years, and are strongly linked to culture and tradition. The fermented foods are better than normal cooked food varieties in terms of nutrition, amenability for digestion, etc. Idli is a cereal-legume based fermented snack food of South India which is popular all over the country. It is consumed mainly as breakfast along with chutney

and sambar [coconut and pulse based preparation, respectively]. It is acid leavened steamed cakes made from rice and black gram lentils. This traditional food is a good source of protein and calories. They are easily digested and often used as food for infants and invalids. Normally idli batter fermentation is a natural fermentation. The essential physical change in the batter is that it becomes leavened by CO2 gas as well as a pleasant flavour develops. Other forms of fermented snacks similar to idli include dosa, dhokla, uttapams, vada, amboli, khaman, etc.

[0003] Idli is a widely consumed breakfast product and therefore ready-to-cook idli batter finds wide acceptability, but during the later stages of fermentation the type of dominating bacteria changes. At this later stage, the batter is probably too sour, thereby reducing the quality of the idlis. Good quality idlis can be made only with batter fermented for a limited time.

[0004] Idli preparation in the conventional manner takes at least 18 h. Although instant idli pre-mixes are available, these do not possess the characteristic texture and also lack the typical fermented aroma. Idlis prepared in different households do not have consistent quality. Hence, ready-to-cook and eat forms of these foods would be popular in the domestic market, as well as with Indian expatriates. [0005] Currently, the available ready-to-cook idli batters have not been preserved and stabilized for more than 2 days, and also have a poor shelf life. If freshly prepared batter is kept for more than the above mentioned period the batter mixture starts fermenting and finally decomposing. Thus it becomes necessary to store such food batters by preservation or increasing shelf life with improved packaging. The stabilization of fermented idli batter is very important with respect to idli texture, quality and safety including maintaining its characteristic spongy structure, desirable sour taste and good aroma. The same applies for other food products like dosa, uttapam, vada, dhokala etc.

[0006] Some have suggested that modified atmospheric packaging may be used to pack the freshly prepared batter. These are packaged in either Low Density Poly Ethylene (LDPE), Poly propylene (PP), Polyethylene terephthalate (PET),

Polyvinylidene chloride (PVDC) or High Molecular (HM) bags.

[0007] The article of M. DURGADEVI (MODIFIED ATMOSPHERE PACKAGING OF READY TO COOK IDLI BATTER) describes ready to cook idli batter packaged in medium thickness (0.012 mm) LDPE flushed with 0% CO ₂ and 7.5 to 15% O ₂ could increase the shelf-life without compromising the sensory qualities at room temperature. It has certain limitations, specifically in accordance with respiration dynamics, an important phenomenon in the fermentation process. In respiration dynamics, the percentage of oxygen utilized and percentage of carbon dioxide released during fermentation of batter is determined. Hence, the above said packaging failed to hold the level of carbon dioxide released as time passes. Such continuous fermentation and releasing of carbon dioxide resulted in the marked swelling of the packaging and also increased the inside pressure, which may cause the contents to leak.

[0008] Indian Patent application no. 354/CHE/2014 discloses the method to extend the shelf life of idli batter, wherein the batter is subject to pre-freezing at -20°C for 1 hr and then shifting at 4°C. The said method utilizes a deep freezing technique which is a costly technology.

[0009] In view of respiration dynamics of fermented food, it is desired to have packaging that is selectively permeable to carbon dioxide/oxygen gas. [0010] US 6,746,762 B1 discloses a film selectively permeable to carbon dioxide gas and food packaging film comprising the same. A film selectively permeable to carbon dioxide gas which includes chitosan having a degree of deacetylation of 70 mol% or higher and in which the ratio of the carbon dioxide gas transmission (CO2TR) to the oxygen gas transmission (O2TR) is 15 or higher. These films are very costly due to the use of natural polymers. [0011] WO 2016021842 A, discloses a fermented food packaging pouch and packaging method using the same, particularly, packaged kimchi. The patent application discloses a gas absorbent food packaging pouch that prevents swelling within the pouch by absorbing carbon dioxide gas.

