Process for making free-flowing, coated, frozen food

Abstract

A free-flowing, coated, frozen food and a method for making the same are disclosed. discrete pieces of a free-flowing frozen food are introduced into a coating vessel where they are agitated to expose their surfaces and to maintain their free-flowing state throughout the coating process. A liquid coating material is sprayed onto the free-flowing pieces to cause coating material to adhere and the temperature at the surfaces of the frozen food pieces to rise. The surfaces of frozen food pieces are then recooled with a cryogen. The spraying and recooling steps are repeated until a thorough, even coating is built up on the discrete pieces of free-flowing food.

Description

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to food products. In particular, it relates to coated, frozen foods and to a method for making the same.

2. Discussion of the Related Art

Among the most popular prepared foods are precooked, frozen foods. Particularly coating-apparatus; and the pasta products that can be advantageously prepared in accordance with the inventive process include ravioli, tortellini, rigatoni, macaroni, and the like. If fresh pasta is used, it is first extruded into a desired shape, then cooked by blanching. To prevent overcooking, the pasta is next chilled by rinsing in cold water. In some embodiments, an intermediate coating of a solid or liquid, food-acceptable, fatty material is applied to the cooked pasta, before the pasta is frozen. The fatty material can be saturated or unsaturated and can be, for example, soybean oil, corn oil, olive oil, cotton seed oil, butter, cream or margarine. The amount of fatty material coated on the cooked pasta is typically from about 0.1 to about 5% and, preferably, from about 0.5 to about 3%, based on the weight of the thus coated pasta.

The cooked pasta is then individually quick frozen, generally, to temperatures of less than about 10° F., preferably less than about 0° F. Techniques for individually quick freezing foods are known in the art. The conditions for individually quick freezing the pieces of a particular food item to be subsequently frozen will depend on the characteristics of the food item, including its size, shape, density, flowability, and the like. The optimum conditions for quick freezing a particular food item will be readily determinable by one skilled in the art without undue experimentation. Some foods are coated immediately after freezing. Other foods are maintained in a frozen state, e.g., at temperatures less than about 10° F., preferably less than about 0° F., for a predetermined period, before coating.

The IQF pasta is then loaded into the coating vessel 12, typically at a temperature of less than about 10° F., preferably at a temperature of less than about 0° F. In a preferred embodiment, cryogen is then introduced into the drum 13 to further cool the frozen pieces of pasta, preferably to a temperature less than about −25° F. Any cryogen suitable for use with food can be used, with normally gaseous substances being preferred. Suitable cryogens include liquid carbon dioxide (which forms a subliming snow at atmospheric pressure) and liquid nitrogen.

The rotation of the coating drum 13, along with the baffles 15, agitate the pieces of frozen food and control the tumbling action of the food throughout the coating process. To ensure an even application of the liquid coating material and the creation of an even coating, and to ensure that the coated pieces remain free flowing, the drum is preferably rotated at a speed of from about 5 to about 20 rpm, while liquid coating material is applied and the coating is being formed.

As best seen in FIG. 2, as the drum 13 rotates, the baffles 15 cause the frozen pieces to be carried from the bottom of the drum upwardly along one side of the drum, until gravity causes the pieces to fall back to the bottom of the drum. The height to which the pieces are lifted depends on the angular velocity (rotational speed) of the drum. The pieces are then projected outward from the side of the drum and fall back to the bottom of the drum, forming a nearly continuous cascading curtain of food pieces. This lifting and falling process is repeated continuously until the coating process is complete.

The inventive process can be used to coat pasta with a wide variety of edible liquid coating materials, including tomato sauce, cheese sauce, and Alfredo sauce. The liquid coating material may contain one or more solid ingredients in suspension. Illustrative solid ingredients for use in a sauce for pasta include basil, garlic, and black pepper.

The temperature at which the liquid coating material is applied is preferably from about 40° F. to 180° F., more preferably from about 60° F. to 70° F. The liquid coating material spray is controlled by the flow rate and the pressure at which the liquid coating material is pumped, as well as the nozzle type, size, and configuration. The flow rate and pressure will depend on the characteristics of the liquid coating material, e.g., its viscosity, and on the characteristics of the frozen food to be coated, e.g., its size and shape, as well as the size and type of the coating vessel. The particular flow rate and pressure to be used for a desired combination of liquid coating material and frozen food will be readily determinable by one skilled in the art without undue experimentation. In a preferred embodiment, the pressure at the manifold inlet is from about 0 psig to about 100 psig, more preferably of from about 20 psig to about 60 psig. The liquid coating material can be applied continuously, or, as in preferred embodiments, intermittently.

