CA2101474A1 - Breaded food - Google Patents
Breaded foodInfo
- Publication number
- CA2101474A1 CA2101474A1 CA002101474A CA2101474A CA2101474A1 CA 2101474 A1 CA2101474 A1 CA 2101474A1 CA 002101474 A CA002101474 A CA 002101474A CA 2101474 A CA2101474 A CA 2101474A CA 2101474 A1 CA2101474 A1 CA 2101474A1
- Authority
- CA
- Canada
- Prior art keywords
- fat
- product
- food
- breaded
- breading
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L17/00—Food-from-the-sea products; Fish products; Fish meal; Fish-egg substitutes; Preparation or treatment thereof
- A23L17/75—Coating with a layer, stuffing, laminating, binding or compressing of original fish pieces
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L13/00—Meat products; Meat meal; Preparation or treatment thereof
- A23L13/50—Poultry products, e.g. poultry sausages
- A23L13/55—Treatment of original pieces or parts
- A23L13/57—Coating with a layer or stuffing
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
- A23L7/10—Cereal-derived products
- A23L7/157—Farinaceous granules for dressing meat, fish or the like
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
- A23P20/10—Coating with edible coatings, e.g. with oils or fats
- A23P20/11—Coating with compositions containing a majority of oils, fats, mono/diglycerides, fatty acids, mineral oils, waxes or paraffins
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
- A23P20/10—Coating with edible coatings, e.g. with oils or fats
- A23P20/12—Apparatus or processes for applying powders or particles to foodstuffs, e.g. for breading; Such apparatus combined with means for pre-moistening or battering
Landscapes
- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Food Science & Technology (AREA)
- Polymers & Plastics (AREA)
- Health & Medical Sciences (AREA)
- Nutrition Science (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Zoology (AREA)
- Marine Sciences & Fisheries (AREA)
- General Preparation And Processing Of Foods (AREA)
- Grain Derivatives (AREA)
Abstract
BREADED FOOD
Abstract of the Disclosure A breaded food product having a piece of core food (e.g., fish, poultry, or vegetable) in an uncooked state, and a breaded coating system on the core food, the coating system comprising bread crumbs and fat, the product having at least 3% and no more than 8% by weight of fat (preferably less than 6%, most preferably less than 5.5%). A breaded food product is made by applying breading on an uncooked core food, and a starch overcoat film on the breading.
Abstract of the Disclosure A breaded food product having a piece of core food (e.g., fish, poultry, or vegetable) in an uncooked state, and a breaded coating system on the core food, the coating system comprising bread crumbs and fat, the product having at least 3% and no more than 8% by weight of fat (preferably less than 6%, most preferably less than 5.5%). A breaded food product is made by applying breading on an uncooked core food, and a starch overcoat film on the breading.
Description
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6~/01~001 BREADED FOOD
Backaround of the Invention - This in~ention relates to commercially prepared breaded foods.
Breaded foods enjoy wide consumer appeal because of their color and crisp appearance,.and their crisp, crunchy texture when eaten. ~owever, because breaded foods (including both food service and retail) are typically deep fried in fat, they recently have been seen as unhealthy.
I Commercial breaded foods are usually distributed in a frozen state. In the so-called "raw-breaded" method of preparation, pieces of the core food, such as fish, are breaded and frozen in the raw state. Before serving, raw-15 breaded foods are deep fried in fat; and some of the fat ~ -becomes incorporated into the food.
y contrast, in the so-called "prefried breaded"
method of preparation, the food is deep fried before -~
~ - fr-ezing.~ Prefried breaded foods are simply heated in a ;~ 20 conventional oven before serving.
In a third production method, the food is not deep-; fried. Rather it is covered with an oil-based coating, breaded, and then frozen in the raw state. For serving, the food i- oven heated. The heat raises the temperature of the oil-based coating, causing it to cook the breading. The resulting product is said to have the taste and appearance ~j of a deep fried product. Sqe, e.g., Monagle, United States ¦~- Patent 4,518,620, which describes coating a core food with a fat-emulsion batter, breading, and an egg white overcoat.