[0012] Surprisingly, inventors of the present invention have found that idli batter must be carefully maintained or packaged with controlled rheology conditions in barrier film and with controlled respiration of gases. This packaging system prevents fermented idli batter in ready-to cook form from becoming unstable and too sour, due to over fermentation or from undergoing chemical changes that give rise to unpleasant aromas.

[0013] Hence, first, an object of the present invention is to provide a film with controlled respiration to carbon dioxide and oxygen gas, is highly safe from the stand point of food hygiene, and has selective gas permeability of carbon dioxide gas transmission to oxygen gas transmission. Second, an object of the present invention is to provide, the above-mentioned film with a ready-to-cook idli batter, wherein the film will store the ready-to-cook idli batter and will provide the characteristic spongy structure, desirable sour taste and good aroma even after an increased storage time.

[0014] Now it has been found by inventors of the present invention, in accordance with this invention, that the above drawbacks of the prior art can be overcome by utilizing the improved formulation of the invention as described in detail hereinafter. Briefly, the improvement resides in using film material and controlling the rheology of the batter. It has been found that this improvement enables adequate, uniform stabilization and preservation of the fermented product even at ambient temperature or without providing storage temperature below 10°C for at least 5 days.

[0015] The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.

SUMMARY

[0016] The disclosed subject matter relates to a preservation and packaging of fermented ready-to-cook food products. More particularly, the present invention relates to a packaging system for fermented, semi-solid idli, vada, dhokala or dosa batter which maintains shelf life at ambient conditions without refrigeration. The system pertains to the control of respiration dynamics of fermented batter with the help of modified film laminates and controlled batter rheology. It means the % of gases flush/permeation inside the packaging holds and controls the fermentation of ready-to-cook fermented batter at ambient temperatures for at least 5 days, while maintaining texture, pH, smell and color of final cooked food, for example, idli.

[0017] The primary objective of the present invention is to provide an improved packaging system for preserving fermented batter of idli, vada, dhokala, amboli, uttapam.

[0018] A further objective of the present invention is to provide a packaged ready-to- cook idli batter to be kept at ambient temperatures for a minimum of 5 days.

[0019] A further objective of the present invention is to provide a ready-to-cook packaged batter that has the typical fermented aroma, and provides a final food product with consistent quality and a characteristic spongy structure when cooked or steamed.

[0020] A further object of the invention is to store fermented batter at ambient temperatures without refrigeration.

[0021] A packaging system is disclosed for storing ready-to-cook fermented semi-liquid product, wherein the semi-solid product comprises fermented batter with a specific gravity of 0.5 to 1 .5 kg/m ³ and a pH of4.5 to 6.5. The system comprises a packaging of fermented and freshly prepared batter in a controlled gas respiration barrier film for storage period of at least 5 days. The packaged system is not subjected to a

temperature below 10 °C during the storage period.

[0022] The disclosed packaging system provides storage for ready-to-cook idli batter at ambient temperature for at least 5 days without loss of texture, quality or safety of final idli. More particularly, the system pertains to the control of respiration dynamics of fermented idli batter with the help of a modified barrier film. Means % of gases flush/permeation inside the packaging stores the idli batter at ambient temperatures and maintains texture, pH, smell and color of final idli. [0023] The presently disclosed subject matter is directed to a packaging system that includes a fermented food product having a specific gravity of 0.5 to 1 .5 kg/m3 and a pH of 4.5 to 6.5 and a gas-permeable laminate having flexible structure materials for packaging. The gas permeable laminate provides a shelf life of at least 5 days for the fermented batter and the system is not subjected to a temperature less than 100°C during the shelf life.

DESCRIPTION OF EMBODIMENTS

[0024] The making and use of various embodiments of the present invention are discussed in detail below and it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.

Definitions

[0025] While the following terms are believed to be well understood by one of ordinary skill in the art, the following definitions are set forth to facilitate explanation of the presently disclosed subject matter.

[0026] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. [0027] Following long standing patent law convention, the terms "a", "an", and "the" refer to "one or more" when used in the subject application, including the claims. Thus, for example, reference to "a formulation" includes a plurality of such formulations, and so forth.

[0028] Unless indicated otherwise, all numbers expressing quantities of components, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the instant specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the presently disclosed subject matter.