The nozzles are aimed so that the liquid coating material is sprayed directly onto the exposed surfaces of the pieces of frozen food as the pieces fall downwardly from the side of the drum 13 to the bottom of the drum. As the liquid coating material adheres to the exposed surfaces, it causes the temperature at the surfaces to rise, e.g., up to as high as 10° F.

Sufficient cryogen is introduced into the vessel 12 to recool the free-flowing pieces. In a preferred embodiment, the spray of liquid coating material is stopped before, the flow of cryogen is introduced.

After the IQF pasta pieces have been recooled, the process is repeated. More liquid coating material is sprayed onto and adheres to the exposed surfaces of the recooled, free-flowing pieces. In a preferred embodiment, the flow of cryogen is stopped, before resuming spraying of the liquid coating material. This added coating material is then cooled by additional cryogen. In some embodiments, the food pieces are recooled to a temperature of less than about 0° F. by at least one of the recooling steps; while in some embodiments, the food pieces are recooled to a temperature of less than about −20° F by at least one of the recooling steps; and, in some embodiments, the food pieces are recooled to a temperature of less than about −35° F. by at least one of the recooling steps.

The effectiveness of the cryogen can be measured by monitoring the temperature of the cryogen as it exits from the coating vessel. It has been found that when the cryogen is effective, the exiting gas has a temperature of from about 0° to about −100° F. The spraying and recooling steps are repeated, until a thick, even coating is built up on the pieces of IQF food.

By using the method in accordance with the invention, it is possible to prepare free-flowing, individually coated pieces of IQF foods. The coatings preferably weigh in the range of from about 5 wt. % to about 75 wt. % and more preferably in the range of from about 40 wt. % to about 75 wt. %, based on the total weight of the coated food. The optimum design, which varies depending on the particular combination of IQF food and liquid coating material, is selected so that a thorough and even coating material, is selected so that a thorough and even coating builds up on the exposed surfaces of the IQF pieces as the pieces repeatedly pass through the coating material. The thickness of the coating is controlled by pre-determining the number of times the coating/recooling/coating process is repeated. Uncoated and partially-coated product is exposed with every cycle of cascading to keep the sauce coating evenly distributed.

The thus coated, free-flowing, frozen pasta is unloaded from the coating vessel. The frozen food can be subsequently packaged. Alternatively, additional frozen ingredients, such as discrete pieces of frozen meats, vegetables or combinations of the two are mixed with the free-flowing, coated, frozen pieces, at temperatures less than about 10° F., preferably less than about 10 0° F., using a blender or tumbler.

Turning to the embodiment shown in FIG. 3, like numbers in FIGS. 1 and 3 indicate like elements. Pasta is provided from a feed line 6 to an IQF unit 8. Once individually quick frozen, discrete pieces of frozen food are transported by a moving belt 10 and loaded through an open end 40, into a pass-through, cylindrical coating vessel 42 which rotates about an inclined longitudinal axis. Suitable pass-through vessels that can be modified to practice the inventive method include oil coating reels manufactured by Spray Dynamics. Pieces of frozen food are continuously moved through a rotating tube 44, and continuously discharged through the vessel outlet 46. As the pieces of frozen food travel the length of the reel, they are also caused to tumble by the rotating tube. A liquid coating material is applied to the surface of the thus agitated frozen food pieces by spray nozzles 48 that apply the liquid coating in a flat-fan pattern. A cryogen, liquid nitrogen in this embodiment, is intermittently introduced throughout the length of the vessel using a pipe header 50, with the result that a thorough, even coating is formed.

Other coated foods that can be prepared in accordance with the invention include pasta salads, glazed vegetables, potatoes au gratin and other potato and cheese sauce products, scrambled simulated-eggs coated with cheddar cheese, french toast sticks or mini-waffles coated with syrup, beef and vegetable stew, soups, chili, meat fillings for tacos, burritos, and the like, meatballs, beef stroganoff, casseroles, stir fry products, cocktail wieners coated with sauce, seafood coated with cocktail or other sauce, riblets coated with barbecue sauce, chicken wings coated with barbecue sauce, chicken tenders coated with teriyaki sauce, fruits coated with yogurt or other dairy coatings, fruit with glazed coatings, fruit cobblers, fruit with pound cake, and bananas foster to name a few.