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Summarv of the Invention The invention achieves a breaded food product which is low in fat and saturated fat, does not require deep frying, and is tasty.
5 - In general, in one aspect,-the invention features a breaded food product having a piece of core food (e.g., fish, poultry, or vegetable) in an uncooked state, and a breaded coating system on the core food, the coating system comprising bread crumbs and fat, the product having at least 3% and no more than 8% by weight of fat (preferably less than 6%, most preferably less than 5.5%).
Preferred embodiments of the invention include the following features. The breaded coating system includes a precoating (comprising starch and flour), a batter (comprising a fat emulsion of low saturated fat oil--e.g., canola oil--in an agueous phase), breading, and a starch overcoat. The oil may be canola oil.
In general, in another aspect, the invention features a method for making a breaded food product in which breading is appl~ed on an uncooked core food, and a starch overcoat film is sprayed on the breading.
Preferred embodiments of the invention include the following features. Before applying the breading, a fat-emulsion coating is applied in amounts such that the finished product comprises less than 30% of calories in fat and less than 1% of its fat in the form of saturated fat.
The fat-emulsion batter is prepared from a low fat oil, an emulsifier, and a stabilizer. The viscosity of the fat-emulsion batter is controlled to effect a desired pickup of breading on the batter in order to achieve a predetermined ~; aggregate fat percentage in the finished product. Before applying the fat-emulsion coating, an undercoating of flour, ~; starch and water is applied to the core food.
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` ~ %~9~ 7l1l The health-oriented breaded food of the invention provides an alternatlve to traditional breaded food, does not reguire deep frying, is low in fat and in saturated fat, is tasty, and has other qualities needed to achieve wide 5 ~consumer acceptance. Tbe coating'system behaves like deep-fry coating systems in terms of adhesion of the breading to the core food, uniform coverage, appearance of crispness, and ability to withstand the rigors of high volume production, i.e., freezing, packaging, storage, transportation, and handling. When oven-baked, the foods are crisp and crunchy rather than soggy and doughy, but are low in fat and less greasy than breaded foods that are deep fried. Controlling the viscosity of the fat emulsion batter assures that the desired low percentage of fat in the lS finished product can be achieved consistently.
Other advantages and features will become apparent from the following description, and from the claims.
Description We first briefly describe the drawings.
; 20 Fig. 1 is a block diagram of a processing line for preparing breaded fish foods.
~ Fig. 2 is a schematic, cross-sectional view, ` enlarged, of a fragment of breaded food.
Cutting Referring to Figs. 1 and 2 (reference numerals lower than 100 refer to Fig. 1, those above 100 to Fig. 2), in a breaded food processing line 10, uncooked white fish with a fat content of less than 1.5%, such as cod, deep-skinned ~ Alaskan pollock or haddock, 110 is cut into pieces ~
¦~ 30 (suitable, e.g., for fish sticks or fish fillets) using two ll~ band saws 11, 12, and a slicer 14. The pieces serve as the ¦~ core food 110 and are covered with a multiple layer breaded - ` 2 ~ ir 7 1 coating system 112. The fish comprises 40%-65% (pre~erably 54%) by weight of the finished product in the case of a fillet, and 40%-65% (preferably 51.5%) in the case of a stick.
5 ~ The flrst stage of the coating system i5 a precoating that includes a two-stage process: prewash followed by predust.
Prewash The prewash component 114 of the precoating comprises from 5% to 10% (preferably 6.5S) by weight of the finished breaded fish stick or fillet. The prewash is an aqueous phase mixture, high in starch, comprising 40% to 60%
(preferably 53.6%) water, 25% to 40% (preferably 35.7%) of a mixture of flour, corn flour, and starch (Newly Weds ~2872), and 6% to 25% (preferably 10.7%) of National Starch Batter Bind. The prewash can be prepared in any suitable mixing device, for example a Wilevco Mixer. A Zahn cup can be used to monitor the viscosity of the prewash mixture.
