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    • 专利摘要:
    method of producing a frozen, coated microwave food product a method of producing a frozen coated microwave food product, such a method comprising the steps of: providing a portion of a solid, or solidified substrate; coating such portion with an aqueous precoating liquid to form a precoated portion; applying a coating of adhesive crumbs to the pre-coated portion to form a portion coated with crumbs; applying a dough to the portion coated with crumbs to form a portion coated with dough; applying a crumb coating to the dough-coated portion to form a breaded portion; frying the breaded portion by contacting such breaded portion for at least 100 seconds with hot oil at a temperature of at least 150 ° C, thereby producing a fried coated portion having a core temperature greater than 70 ° C; and freezing the fried coated portion by introducing such fried portion in a freezer; where the core temperature of the fried coated portion is not less than 50 ° C, preferably not less than 60 ° C, when such a fried portion is introduced into the freezer and where such core temperature is reduced to less than -15 ° C using cryogenic freezing.
    公开号:BR112013019104B1
    申请号:R112013019104-0
    申请日:2012-01-18
    公开日:2020-03-31
    发明作者:Keith Pickford
    申请人:Crisp Sensation Holding S.A.；
    IPC主号:
    专利说明:

    METHOD OF PRODUCTION OF A COATED, FROZEN FOOD PRODUCT FOR MICROWAVES
    TECHNICAL FIELD OF THE INVENTION
    This invention relates to a method of producing coated food products that can be cooked or reheated using a microwave oven or using a conventional oven combined with a microwave, collectively referred to herein as a microwave oven. The invention also relates to an apparatus for carrying out the method and to food products manufactured by the method or using such an apparatus. The invention relates particularly, but not exclusively, to products coated with crumbs, particularly chicken nuggets or other products in which a substrate of meat, fish, poultry, vegetable, fruit, fungus or dairy materials is coated with a dough coating. and one or more layers of crumbs, in which the products can be cooked or reheated from a frozen state using a microwave oven.
    BACKGROUND OF THE INVENTION
    The use of a microwave oven to cook or reheat coated products is problematic, because the substrate is heated from the inside by microwave radiation producing steam that can damage the dough and crumb coatings. Conventional coated products are therefore unsuitable for use in microwave ovens.
    Many food materials, for example, natural chicken muscle, fish or red or vegetable meat or processed foods contain a large percentage of water. Most fresh foods contain more than 60% water.
    Petition 870190125279, of 11/29/2019, p. 4/7
    2/29
    Some of this water is bound, that is, rigidly bound to the constituent cells. The remaining mobile water is available and can be frozen. If a food product is frozen at a core temperature between -1 ° C and -30 ° C or below and is placed and irradiated in a microwave oven, the microwave energy will be absorbed first by the available frozen water. Whereas in conventional cooking the heat is applied from the outside, from the outside to the inside, in microwave cooking the heat is generated from the inside. The heating process can be very fast, so that the available water is converted into steam. When a food product is left to stand after heating in a microwave oven, water can continue to be expelled from this product. This is particularly noticeable, for example, in heating frozen fish muscle. The loss of water causes any food coating, particularly a coating of dough, pie dough (or puff pastry) or bread crumb to become soggy and unpleasant on the palate. In addition, the substrate core may become dry due to water loss.
    WO 93/03634 describes a method of producing a coated food product that can be reheated by microwave irradiation, such a method comprising: applying a prior sprinkling to the food product; applying a dough to the pre-collected food product; fry the food product coated with dough (breaded) and cool the fried product.
    WO 95/30344 describes a process for coated food products for microwaves, comprising the stages of application of pre-dusting, dough application, crumb application, flash frying, freezing and packaging.
    WO 97/03572 describes a process for
    3/29 coated food products, for microwaves, such as chicken nuggets, comprising the stages of application of previous sprinkling, application of dough, application of crumbs, flash frying, freezing and packaging.
    WO 2010/001101 describes a method of manufacturing a food product coated with crumbs, comprising the steps of: forming an aqueous mixture comprising: flour, sodium bicarbonate, water and optional additives; add the mixture to an extruder; adding an aqueous gelling agent to the extruder; extruding the resulting mixture at a temperature above 100 ° C to form an expanded porous product; dry the product and grind the dry product to form a crumb. The crumb thus obtained is particularly suitable for use in the preparation of coated food products that are cooked or reheated from a frozen state using a microwave oven.
    SUMMARY OF THE INVENTION the inventor has developed a method for producing a frozen coated food product that can be reheated or baked in a microwave oven to produce a ready-to-eat product with excellent organoleptic properties, in particular a crunchy coating in combination with a juicy moist core.
    A first aspect of the present invention provides a method for producing a frozen coated food product that can be reheated or baked in a microwave oven, such a method comprising the steps of:
    providing a portion of a solid, or solidified substrate;
    coating such portion with an aqueous pre-coating liquid to form a pre-coated portion;
    apply a coating of adhesive crumbs to the
    4/29 pre-coated portion to form a portion coated with crumbs;
    applying a dough to the portion coated with crumbs to form a portion coated with dough;
    applying a crumb coating to the dough-coated portion to form a breaded portion;
    frying the breaded portion, thus producing a fried coated portion with a core temperature greater than 70 ° C, and freezing the fried coated portion by introducing such portion into a freezer;
    wherein the core temperature of the fried coated portion is not less than 50 ° C when such a fried portion is introduced into the freezer and where that core temperature is reduced to less than -15 ° C using cryogenic freezing.