The following examples are included to further illustrate the invention. They are not limitations thereon.

EXAMPLE 1

Rigatoni coated with a marinara sauce is prepared in accordance with the inventive process. The rigatoni is 2 inches long and 0.4 inches in diameter, with a wall thickness of 0.8 inches. It has a bulk density of 24.4 lb./ft³, an outside surface area of 402 in²/lb., and a weight of 0.63 lb./100 pieces. 123.75 lb. lbs. of IQF rigatoni is introduced into a Blentech Model VTl-0350 rotatable coating drum. An exemplary drum is 55 inches long and 46 inches in diameter. It is fitted with four nozzles spaced 4.25 inches from one another, at 26.75, 31, 35.25, and 39.5 inches from its open end. The drum rotates at a speed of 12 rpms rpm.

185 lbs. of liquid nitrogen is introduced into the drum, intermittently, over a period of 23.1 minutes (277 turns). During this time, 101.25 lbs. of sauce is intermittently applied over a total of 3.5 minutes (42 turns), with the period for each individual application of sauce increasing from 25 to 85 seconds. The total tumbling time is 29.8 minutes (358 turns). The resulting free-flowing product comprises 55% rigatoni and 45% sauce, by weight.

EXAMPLE 2

Rigatoni coated with an Alfredo sauce was prepared in accordance with the inventive process. 123.75 lb. lbs. of IQF rigatoni was introduced into a Blentech rotatable coating-drum coating drum fitted with a single nozzle. The drum rotated at a speed of 10 rpms rpm.

A total of 145 lbs. of carbon dioxide was intermittently injected into the drum at a flow rate of 38.9 lb./min. and a pressure of 275 psig. Initially, the carbon dioxide was injected for 15 seconds to further cool the rigatoni. Thereafter, sauce having a temperature of 53° F. and carbon dioxide were alternately introduced into the drum. The sauce was injected for a period of 25 seconds, at a pressure of 15 psig. The carbon dioxide was then injected for 12 seconds. This cycle was repeated 16.4 times until 101.25 lbs. of sauce had been sprayed. After the last application of sauce, carbon dioxide was injected for 15 seconds to finally cool the coated product to a temperature less than −40° F. The resulting free-flowing product comprised 55% rigatoni and 45% sauce, by weight.

EXAMPLE 3

Rigatoni coated with an Alfredo sauce was prepared in accordance with the inventive process. 750 lb. of IQF rigatoni was introduced into a rotatable coating-drum coating drum manufactured by Peter Heller GmbH and fitted with four nozzles. The initial temperature of the rigatoni was 2° F. The drum rotated at a speed of 7.5 rpms rpm.

A total of 1380 lbs. of carbon dioxide was intermittently injected into the drum at a flow rate of 58.1 lb. lbs./min. Initially, the carbon dioxide was injected for 2.3 minutes to further cool the rigatoni. Thereafter, sauce having a temperature of 70° F. and carbon dioxide were alternately introduced into the drum. The sauce was injected for a period of 2 seconds followed by a by a pause of 2 seconds for a total duration of 1.3 minutes, at a pressure of 24 psig. The carbon dioxide was then injected for 30 seconds, followed by a pause of 4 seconds for a duration of 2.3 minutes. This cycle was repeated 9.2 times until 675 lbs. 675 of sauce had been sprayed. After the last application of sauce, average temperature of the coated product was about −20° F. The resulting free-flowing product comprised 55% rigatoni and 45% sauce, by weight.

The temperature of the (coated) pasta was calculated after each step of the coating process and the results are reported below.

Cycle No.	Sauce	Carbon Dioxide
		−28.8° F.
1	2.3° F.	−25.8° F.
2	2.6° F.	−23.5° F.
3	2.9° F.	−21.4° F.
4	3.1° F.	−19.6° F.
5	3.3° F.	−18.1° F.
6	3.5° F.	−16.7° F.
7	3.6° F.	−15.4° F.
8	3.8° F.	−14.3° F.
9	3.9° F.	−13.3° F.
10	4.0° F.	−12.4° F.
10.2	−9.0° F.	−21.0° F.