[0029] As used herein, the term "about", when referring to a value or to an amount of mass, weight, time, volume, concentration, percentage, and the like can encompass variations of, and in some embodiments, ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1 %, in some embodiments ±0.5%, in some embodiments ±0.1 %, and in some embodiments ±0.01 %, from the specified amount, as such variations are appropriated in the disclosed foam and methods. [0030] As used herein, the term "fermented food product" refers to any food or substance that can be used or prepared for use as food, foodstuff, food, or nutrient that has undergone some form of fermentation. Examples of fermented food products include idli batter, vada batter, dhokla batter, cheese, olives, pickles, wine, beer, sake, whisky, brandy, cider, mead, fermented bean curd, bread, kefir, cultured milk products, yogurt, chorizo, salami, pepperoni, fish sauce, indian pickle, kimchi, and sauerkraut.

[0031] Copolymers can be identified, i.e., named, in terms of the monomers from which the copolymers are produced. For example, the phrase "propylene/ethylene copolymer" refers to a copolymer produced by the copolymerization of both propylene and ethylene, with or without additional comonomer(s). A copolymer comprises recurring "mer" units derived from the monomers from which the copolymer is produced, e.g., a

propylene/ethylene copolymer comprises propylene mer units and ethylene mer units.

[0032] All formulation percentages used herein are presented on a "by weight" basis, unless designated otherwise.

[0033] Although the majority of the above definitions are substantially as understood by those of skill in the art, one or more of the above definitions can be defined herein above in a manner differing from the meaning as ordinarily understood by those of skill in the art, due to the particular description herein of the presently disclosed subject matter.

[0034] In some embodiments, the ready-to-cook fermented batter may also be referred to as "fermented batter", "idli batter", "batter", "ready-to-cook idli batter", "food batter", "fermented idli batter", "ready-to-cook batter", "idli batter", "vada batter", "dhokla batter". [0035] The stability of fermented idli batter is determined by final idli texture, nutrient composition and sensory quality. From the point of view of cost and convenience of storage, it is preferred that the ready-to-cook fermented idli batter should have storage stability at ambient temperature. [0036] A system is provided for storing ready-to-cook fermented semi-liquid product, wherein the semi-liquid product comprises fermented batter like batter of idli or vada with a specific gravity of 0.5 to 1 .5 kg/m3and a pH of 4.5 to 6.5. The system comprises the packing of freshly prepared idli batter in a controlled gas respiration barrier packaging for a storage period of at least 5 days. The packaged idli batter is not subjected to a temperature below 10 °C during the storage period.

[0037] Hence accordingly, a system for packaging fermented batter to get a long shelf life when stored at ambient temperature is disclosed. In some embodiments, a packaging system for fermented batter is developed to provide shelf stability up to 5 days even stored at ambient temperatures without the use of refrigeration. The improved packaging system helps to prevent over fermentation as well as maintain quality and taste.

[0038] One of the embodiments of the present invention in the system is a packaging system developed for ready-to-cook batters which need to be cooked/steamed before serving. [0039] Ready to cook food products like batters used for idli, dosa, vada, moong dal cheela, jalebi and uttapams are the healthiest choice and are more preferred in Asia as compared to other continents. They are made from fermented batters. Fermented batters can be prepared by soaking the rice, pulse or mixture of rice and pulses;

grinding with water; mixing with additional water; and packaged. [0040] Fermented batters may be the final batter produced after fermentation by natural process or by using starter such as inoculated lactobacillus culture, or any other bacteria well known to those skilled in the art that causes fermentation.

[0041] In accordance to one embodiment, a packaging system may be for ready-to-cook batter comprising; fermented batter having a specific gravity of 0.5 to 1 .5 kg/m3and a pH of 4.5 to 6.5; and a gas-permeable laminate having flexible structure materials for packaging, characterized by the gas permeable laminate providing a shelf life of at least 5 days for the fermented batter and the system is not subjected to a temperature below 100C during the shelf life.