    According to a second aspect of this. invention, an apparatus is provided for carrying out the method mentioned above, such apparatus comprising:
    substrate forming apparatus for preparing portions of a solid, or solidified substrate;
    coating apparatus, arranged to receive the portions and immerse the portions in a viscous aqueous coating composition to produce pre-coated portions;
    a first crumb applicator, arranged to receive the pre-coated portions and to apply a layer of crumbs over the pre-coated portions in order to form portions coated with crumbs;
    a dough coating applicator, arranged to receive the crumb-coated portions and immerse the crumb-coated portions in a dough to produce dough-coated portions;
    5/29 a second crumb applicator, arranged to receive the portions coated with dough and to apply a layer of crumbs over the portions coated with dough to form portions with multiple coatings;
    a fryer, arranged to receive the multi-coated portions and immerse the multi-coated portions in hot oil to produce hot-fried coated portions;
    a cryogenic freezer, arranged to receive and cryogenically freeze the hot fried coated portions.
    DRAWINGS
    The invention is further described by way of example, but not in any limiting sense, with reference to the accompanying drawings, of which:
    Figure 1 is a flow chart that illustrates the steps of the method;
    Figure 2 is a side view of the apparatus according to the present invention;
    Figure 3 is a cross-sectional view of a coating apparatus;
    Figure 4 is a cross-sectional view of a crumb coating apparatus, and
    Figure 5 is a perspective view of a deep fryer.
    DETAILED DESCRIPTION OF THE INVENTION
    Likewise, a first aspect of the present invention relates to a method for producing a frozen microwave coated food product, such a method comprising the steps of:
    providing a portion of a solid, or solidified substrate;
    coating such portion with an aqueous pre-coated liquid to form a pre-coated portion;
    applying a crumb coating to the pre-coated portion to form a crumb-coated portion;
    applying a dough to the portion coated with crumbs to form a portion coated with dough;
    applying a crumb coating to the dough-coated portion to form a breaded portion;
    frying the breaded portion, by contacting such breaded portion for at least 100 seconds with hot oil at a temperature of at least 150 ° C, thereby producing a fried coated portion that has a core temperature greater than 70 ° C; and freezing the fried coated portion, passing that fried portion in a freezer;
    wherein the core temperature of the fried coated portion is not less than 50 ° C, preferably not less than 60 ° C when such a fried portion enters the freezer and at which. the core temperature is reduced to below -15 ° C using cryogenic freezing.
    The invention relates to a frozen microwave product, which is a product that was cooked before freezing and that can be reheated in a microwave oven or in a conventional oven combined with a microwave to provide a satisfactory product with a juicy core and a crunchy crumb coating. The products of the present invention can also be reheated in a conventional thermal oven.
    It has been found that freezing conditions are important to produce a frozen coated food product that, despite comprising a moist core, can be heated in a microwave oven to provide a hot ready-to-eat product with a crunchy coating. More specifically, it was found that the
    7/29 core temperature of the fried coated portion should be reduced very quickly after frying, that is, while the core temperature of the fried portion is still high. While not wishing to be bound by theory, it is believed that rapid freezing of the fried portion can increase the structural integrity of the product, can reduce the formation of ice crystals and can reduce the size of any ice particles that may be formed inside. of product. If ice crystals are present in a breaded product, they can become overheated in a microwave oven, creating hot spots in the core. In addition, the migration of ice crystals during storage can cause a localized accumulation of ice which, on heating, can result in the release of excessive moisture close to the surface coating.
    To minimize the formation of ice crystals during freezing, the fried portion should be introduced. in the freezer as soon as possible after frying. Therefore, the core temperature of the fried coated portion preferably cannot decrease by more than 25 ° C, more preferably by no more than 20 ° C and more preferably by no more than 15 ° C, before the fried portion be introduced into the freezer, especially before being placed in contact with liquefied gas.
    In a particularly preferred configuration, the fried coated portion has a core temperature of more than 65 ° C, preferably greater than 70 ° C, when it is introduced into the freezer.
    In a preferred configuration, the core temperature of the fried portion is not allowed to fall below the specified temperature when the substrate is introduced into the freezer.
    In another preferred configuration, the temperature of the
    8/29 core of the fried coated portion is reduced at a very high rate of 60 ° C to -15 ° C. Typically, this temperature drop is accomplished in less than 40 minutes, more preferably in less than 30 minutes and most preferably in less than 20 minutes, depending on the weight of the particles, particle size, inlet temperature and the number of particles passing through the freezer.
    With the use of the freezer that is employed in the present method, the core temperature of the fried coated portion is typically reduced to less than -20 ° C or even less than 22 ° C.
    The cryogenic freezing of the fried coated portion in the present method comprises, suitably, contacting said fried portion with a liquefied gas or vaporized liquefied gas, more preferably a cryogenic substance, especially liquid nitrogen.
    In a particularly preferred configuration, the fried portion has a core temperature of at least 50 ° C, more preferably at least 60 ° C, even more preferably at least 65 ° C and most preferably at least 70 ° C when it comes in contact with a cryogenic substance.
    Portions of solid or solidified substrate that are coated with the aqueous precoat liquid can be in the solid state at room temperature or, alternatively, can be liquid or pasty at room temperature. In the latter case, for example, if the substrate is not solid at room temperature, the substrate is
    cooled down a temperature low enough for make it solid, before if apply the net of pre- coating.The benefits gives gift invention are particularly appreciated when the substrate contains an
    9/29 remarkable amount of water. During reheating in a microwave oven, some water contained in the substrate will turn into steam. Although the inventor does not want to be limited by theory, it is believed that the fried coating of the present microwave product is permeable to the vapor that is generated during microwave reheating and that it is difficult to absorb any vapor, thus retaining its nature crunchy. Typically the substrate contains at least 15% by weight, more preferably at least 25% by weight and even more preferably at least 30% by weight of water. The water content of the core material does not normally exceed 90% by weight.