While the invention has been described in detail with reference to certain preferred embodiments thereof, it will be understood that modifications and variations are within the spirit and scope of that which is described and claimed.

Claims

1. A process for coating discrete pieces of a free-flowing, frozen food comprising the steps of:

(a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

(b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

(c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces and thereby to cause the temperature of the frozen food pieces to rise;

(d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

(e) repeating steps (c) and (d) until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food.

2. The process in accordance with claim 1 A process for coating discrete pieces of a free-flowing, frozen food comprising:

a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces thereby causing the temperature of the frozen food pieces to rise;

d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

e) repeating steps c and d until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food, wherein the temperature of the frozen food is less than about −25° F. when it is first sprayed with the liquid coating material in step (c).

3. The process in accordance with claim 2, further comprising reducing the temperature of the frozen food pieces initially having a temperature greater than about 10° F. with the cryogen in the coating vessel before the frozen food pieces are sprayed with the liquid coating material in step (c).

4. The process in accordance with claim 2, further comprising reducing the temperature of the frozen food pieces initially having a temperature greater than about 0° F. with the cryogen in the coating vessel before the frozen food pieces are sprayed with the liquid coating material in step (c).

5. The process in accordance with claim 1 2, further comprising stopping the spraying in step (c), before the recooling with the cryogen in step (d).

6. The process in accordance with claim 1 2, further comprising stopping the recooling in step (d), before repeating step (c).

7. The process in accordance with claim 1 2, wherein the food pieces are recooled to a temperature of less than about 0° F. by at least one of the recooling steps in (d).

8. The process in accordance with claim 1 2, wherein the food pieces are recooled to a temperature of less than about −20° F. by at least one of the recooling steps in (d).

9. The process in accordance with claim 1 2, wherein the food pieces are recooled to a temperature of less than about −35° F. by at least one of the recooling steps in (d).

10. The process in accordance with claim 1 2, wherein the frozen food is selected from the group consisting of pasta, rice, potatoes, vegetables, fruits, meats, seafood, simulated-eggs and mixtures thereof.

11. The process in accordance with claim 10, wherein the frozen food is pasta.

12. The process in accordance with claim 11, further comprising coating the pasta with from about 0.1 to about 5% fatty material, based on the weight of the coated pasta, prior to individually quick freezing the pasta.

13. The process in accordance with claim 12, wherein the pasta is coated with from about 0.5 to about 3% soybean oil, corn oil, olive oil, cotton seed oil, butter, cream, or margarine, prior to being individually quick frozen.

14. The process in accordance with claim 1 A process for coating discrete pieces of a free-flowing, frozen food comprising:

a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces thereby causing the temperature of the frozen food pieces to rise;

d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

e) repeating (c) and (d) until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food, wherein the liquid coating material is sprayed at a pressure of from about 0 psig to about 100 psig.

15. The process in accordance with claim 14, wherein the liquid coating material is sprayed at a pressure of from about 20 psig to about 60 psig.

16. The process in accordance with claim 1 A process for coating discrete pieces of a free-flowing, frozen food comprising:

a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to ad here to the surfaces thereby causing the temperature of the frozen food pieces to rise;

d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

e) repeating (c) and (d) until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food, wherein the cryogen is carbon dioxide or nitrogen.

17. The process in accordance with claim 1 A process for coating discrete pieces of a free-flowing, frozen food comprising:

a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces thereby causing the temperature of the frozen food pieces to rise;

d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

e) repeating (c) and (d) until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food, wherein the coating weighs in the range of from about 5 wt. % to about 75 wt. %, based on the weight of the coated food.

18. The process in accordance with claim 1 A process for coating discrete pieces of a free-flowing, frozen food comprising:

a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces thereby causing the temperature of the frozen food pieces to rise;

d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

e) repeating (c) and (d) until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food, wherein the coating weighs in the range of from about 35 wt. % to about 65 wt. %, based on the weight of the coated food.

19. The process in accordance with claim 1 A process for coating discrete pieces of a free-flowing, frozen food comprising:

a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces thereby causing the temperature of the frozen food pieces to rise;

d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

e) repeating (c) and (d) until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food, further comprising blending discrete pieces of an additional frozen food with the coated, frozen food.