[0042] Accordingly, the fermented batter is prepared by taking a mixture of rice and pulses at a ratio of 5:1 to 1 : 1. The term "fermented batter" as used herein means batter prepared by grinding overnight soaked rice, pulses, or mixture of rice and pulses. The term "fermented batter" may also refer to batter that undergoes fermentation such as, but not limited to sourdough bread batter, yeast fermented bread batter, and rye bread batter. "Pulses" includes urad dal, Bengal gram, moong dal, chickpeas, garbanzo, garbanzo beans or any other edible pulses. The batter is prepared from rice, pulses, or mixture of rice and pulses which has a specific gravity.

[0043] In another embodiment the storage and preservation of the fermented batter of rice, pulses, or mixture or rice and pulses are met with the following parameters: pH: In the range of 4.5 to 6.5, Acidity: In the range of 0.3 to 0.5 and Specific gravity: In the range of 0.5 to 1.5 kg/m3. More preferably, the fermented batter has the following parameters: specific gravity in the range of 0.8 to 1 .2 kg/m3 and pH in the range of 5.0 to 6.2.

[0044] Examples of ingredients of fermented batters include rice, pulses and lentils. Further non-limiting examples of fermented batters include urad dal, Bengal gram, moong dal, soybean, or turdal. [0045] The batter includes for, example idli, vada, dosa, moong dal cheela, jalebi, dhokla, khaman and uttapams. In a particular embodiment, the fermented batter is an idli batter.

[0046] Any fermentation and grinding process may be used to prepare the fermented batter. Methods for soaking, fermentation and grinding are well known in the art and are disclosed. The process of preparing fermented batter generally involves the sequential steps of soaking the rice and pulses in water overnight, separate grinding of the rice and pulses with water, mixing the grinded rice and pulses into a mixture, and using the mixture for preparing a food product. These steps are well known in the art. The ready- to-cook batter is therefore widely sold in supermarkets, retail stores, or acquired from an outside plant kitchen. The ready-to-cook batter is subjected to the final baking/cooking phase when needed. The ready-to-cook batter is frozen after preparation and packaging to increase the shelf life. The disadvantages of the freezing technique are evident as handling frozen products requires specially refrigerated rooms for storage and specially refrigerated wagons for transport and delivery, thus increasing costs.

There are also disadvantages in using a separate sterilization step, either before or after packaging of the ready prepared fermented batter.

[0047] More particularly the present invention relates to a method for packaging a fermented ready-to-cook batter product into an oxygen-barrier polymeric packaging material under regulated atmosphere and getting a prolonged shelf-life package when the product is stored at ambient temperature or at room temperature. [0048] In accordance to a second embodiment, the present invention provides a packaging system wherein a packaging pouch is a gas-permeable laminate. In another embodiment, the gas-permeable laminate is a multi-layer coextrudate with a thickness preferably 40 to 60 pm, more preferably 50 to 60pm high carbon dioxide transmission rates, and comparatively very low oxygen transmission rates. [0049] The multi-layer coextrudate has at least one layer with oxygen-barrier properties, at least one layer with carbon dioxide transmission properties and one or more layer that is a tie layer. The tie layer is made up of polymer selected from ethylene copolymer.

[0050] In accordance to one more embodiment, the gas-permeable laminate has high carbon dioxide transmission rates and very low oxygen transmission rates, wherein the carbon dioxide transmission rate is 1500 to 2500 cc/m ² /day measured at 23 °C/ 0 % Rh, the oxygen transmission rate is 300-500 cc/m ² /day measured at 23 °C/ 0 % Rh and the water vapor transmission rate is 15-40 gm/m ² /day measure at 38 °C & 90 % Rh.

[0051] The multi-layer coextrude may have 7 layers. The 7 layers may be a resin layer, a 50μ natural poly 50% LLDPE layer, a 25% very low-density polyethylene layer, a nylon layer, an ethylene vinyl alcohol layer, a polypropylene copolymer layer, and an ethylene copolymer layer.

[0052] The present invention is further described with the help of the following

examples, which are given by way of illustration all the parts, percent's and ratios are by weight unless otherwise indicated and therefore should not be construed to limit the scope of the invention in any manner. [0053] Any numerical value ranges recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable (e.g., temperature, pressure, time) may range from any of 1 to 90, 20 to 80, or 30 to 70, or be any of at least 1 , 20, or 30 and/or at most 90, 80, or 70, then it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , and 30 to 32, as well as at least 15, at least 22, and at most 32, are expressly enumerated in this specification. For values that are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 , or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0054] The above descriptions are those of preferred embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the claims, which are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents. The definitions and disclosures set forth in the present Application control over any inconsistent definitions and disclosures that may exist in an incorporated reference.