    Examples of food materials that can be used to form substrate portions include fish, meat, poultry, seafood, shrimp, dairy products (for example, cheese), ragout and combinations thereof. According to a particularly preferred configuration, source material. animal selected from fish, meat, poultry, seafood, shrimp and combinations thereof represents at least 40% by weight, more preferably at least 60% by weight and even more preferably at least 80% by weight of the uncoated portion of the substrate.
    The present method can be used appropriately to produce coated food products from portions of solid substrate with a weight in the range of about 15 to 200 g. Preferably, the portions of the solid substrate have a weight in the range of about 10 to 50 g, generally about 25 g.
    Preferably, the substrate portion is not more than 50 mm thick, more preferably not more than 25 mm, even more preferably not more than 15 mm. This allows sufficient penetration of microwave radiation in a period of 2 to 3 minutes, using the
    10/29 power available in a typical home microwave oven. Thicker portions can be partially heated, turned or further heated until completion of preparation, if desired.
    The substrate portions can be whole portions, for example, portions of whole muscle, such as individual steaks or fillets or larger pieces that can be cut into individual portions after cooking or reheating. Alternatively, the pieces may comprise cut or crushed pieces, for example, nuggets or chopped products that can be reshaped into larger portions. It is preferred to use pieces with cores of uniform size and weight.
    solid or solidified substrate can be extruded or ejected in portions, for example, on a wire mesh conveyor, using a matrix (or mold). The temperature of the extrudate portions can be in the range of -6 o to 6 ° C, preferably of -4 o to -1 ° C to harden the substrate in order to facilitate handling during subsequent processing steps.
    The substrate, especially if it is composed of cut or crushed pieces, is preferably impregnated with an aqueous or particulate stabilizer composition, for example, by immersion, permeation or injection (pulsed vacuum injection) in the substrate before the formation of portions. Examples of suitable stabilizer compositions can be found in WO 97/03572, the disclosure of which is incorporated herein by reference for all purposes. The substrate can be impregnated with the stabilizer composition until the ingredients penetrate at least the surface layer. It is advantageous that the stabilizer impregnation region extends over the entire substrate or, at least, that it impregnates most of the structure of the
    11/29 substrate. Impregnation can be achieved by immersion, permeation or injection into the substrate before the portions are formed. Vacuum permeation is conveniently employed.
    The application of the adhesive crumbs is facilitated by the use of the aqueous pre-coating liquid, since the crumb particles will not adhere sufficiently to a dry substrate or to each other to form a cohesive shell surrounding the substrate. Therefore, the use of the pre-coating liquid has the additional advantage that the crumb layer can adhere to the substrate, providing a complete covering or shell surrounding the substrate to reduce water vapor leakage and prevent any fat infiltration during frying.
    aqueous pre-coating liquid that is applied to the substrate portion typically contains at least 80% by weight, preferably at least 90% by weight of water. In order to minimize dripping and to maximize the adhesion of. crumbs, the pre-coating liquid is preferably viscous and can have a minimum viscosity of 300 cP, measured with a Brookfield viscometer with a number 3 probe (spindle) at 60 rpm at 10 ° C. Even more preferably, such viscosity is in the range of 350 to 450 cP, more preferably in the range of 380 to 420 cP when fully hydrated.
    aqueous pre-coating liquid preferably contains 0.1% to 5% by weight, more preferably 0.3% to 3% by weight of dry matter.
    The pre-coating layer serves as an additional barrier to the loss of moisture by the substrate during the subsequent microwave heating phase. Without wishing to be limited by theory, it is believed that the pre-coat layer serves as a barrier against the capture of fat by the core, preventing a degradation of the flavor of the
    12/29 core. The impregnation of the core with a stabilizing composition, as described above, contributes to maintaining an ideal moisture content of the core during cooking or reheating.
    aqueous pre-coating liquid can be applied over the solid or solidified substrate portion by immersing such substrate in a bath containing the aqueous pre-coating liquid or by spraying or brushing such pre-coating liquid over the portion. Preferably, the pre-coating liquid is applied by immersion in a pre-coating liquid bath, for example, passing the portion through such a bath, with the aid of a conveyor belt. The term bath refers to any suitable container, tub or container suitable for containing a liquid.
    Another important feature of the present method is the application of a layer of adhesive crumbs before applying a putty. This crumb layer binds to the substrate with the aqueous pre-coating liquid and forms a thermal stabilization barrier underlying the dough coating and the optional external crumb coating (s). This can provide a barrier against the escape of moisture and the entry of oil during an extended frying step. This crumb shell also serves to protect the substrate surface from excessive local heating during frying.
    Particularly good results can be obtained if the adhesive crumb shell used in the present method is an extruded ground meal containing 0.05% to 5% by weight, more preferably from 0.1% to 3% by dry weight of hydrocolloid added. Crumbs without the addition of a hydrocolloid usually form a soggy mass immediately after mixing with water. The hydrocolloid contained
    13/29 in the crumbs can be any hydrocolloid that forms a sun when mixed with water. The preferred hydrocolloids produce a crumb shell that maintains its shape when in contact with water at a temperature of 20 ° C for a period of 60 seconds.
    added hydrocolloid term as used herein refers to hydrophilic polymers which are not naturally present in the floury component of the paste extrudate, and which are capable of increasing the viscosity of an aqueous medium to which they have been added. These hydrophilic polymers are suitably selected from polysaccharides, modified polysaccharides and proteins.