20. The process in accordance with claim 19, wherein the additional frozen food is selected from the group consisting of meat, vegetables or combinations thereof.

21. The process in accordance with claim 1 2, wherein the process is a batch process.

22. The process in accordance with claim 21, wherein the coating vessel is a rotatable coating drum.

23. The process in accordance with claim 22, wherein the agitation is by rotating the coating drum at a speed of from about 5 to about 20 rpm.

24. The process in accordance with claim 1 A process for coating discrete pieces of a free-flowing, frozen food comprising:

a) loading discrete pieces of a free-flowing, frozen food in a coating vessel;

b) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

c) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces thereby causing the temperature of the frozen food pieces to rise;

d) introducing a cryogen into the coating vessel to recool the frozen food pieces; and

e) repeating (c) and (d) until a thorough, even coating is built up on the discrete pieces of free-flowing, frozen food, wherein the process is a continuous process.

25. A process for coating discrete pieces of a free-flowing, frozen food comprising:

(a) loading discrete pieces of an individually quick frozen food selected from the group consisting of pasta, rice, potatoes, vegetables, fruits, meats, seafood, simulated-eggs, and mixtures thereof into a coating vessel, the temperature of the individually quick frozen food being greater than about 0° F.;

(b) introducing a flow of a cryogen selected from the group consisting of carbon dioxide and nitrogen into the coating vessel and reducing the temperature of the frozen food pieces to less than about −25° F.;

(c) agitating the discrete frozen food pieces to expose their surfaces and to maintain the discrete pieces in a free-flowing state throughout a coating process;

(d) spraying a liquid coating material onto the exposed surfaces of the free-flowing pieces to cause coating material to adhere to the surfaces and thereby to cause the temperature of the frozen food pieces to rise;

(e) stopping the spray of liquid coating material and resuming the flow of cryogen into the coating vessel to recool the frozen food pieces with the cryogen; and

(f) stopping the flow of the cryogen and then repeating steps (d) and (e) until a thorough, even coating weighing in the range of from about 5 wt. % to about 75 wt. %, based on the weight of the coated food, is built up on the discrete pieces of free-flowing food.

26. The process in accordance with claim 25, wherein the food pieces are recooled to a temperature of less than about 0° F. by at least one of the recooling steps (e) or (f).

27. The process in accordance with claim 25, wherein the food pieces are recooled to a temperature of less than about −20° F. by at least one of the recooling steps (e) or (f).

28. The process in accordance with claim 25, wherein the food pieces are recooled to a temperature of less than about −35° F. by at least one of the recooling steps (e) or (f).

29. The process in accordance with claim 25, wherein the frozen food is pasta.

30. The process in accordance with claim 25, wherein the coating weighs in the range of from about 35 wt. % to about 65 wt. %, based on the weight of the coated food.

31. The process in accordance with claim 25, wherein the process is a batch process.

32. The process in accordance with claim 25, wherein the coating vessel is a rotatable coating-drum coating drum and the frozen food pieces are agitated by rotating the coating-drum coating drum at a speed of from about 5 to about 20 rpm.

33. The process in accordance with claim 25, wherein the process is a continuous process.

34. The process in accordance with claim 25, further comprising blending discrete pieces of an additional frozen food with the coated, frozen food.

35. The process in accordance with claim 34, wherein the additional frozen food is selected from the group consisting of meat, vegetables or combinations thereof.

36. The process in accordance with claim 2, wherein the liquid coating material has a temperature of about 180° F. or less when sprayed onto the exposed surfaces of the free-flowing pieces.

37. The process in accordance with claim 2, wherein the liquid coating material has a temperature of about 60° F. to 70° F. when sprayed onto the exposed surfaces of the free-flowing pieces.

38. The process in accordance with claim 2, wherein the liquid coating material has a temperature of about 40° F. to 60° F. when sprayed onto the exposed surfaces of the free-flowing pieces.

39. The process in accordance with claim 2, wherein the liquid coating material includes solid ingredients.

40. The process in accordance with claim 39, wherein the solid ingredients include spices.

41. The process in accordance with claim 2, wherein the liquid coating material comprises of one from a group comprising of dairy-based sauce and tomato-based sauce.

42. The process in accordance with claim 2, wherein the pieces includes pieces extending at least three inches in one dimension.