EXAMPLES [0055] The following Examples provide illustrative embodiments. In light of the present disclosure and the general level of skill in the art, those of ordinary skill in the art will appreciate that the following Examples are intended to be exemplary only and that numerous changes, modifications, and alterations can be employed without departing from the scope of the presently disclosed subject matter. Example 1 : Preparation of Idli Batter

[0056] Rice and rued dal were mixed at a ratio of 4: 1 and soaked overnight. They were ground separately in the morning and then mixed before being packaged. All grinding was done with water as a medium.

Example 2: Packaging System for Idli batter [0057] The batter prepared in Example 1 was dispensed in the packaging having the properties mentioned in Table 1 . The batter was sealed and stored at a controlled temperature of 25°C to study shelf life. Packaging, storage and stabilization of fermented materials like idli batter at ambient temperature (for minimum 5 days without refrigeration) are set forth in the appended claims with high C0 ₂ transmission rates (1500-2500 COTR 23 °C/ 0 % Rh (cc/m ² /day), very low oxygen transmission rates (300-500 OTR 23 °C/ 0 % Rh (cc3/m ² /day)), and water vapor transmission rates about 22 VWTR 38 °C & 90 % RH (gm/m ² /day).

Table 1

[0058] Chemical analysis was performed on day 0 (before packaging) and then on day 1 to 6 days after storage at room temperature, preferably 25°C. pH, color, texture, aroma and flavor were also tested to observe impact of shelf life on batter integrity.

A. Effect on Chemical Properties Table 2

B. Effect on Organoleptic Properties

Table 3

[0059] It was observed that there no changes from day 0 to day 5, but changes in chemical and sensory parameters were not observed until day 5. Day 4 the batter had a slightly acidic taste and an acidic taste was observed on day 6. The texture stayed soft from day 0 to day 6, but the ready idli taste had a fermented taste on day 5. When checked for organoleptic changes, it was seen not to differ from day 0 and the flavor, aroma, and most importantly the consistency, specific gravity and pH which are vital to batter, stayed intact.

[0060] An increased shelf life of 5 days minimum was achieved at room temperature without compromising physical, chemical and microbiological parameters of the idli batter.

Example 3: Effect of Batter Gravity and pH on stability

[0061] The batter prepared in Example 1 was diluted with water and acidity was controlled to achieve required specific gravity as well as pH. Then, the batter was dispensed in the packaging having the properties mentioned in Table 1 . The batter was sealed and stored at a controlled temperature of 25°C to study shelf life.

Table 4

Table 5

Day Batter pH Packaging

0 6.03 No Bloating

1 5.86 No Bulging

2 5.72 No change seen

3 5.42 Still intact

4 5.39 No bulging

5 4.78 shape unchanged Example 4: Effect of permeation rate on stability

[0062] The batter prepared in Example 1 was dispensed in the packaging having the properties mentioned in Table 6. The batter was sealed and stored at controlled temperatures of 25°C to study shelf life.

Table 5

Example 5: Preparation of vada batter

[0063] Whole urad dal was soaked for 3 to 6 hours and was then ground to a smooth batter by adding rock salt and a small amount of water. The proportion of whole urad dal: rice: rock salt was 10: 1 :0.5. Separately, rice was ground and mixed in urad dal batter. The batter with rock salt is then packaged directly in the packaging with the properties mentioned in Table 1. The batter was sealed and stored at a controlled temperature of 25°C to study shelf life. Table 6

Example 6: Preparation of dhokla Batter

[0064] Roasted gram is taken and ground with rava/semolina at a ratio of 10:2. The grinding medium is sour curd. Salt is added as desired along with lime juice and sugar to create a batter. The batter is then packaged directly in the packaging with the properties mentioned in Table 1. The batter was sealed and stored at a controlled temperature of 25°C to study shelf life.

Table 7