    The hydrocolloid used in the adhesive crumbs can be selected from natural gums, modified gums, gelatin, pectin, alginate, modified starch, agar, carrageenan, furcelaran, arabinogalactan, xanthan, and combinations thereof. Preferably, the hydrocolloid is selected from natural gums and their combinations.
    Examples of natural gums that can be used with the hydrocolloids added to the molten flour extrude include guar gum, xanthan gum, locust bean gum, arabic gum, tragacanth, karaya gum, combinations of these.
    More preferably, the added hydrocolloid can be selected from guar gum, locust bean gum, xanthan gum and combinations thereof.
    The adhesive crumbs employed in the present method typically have an average weighted particle size of less than 2 mm. More preferably, the adhesive crumbs have a weighted average particle size of 0.1 to 1.5 mm, even more preferably 0.15 to 1 mm, and most preferably 0.25 to 0.9 mm .
    14/29
    The mass that is applied to the crumb-coated portion according to the present method preferably comprises, calculated by weight of dry matter, 20% to 55% by weight of starch; 20 to 55% by weight of flour and 3% to 20% by weight of egg solids. Examples of dough formulations that can be suitably employed in the present process are described in WO 96/32026. The starch contained in the dough may be provided by a floury component, or it may have been added as a purified starch ingredient, for example, starch with a high amylose content.
    Typically, the dough has a viscosity of 200 to 1000 cP, more preferably 300 to 800 cP, even more preferably 500 to 600 cP, measured with a Brookfield viscometer with a number 3 probe (spindle) at 60 rpm when it is applied to the portion coated with crumbs.
    The dough can be applied over the crumbed portion by an apparatus comprising a bath containing. the mass through which the crumbed portion passes through a conveyor. A tempura applicator is preferred, which is a bath containing a circulating mass through which a conveyor passes, for example, TempuDipper ™ (CFS), although a curtain type applicator, for example WetCoater ™ Applicator (CFS), can also be used. or other convenient device with a similar specification.
    Advantageously, the coating crumbs employed in the present method have a larger particle size than adhesive crumbs. Preferably, the coating crumbs have an average weighted particle size that is at least 50% larger than the average weighted particle size of the adhesive crumbs.
    The present method can adequately employ a crumb coating apparatus which comprises a
    15/29 first conveyor and a second endless conveyor located below one end of the first conveyor, and passing under a stream of fine crumb particles so that the portions fall from the first conveyor onto a layer of particles in the second carrier. The second conveyor can pass through a curtain of fine crumbs that fall on the surface of the conveyor so that the portion falls on the crumbs causing them to adhere to the surface layer of the aqueous pre-coating and is then coated by the particle curtain. of falling crumbs. The apparatus may comprise a dispenser that has an outlet that extends along the conveyor in order to provide that the curtain of fine crumbs extends along the path of the portions on the conveyor. A roller can be located above the conveyor on the outlet side to weigh the coated portion in order to improve the adherence of the fine crumb.
    Excess crumbs can be applied to the portion using a crumb applicator, for example, a CrumbMaster ™ (CFS). The crumb-coated portion can be passed through a roller to improve adhesion.
    The total amount of the aqueous pre-coating liquid, dough and crumbs that is applied to the portion in the present process is preferably selected in such a way that, after frying, the fried portion has a weight that exceeds the weight of the portion uncoated solid substrate by 25% to 100%, preferably 30% to 60%.
    One or more crumb coatings together typically represent between 5% to 80% by weight, preferably between 15% to 50% by weight of the fried portion.
    The breaded portion is fried to cook the substrate and the coating layers. The cooking period is
    16/29 sufficient preference to completely cook the substrate in order to avoid any risk to health, in case a frozen product is insufficiently reheated from the frozen state in a microwave oven. A relatively long period of reheating in a microwave oven is undesirable, since the substrate is heated from the inside by microwave energy, which results in a loss of moisture. This can lead to a dry core and cause damage to the coating layers.
    A homogeneous external coating of crumbs, without any part of the underlying mass layer being exposed, is advantageous to provide a uniform brownish appearance after a long frying period. This can be compared to a shorter frying period, as is generally used for breaded products cooked in a conventional manner.
    For conventionally cooked breaded products, such as chicken nuggets, a short frying period, for example, 90 seconds or less was followed by an additional period of cooking in a hot air oven. This is disadvantageous for products that can be cooked in a microwave because the core of the substrate may not be completely cooked during reheating from the frozen state. Prolonged heating of conventional products in a microwave oven causes an excessive loss of moisture and, consequently, damage to the coating layers.
    During the frying step, the breaded portion, optionally after having been coated with one or more additional layers of crumbs, is preferably placed in contact with the hot oil for 120 to 300 seconds, more preferably for 130 to 240 seconds, still more preferably for 140 to 180 seconds.
    The hot oil that is used to fry the portion
    17/29 breaded preferably is at a temperature of 160 ° to 200 ° C, more preferably from 170 ° to 195 ° C and even more preferably from 175 ° to 190 ° C.
    The oil used is preferably vegetable oil.
    The term vegetable oil encompasses unmodified vegetable oils, hydrogenated vegetable oils, fractions of vegetable oils (for example, fractions of olein or stearin), interesterified vegetable oils and combinations thereof. Pure rapeseed oil is preferred.
    Preferably, the core temperature of the fried portion is greater than 72 ° C, more preferably greater than 74 ° C.
    fried coating of the present food product - including all coating layers, preferably has an average thickness of 8 mm, more preferably 5 mm, and even more preferably 3 mm, depending on the size of the crumbs used.
    Frying according to the present invention is advantageous in comparison to flash frying followed by cooking with hot air, because the latter may not generate a coating with the desired hardness, without loss of moisture by the core.