43. The process in accordance with claim 11, wherein the pasta is ravioli, tortellini, rigatoni or macaroni.

44. The process in accordance with claim 2, wherein the pieces includes meat and the liquid coating material is a meat-based sauce.

45. The process in accordance with claim 2, wherein the pieces comprise of fruit and the liquid coating material comprises a glaze.

46. The process in accordance with claim 2, wherein the pieces comprise of vegetable and the liquid coating material comprises a glaze.

47. The process in accordance with claim 2, wherein the pieces comprise of fruit and the liquid coating material comprises a fruit-based sauce.

48. The process in accordance with claim 2, wherein the pieces comprise seafood.

49. The process in accordance with claim 48, wherein the liquid coating material has a temperature of about +40° F. when sprayed on the exposed surfaces of the pieces.

50. The process in accordance with claim 48, wherein the pieces are recooled to a temperature ranging between −20° F. to −25° F. by at least one of the recooling in (d).

51. The process in accordance with claim 48, wherein the coating weighs in the range from about 35 wt. % to about 50 wt. %, based on the weight of the coated food.

52. The process in accordance with claim 2, wherein the cryogen after recooling the frozen food pieces has a temperature of about 0° F. to about −100° F.

53. The process in accordance with claim 2, wherein the cryogen is introduced into the coating vessel at a controlled flow rate.

54. The process in accordance with claim 53, wherein the flow rate is controlled in units of weight of the cryogen over time.

55. The process in accordance with claim 2, wherein duration of the spraying of (c) increases with repetition of (c).

56. The process in accordance with claim 2, wherein duration of the recooling of (d) varies between repetition of (d).

57. The process in accordance with claim 2, wherein there is a pause between the spraying of (c) and the recooling of (d).

58. The process in accordance with claim 22, wherein the drum has baffles which extend substantially the length of the drum.

59. The process in accordance with claim 22, the drum has baffles that are angled.

60. The process in accordance with claim 23, wherein the drum has baffles forming a spiral extending radially along the length of the drum.

61. The process in accordance with claim 2, wherein the coating vessel keeps the piece in constant motion throughout the coating process.

62. The process in accordance with claim 22, wherein the drum rotates at the speed of from about 5 to about 20 rpm, while the liquid coating material is applied and the coating is being formed.

63. The process in accordance with claim 22, wherein the coating drum agitates the discrete frozen pieces to substantially continuously cascading within the drum.

64. The process in accordance with claim 22, wherein the drum rotates about an inclined longitudinal axis.

65. The process in accordance with claim 2, wherein the pieces are continuously moved into the coating vessel through a rotating tube.

66. The process in accordance with claim 22, wherein the pieces are continuously discharged through an outlet in the drum.

67. The process in accordance with claim 2, wherein spraying a liquid coating material employs a spray bar extending along a longitudinal axis of rotation of the drum.

68. The process in accordance with claim 2, wherein spraying a liquid coating material employs a spray bar with nozzles.

69. The process in accordance with claim 68, wherein the nozzles are positioned to spray the liquid coating material onto the exposed surfaces of the pieces while cascading downwardly within the drum.

70. The process in accordance with claim 68, wherein the nozzles are evenly spaced along the bar.

71. The process in accordance with claim 68, wherein the nozzles are directed at an angle of from about zero to about ninety degrees from vertically down.

72. The process in accordance with claim 68, wherein the nozzles are configured with a substantially flat fan spray pattern.

73. The process in accordance with claim 68, wherein the nozzles are positioned substantially in the center of the coating vessel.

74. The process in accordance with claim 68, wherein the nozzles are outwardly and radially oriented relative to the bar.

75. The process in accordance with claim 68, wherein the nozzles have orifices with diameters ranging substantially from 0.1 inches to 0.25 inches.

76. The process in accordance with claim 28, wherein the nozzles have orifices with diameters ranging substantially from 0.25 inches to 0.5 inches.

77. The process in accordance with claim 68, wherein the nozzles have orifices with diameters of at least substantially 0.5 inches.

78. The process in accordance with claim 68, wherein the nozzles are configured with a substantially full cone spray pattern.

79. The process in accordance with claim 68, wherein the nozzles are configured as straight spray jets.

80. The process in accordance with claim 48, wherein the coating vessel agitates the pieces at a speed ranging from about 5 rpm to about 6 rpm.