    The breaded portion is suitably fried by immersing the breaded portion in hot oil, for example, by passing it in a bath of hot oil through a conveyor belt. The frying apparatus preferably comprises a double layer of parallel endless belts, both layers passing under the oil surface, a portion carried over a lower layer being prevented from floating during frying by contact with the upper layer. The belt may comprise wire screens or other perforated configurations.
    Frozen products are properly packaged
    18/29 for storage and distribution. Packaging in an inert atmosphere, for example, nitrogen, is preferred.
    The frozen product can be reheated or cooked from the frozen state, before use, using an oven selected from: a microwave oven, a conventional oven or grill, fried in a skillet or by immersion, or an oven with a combination of microwave and conventional heating.
    Another aspect of the invention relates to a microwave-coated food product that is obtained by a method as previously defined here. Most preferably, such a food product is a frozen coated food product.
    Yet another aspect of the invention relates to an apparatus for producing a frozen coated food product as defined above, such apparatus comprising:
    an apparatus for forming the substrate arranged to form portions of a solid, or solidified substrate;
    a coating apparatus, positioned downstream of the substrate-making apparatus, arranged to immerse the portions in a viscous aqueous coating composition to produce pre-coated portions;
    a first crumb applicator, positioned downstream of the coating apparatus, arranged to apply a layer of crumbs over the pre-coated portions to form portions coated with crumbs;
    a dough coating applicator, positioned downstream of the crumb applicator, arranged to immerse the crumb-coated portions in a dough to produce dough-coated portions;
    a second crumb applicator, positioned at
    19/29 downstream of the pasta coating applicator, arranged to apply a layer of crumbs over the pasta coated portions to form portions with multiple coatings;
    a fryer, positioned downstream of the second crumb applicator, arranged to immerse portions with multiple coatings in hot oil to produce hot fried coated portions;
    a cryogenic freezer, positioned downstream of the fryer, arranged to receive and freeze the hot fried portions quickly.
    Figure 1 is a flow chart illustrating the steps of the method of a configuration of the present invention. The device is shown in side view in Figure 2 and the components are shown in more detail in Figures 3 to 5.
    In a pre-processing step (1), pieces of chicken or other substrates are cut to an appropriate size or crushed as needed. The substrate pieces are impregnated with a stabilizer composition, as described in Examples 1 and 2. A forming machine (20) is used. A conventional forming machine can be arranged to extrude pieces of chicken substrate with a predetermined thickness and one or more shapes. The pieces are extruded on a conveyor arranged to transport them to a tempura bath containing an aqueous coating composition, as described in Example 3.
    The tempura coating apparatus is shown in Figure 3. It comprises a reservoir (30) for an aqueous or pre-gel coating composition (31). A first lower conveyor (32) carries the pieces (35) below the surface of the aqueous composition. A second upper conveyor (34) prevents the pieces (35)
    20/29 float. This ensures a complete coating of the pieces. The upper and lower conveyors are arranged in parallel to form a channel within which the pieces are located during the coating process.
    A second lower conveyor (33) carries the pieces of substrate out of the reservoir under the upper conveyor (34). The pieces of substrate that emerge from the reservoir pass under a jet of air (36) to remove excess liquid.
    After the application of the aqueous or pre-gel coating, a coating of fine crumbs is applied using a crumb applicator.
    Substrates coated with fine crumbs then pass through a tempura dough applicator (6) to apply the dough, followed by the application of the outer crumb layer. The dough mixture is prepared in a mixing tank with a high shear mixer and a heating system to maintain the temperature at 42 ° C for 30 minutes. The mixture is then transferred to a holding tank, maintained at 3 ° C to 4 ° C, with the viscosity being adjusted as necessary by adding water before being pumped into the tempura applicator.
    The dough coating can be applied using a tempura coating device of the type shown in Figure 3. Pieces of substrate that have been coated with the aqueous coating and fine crumbs are passed through a dough bath using a wire mesh conveyor, so that complete immersion of the pieces is obtained.
    A first layer of coarse crumbs can be applied (7) to the dough-coated product followed by finer crumbs to fill the spaces between the coarse crumb particles (8). Alternatively,
    21/2 9 a single outer layer of crumbs can be used, particularly when using large external crumbs.
    When two outer crumb layers are used, a first outer crumb coating can be applied using a conventional crumb applicator. The crumbs are preferably sieved to remove fines and small particles. A second outer crumb coating can be applied to ensure complete coverage of the breaded substrate.
    The product coated with crumbs is then passed through an elongated reservoir (9) containing heated oil, to fry the product.
    A frying time of 2 minutes and 20 seconds was used, although this may vary depending on the weight and size of the particles. After frying, the core temperature of the product was in the range of 74 ° C to 85 ° C. A small weight loss has been observed due to the loss of water by the substrate, but this is usually compensated by an oil absorption.
    After frying, the hot fried products were passed directly, without delay, through a cryogenic freezer using a conveyor, so that the core temperature of the fried products is reduced to a maximum of -25 ° C, usually -30 ° C to -35 ° C or less for a period of 30 minutes or less.
    The fryer construction is shown in detail in Figure 5. The deep fryer reservoir contains rapeseed oil that is heated to a constant temperature of 180 ° to 188 ° C. Pure rapeseed oil is used.
    The frozen products were packed in hermetically sealed packages (12). The package can be washed with nitrogen (13), although this may not be
    22/29 used, depending on the desired shelf life for the packaged products.
    The crumbs were prepared as described in WO 2010/001101, the disclosure of which is incorporated herein by reference for all purposes.
    Examples
    Example 1 - Composition of stabilizer
    A stabilizer composition was prepared using the following ingredients:
    Ingredient THE.015.0 Cellulose gum (Methocel ™ A4M) Modified starch (Thermflo ™) 24.0 Polydextrose40, 0 Xanthan gum6, 0 Egg Albumin15.0 TOTAL100.0 The composition was dissolved in water to produce a solution with an appropriate concentration to stabilize the particular substrate in use. For this purpose, the powder mixture
    dry was partially hydrated in a vat and then poured into a bowl cutter. The cutter was then switched on for two or three minutes until the mixture was fully hydrated. The mixture can be hydrated directly in the bowl cutter, if necessary. Alternatively, the stabilizer can be hydrated using a high shear mixer equipped with a general purpose head.
    This general purpose formula can be modified to increase its efficiency on specific substrates. The above formula can be modified by adding citric acid (up to 1%) and ascorbic acid (up to 2%), with polydextrose (eg Litesse II (trademark)) being reduced accordingly.
    23/29
    Example 2 - Substrate impregnation with
    Composition of Stabilizer
    A mixture for nuggets or chicken sticks was prepared with the following composition that was prepared as
    a dry mixture as an alternative à u .use of an hydrated stabilizer composition. Was used The stabilizer of Example 1. Chicken emulsion20%Leather - 3 mm18%Chicken breast - 10 mm50%Water2%Screw thread2%Stabilizer (Example 1)5%Spices3% 100%The chicken breast was cooled at -3 ° C and chopped using a 10 mm plate. After chopping, temperature was 0 to 3 ° C. Added Water with mixing. An chicken emulsion comprising the following s ingredients was added with mixture: Chicken skin44%Water44%Isolated soybean11%salt1% 100%
    The stabilizer according to Example 1 was added and mixed thoroughly. Thread was added with mixture, followed by seasoning. A dry powder flavoring was preferred. The composition was allowed to dissolve in use in the water present in the substrate, to form an aqueous solution of the stabilizer in situ. (Step 1)
    Vacuum was applied to the mixture to consolidate the structure and then the chicken mixture was cooled until
    24/29
    -3 ° C (Step 2) and shaped into shaped pieces (Step 3).
    A similar procedure was used for other minced / minced meat products. Large particulate cores can be manufactured using a similar method.
    Example 3 - Composition of Aqueous Coating
    The following mixture was prepared:
    Modified starch (Thermflo) 35% Thickener (Methocel A4M) 25% Xanthan gum 25% Egg albumin 15%
    100%
    The mixture was dissolved in water to form a 1% solution using a CFS Scanbrine mixer with paddle stirring. The solution was left to stand for 24 hours to form a fully hydrated gel or viscous solution.
    A pump is required to operate the machine, but after a short time bubbles may form in the gel solution in the applicator. To avoid this problem, food-grade defoaming agents can be used. Polydimethylsiloxane is preferred, but methylphenylpolysiloxane or polyethylene glycol can be used.
    Example 4 - Mass Coating Composition
    A dough coating composition was prepared by mixing the following ingredients:
    Ingredient%
    Soy flour (Hisoy) 31.0
    Starch with high amylase content (Hylon 7) 48.0 Cellulose gum (Methocel A4M) 2.0
    Whole egg (Henningsen Wl) 13,0
    D-xylose3.0
    Monosodium phosphate1,9
    25/29
    Ammonium bicarbonate
    Glucone D-lactone0.7
    Sodium acid pyrophosphate0,3
    Alpha-amylase 0.1
    100.0
    The dough was mixed in batches using a high shear Silverson DX mixer mounted on an easel with a crack disintegration work head. The batches were mixed in the proportion of 25 kg of water to 12.5 kg of dry powdered mass in a tank with a diameter of 68 cm. Then, the mixture was diluted as needed, for example, to give a 2.4: 1 water: powder ratio.
    In large-scale production the dough ingredients were mixed in a water: powder ratio of 2.4: 1 using two 200-liter stainless steel containers connected by a pump and a Silverson in-line mixer with a high working head crack disintegration shear. A tank was equipped with a shovel and was filled with water at 15 ° to 20 ° C. The dry ingredients were added to the water and wetted by rotating the paddle. The second tank was equipped with a cooling jacket and a return tube to the first tank. The mixture of the dough was circulated through the high shear head until it reached a temperature of 42 ° C by means of mechanical heat transfer. External heating can be used to avoid a tendency for excess starch shear. When the temperature reached 42 ° C, both the mixture and the enzymolysis were complete. The dough was transferred to the second tank and cooled. A heat exchanger can be used to cool the mixture. After cooling, the dough was pumped into a tempura type applicator.
    The viscosity of the dough mixture was in the range of 550 to 650 cP, as measured with a probe
    26/29 (spindle) number 3 at 60 rpm. The dough showed a good uptake rate and a crunchy coating after frying.
    Example 5 - Crumb Preparation
    A hydrocolloid containing crumbs was produced by the extrusion of a flour mixture to dough as described in document W02010 / 001101.
    A flour composition was prepared as follows:
    Dough mix 96.4%
    Sodium bicarbonate (baking powder Bex) 2.0%
    0.6% glyceryl monostearate
    Salt 1.0%
    100.00%
    The gelling agent was as follows:
    Guar Gum 67.00%
    Sodium metabisulfite 33.00%
    100.00% gelling agent was hydrated to 3% in 97% water. This was done using a high shear mixer. The hydrated mixture was allowed to rest for at least 12 hours after mixing.
    The Hutchinsons Golden Cake Flour cake mix (150 kg per hour) was mixed with water (35 kg per hour) to form a paste. The slurry was fed to a Clextral twin screw extruder. The hydrated gelling agent was injected into the flat area of the extruder in an amount of 7.5% (13.88 kg per hour). The extruded mixture was cut into pieces and allowed to expand to form a bubble. When it dries to a moisture content of 2% w / w the bulk density was 150 gl 1 . The bubble was dried and shaped and the resulting bran was small and crunchy. The application of this to a food substrate provided a hard and crunchy coating. The bag-dried product had an expiration date greater than 12
    27/29 months.
    After extrusion, the extrudate can be molded and sieved to produce crumb particles of the desired size that pass through a 4 mm sieve, but are retained by a 3 mm sieve. The fines of the crumbs that passed through a 1 mm sieve, resulting from the grinding of larger bran particles were used for application to the portions of substrate coated with the aqueous coating.
    Example 6 - Production of Frozen Chicken Nuggets for Microwaves
    Stabilized substrates prepared according to Example 2 were coated with an aqueous coating composition, as described in Example 3. A thin coating of crumbs was applied, as described in Example 5, followed by a mass coating as described in Example 4 .
    Then a layer of coarse crumbs from Example 5 (particle size 3 to 4 mm) was applied using a CrumbMaster applicator (24) manufactured by CFS, Bakel, The Netherlands.
    A cross-sectional view of the crumb applicator is shown in Figure 4.
    An endless conveyor (40) passing over a guide plate (46) receives pieces of substrate coated with putty (41). A supply of crumbs of 2 mm (42) contained in the feeder (43) has an outlet that extends along the width of the conveyor (40). Complementary crumbs can be added via entries (51). The excess of crumbs (45) that passes through the mesh / grid type conveyor (40) is collected through a screw elevator (47) and ejected to the top (48) of the feeder (43). A roll (44) serves to compress the crumbs on the
    28/29 surface of the substrate particles. An air blower (49) removes excess crumbs from the coated particles, after which the particles (50) pass through a second crumb application station (Step 8) to apply finer crumbs to fill the spaces between the larger crumbs applied in Step 7. The configuration of the dough and crumb applicator (25) is similar to that of the first crumb applicator (24).
    After the application of the first and second layers of crumbs, the coated substrates enter a fryer (26). The fryer construction is shown in detail in Figure 5.
    Heated oil (60) contained in an elongated reservoir (61) is heated to a constant temperature of 180 ° to 188 ° C. Pure rapeseed oil is used.
    Parallel upper and lower conveyors (62, 63) prevent the substrate pieces from floating while passing through the fryer. A frying time of 2 minutes and 20 seconds can be used, although this may vary depending on the weight and size of the particles. After frying, the temperature of the particle core was in the range of 74 ° to 85 ° C. A small weight loss was observed due to the loss of water by the substrate, but this is mainly compensated for by an oil absorption.
    After frying, the fried products are transferred directly and without delay to a freezing station.
    The fried products when removed from the hot oil had an external temperature of about 180 ° C and a core temperature of about 90 ° C. The products were transferred by the conveyor to a cryogenic freezer for a period of not less than 2 minutes. During this time the temperature of the outer crumb layer was
    29/29 reduced due to contact with the atmosphere, but the core temperature may rise for a brief period, due to the heat transfer from the outer layer of crumbs to the core. At the entrance to the freezer, the core 5 temperature can be between 70 ° C and 100 ° C, generally around 75 ° C.
    fried product from Step 9 was immediately transferred in Step 10 to a cryogenic freezer which reduced the core temperature to a maximum of -25 ° C, preferably -30 ° C. The time between removing the fryer and entering the freezer was less than 2 minutes.
    The transfer from the fryer to the freezer is arranged so that the core temperature of the product is reduced from 75 ° C to -30 ° C in a period of maximum 15 15 minutes.
    权利要求:
    Claims (10)
    [1]
    1. METHOD OF PRODUCTION OF A COATED, FROZEN FOOD PRODUCT FOR MICROWAVES, characterized by understanding the steps of:
    providing a portion of a solid, or solidified substrate;
    coating such portion with an aqueous pre-coated liquid to form a pre-coated portion;
    applying a coating of adhesive crumbs to the pre-coated portion to form a portion coated with crumbs;
    applying a dough to the portion coated with crumbs to form a portion coated with dough;
    applying a crumb coating to the dough-coated portion to form a breaded portion;
    frying the breaded portion by contacting such breaded portion for at least 100 seconds with hot oil at a temperature of at least 150 ° C, thereby producing a fried coated portion having a core temperature greater than 70 ° C, and freezing the portion fried coated by introducing such a portion into a freezer, where the core temperature of the fried coated portion is not less than 50 ° C, preferably not less than 60 ° C when such a fried portion is introduced into the freezer and wherein such core temperature is reduced to less than -15 ° C using cryogenic freezing.
    [2]
    2/4 of the core is not less than 70 ° C when it is placed in the freezer.
    METHOD according to claim 1, characterized in that the fried coated portion has a core temperature of not less than 65 ° C when it is introduced into the freezer.
    [3]
    3/4 core of the fried coated portion does not decrease by more than 25 ° C, before the fried portion enters the freezer.
    METHOD according to claim 11, characterized in that the core temperature of the fried coated portion does not decrease by more than 20 ° C, before the fried portion enters the freezer.
    13. METHOD according to any one of the preceding claims, characterized in that the aqueous precoating liquid has a minimum viscosity of 300 cP, measured using a Brookfield viscometer with a number 3 probe (spindle) at 60 rpm at 10 ° C.
    Method according to any one of the preceding claims, characterized in that the layer of adhesive crumbs contains at least 80% by weight of a ground meal paste extrudate containing 0.05% to 5% by weight of added hydrocolloid.
    15. METHOD according to claim 14, characterized in that the hydrocolloid is selected from the group consisting of guar gum, locust bean gum, arabic gum, tragacanth, karaya gum, ghatti gum, xanthan gum, and mixtures thereof.
    16. METHOD according to any one of the preceding claims, characterized in that the mass comprises, calculated by weight of dry matter, 20% to 55% by weight of starch; 20% to 55% by weight of flour, 3% to 20% by weight of egg solids.
    17. METHOD according to any one of the preceding claims, characterized in that the mass, when applied to the crumb-coated portion, has a viscosity of 200 to 1000 cP, measured using a Brookfield viscometer with probe number 3 at 60 rpm.
    18. METHOD according to claim 17, characterized by the mass, when it is applied to the portion
    Petition 870190008017, of 01/24/2019, p. 9/14
    METHOD according to claim 2, characterized in that the fried coated portion has a temperature
    Petition 870190008017, of 01/24/2019, p. 7/14
    [4]
    4/4 coated with crumbs, have a viscosity of 500 to 6000 cP, measured using a Brookfield viscometer with number 3 probe at 60 rpm.
    19. METHOD according to any of the
    Method according to any one of the preceding claims, characterized in that the fried coated portion has a core temperature of not less than 50 ° C when it is subjected to cryogenic freezing.
    [5]
    5 previous claims, characterized by the total amount of the aqueous pre-coating liquid, dough and crumbs that is applied to the portion being such that, after frying, the fried portion has a weight that exceeds the weight of the uncoated portion of solid substrate in 25% to 100%.
    5. METHOD according to claim 4, characterized in that the fried coated portion has a core temperature of not less than 60 ° C when it is subjected to cryogenic freezing.
    [6]
    METHOD according to claim 5, characterized in that the fried coated portion has a core temperature of not less than 65 ° C when it is subjected to cryogenic freezing.
    [7]
    METHOD according to claim 6, characterized in that the fried coated portion has a core temperature of not less than 70 ° C when it is subjected to cryogenic freezing.
    [8]
    8. METHOD according to any one of the preceding claims, characterized in that the fried coated portion comes in contact with a cryogenic substance until the core temperature of the portion is below -15 ° C.
    [9]
    9. METHOD according to claim 8, characterized in that the fried coated portion comes into contact with a cryogenic substance until the core temperature of the portion is below -20 ° C.
    10. METHOD according to claim 9, characterized in that the fried coated portion comes into contact with a cryogenic substance until the core temperature of the portion is below -22 ° C.
    11. METHOD according to any one of the preceding claims, characterized by the temperature of the
    Petition 870190008017, of 01/24/2019, p. 8/14
    [10]
    20. METHOD according to claim 19, characterized in that the fried portion has a weight that exceeds the weight of the uncoated portion of solid substrate by 30% to 60%.
    类似技术:
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    BR112013019104B1|2020-03-31|METHOD OF PRODUCTION OF A COATED, FROZEN FOOD PRODUCT FOR MICROWAVES
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    US9648900B2|2017-05-16|Production of microwaveable coated food products
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    TW201739360A|2017-11-16|Coated food products |
    NZ613134B2|2015-01-06|Production of microwaveable coated food products
    US20160135487A1|2016-05-19|Stabilised food products
    同族专利:
    公开号 | 公开日
    CY1116419T1|2017-02-08|
    JP2014503225A|2014-02-13|
    MY156942A|2016-04-15|
    UA109045C2|2015-07-10|
    WO2012101025A1|2012-08-02|
    EP2481295B1|2015-03-25|
    CL2013002157A1|2014-02-14|
    CA2825455C|2016-02-02|
    EA023823B1|2016-07-29|
    IL227577D0|2013-09-30|
    JP5970474B2|2016-08-17|
    DK2481295T3|2015-05-11|
    CN103369971A|2013-10-23|
    PT2481295E|2015-05-19|
    IL227577A|2016-08-31|
    HK1173343A1|2013-05-16|
    EA201370159A1|2013-12-30|
    CN103369971B|2018-05-15|
    TW201236573A|2012-09-16|
    MX338364B|2016-04-13|
    TWI511673B|2015-12-11|
    KR20160045910A|2016-04-27|
    KR20130125808A|2013-11-19|
    MX2013008719A|2013-08-14|
    SI2481295T1|2015-06-30|
    KR101707670B1|2017-02-27|
    PL2481295T3|2015-08-31|
    SG191969A1|2013-08-30|
    CA2825455A1|2012-08-02|
    AU2012210700B2|2015-07-23|
    AR084929A1|2013-07-10|
    ZA201305296B|2014-03-26|
    BR112013019104A2|2017-11-07|
    RS53913B1|2015-08-31|
    ES2535298T3|2015-05-08|
    HRP20150379T1|2015-05-22|
    EP2481295A1|2012-08-01|
    NZ613134A|2014-09-26|
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    法律状态:
    2018-02-14| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2018-07-03| B15K| Others concerning applications: alteration of classification|Ipc: A23B 4/09 (2006.01), A23L 13/00 (2016.01), A23L 13 |
    2018-10-30| B07A| Technical examination (opinion): publication of technical examination (opinion)|
    2019-09-03| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|
    2020-03-03| B09A| Decision: intention to grant|
    2020-03-31| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 18/01/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    EP11152421.1|2011-01-27|
    EP11152421.1A|EP2481295B1|2011-01-27|2011-01-27|Production of microwaveable coated food products|
    PCT/EP2012/050738|WO2012101025A1|2011-01-27|2012-01-18|Production of microwaveable coated food products|
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