The prewash is applied using a commercial batter table 16 (e.g., a Stein). The batter table has a single curtain and is modified with upper and lower air knives and a scraper bar to insure an even application of prewash.
This assures that enouqh solids from the prewash remain on the uncooked food to bind any excess water in the core food and prevent seepage of moisture from the core food during preparation and cooking.
Predust The prewash covered Pollock, while still wet, is coated with a predust 118 comprising 4% to 7% (preferably 5%) by weight of the finished breaded fish stick otr fillet.
The predust comprises a fine crumb breading (such as Newly Weds ~6162), which serves as a further moisture barrier to prev-nt vater fro= being dravn out of the core food.
6~/01~001 BREADED FOOD
Backaround of the Invention - This in~ention relates to commercially prepared breaded foods.
Breaded foods enjoy wide consumer appeal because of their color and crisp appearance,.and their crisp, crunchy texture when eaten. ~owever, because breaded foods (including both food service and retail) are typically deep fried in fat, they recently have been seen as unhealthy.
I Commercial breaded foods are usually distributed in a frozen state. In the so-called "raw-breaded" method of preparation, pieces of the core food, such as fish, are breaded and frozen in the raw state. Before serving, raw-15 breaded foods are deep fried in fat; and some of the fat ~ -becomes incorporated into the food.
y contrast, in the so-called "prefried breaded"
method of preparation, the food is deep fried before -~
~ - fr-ezing.~ Prefried breaded foods are simply heated in a ;~ 20 conventional oven before serving.
In a third production method, the food is not deep-; fried. Rather it is covered with an oil-based coating, breaded, and then frozen in the raw state. For serving, the food i- oven heated. The heat raises the temperature of the oil-based coating, causing it to cook the breading. The resulting product is said to have the taste and appearance ~j of a deep fried product. Sqe, e.g., Monagle, United States ¦~- Patent 4,518,620, which describes coating a core food with a fat-emulsion batter, breading, and an egg white overcoat.
; :
I
~ ,~
~ .
~:~
.
::
:::
- ` 2 ~ 7 ~
Summarv of the Invention The invention achieves a breaded food product which is low in fat and saturated fat, does not require deep frying, and is tasty.
5 - In general, in one aspect,-the invention features a breaded food product having a piece of core food (e.g., fish, poultry, or vegetable) in an uncooked state, and a breaded coating system on the core food, the coating system comprising bread crumbs and fat, the product having at least 3% and no more than 8% by weight of fat (preferably less than 6%, most preferably less than 5.5%).
Preferred embodiments of the invention include the following features. The breaded coating system includes a precoating (comprising starch and flour), a batter (comprising a fat emulsion of low saturated fat oil--e.g., canola oil--in an agueous phase), breading, and a starch overcoat. The oil may be canola oil.
In general, in another aspect, the invention features a method for making a breaded food product in which breading is appl~ed on an uncooked core food, and a starch overcoat film is sprayed on the breading.
Preferred embodiments of the invention include the following features. Before applying the breading, a fat-emulsion coating is applied in amounts such that the finished product comprises less than 30% of calories in fat and less than 1% of its fat in the form of saturated fat.
The fat-emulsion batter is prepared from a low fat oil, an emulsifier, and a stabilizer. The viscosity of the fat-emulsion batter is controlled to effect a desired pickup of breading on the batter in order to achieve a predetermined ~; aggregate fat percentage in the finished product. Before applying the fat-emulsion coating, an undercoating of flour, ~; starch and water is applied to the core food.
.
~:
~ ' ~ ~~ ' ~ . .
` ~ %~9~ 7l1l The health-oriented breaded food of the invention provides an alternatlve to traditional breaded food, does not reguire deep frying, is low in fat and in saturated fat, is tasty, and has other qualities needed to achieve wide 5 ~consumer acceptance. Tbe coating'system behaves like deep-fry coating systems in terms of adhesion of the breading to the core food, uniform coverage, appearance of crispness, and ability to withstand the rigors of high volume production, i.e., freezing, packaging, storage, transportation, and handling. When oven-baked, the foods are crisp and crunchy rather than soggy and doughy, but are low in fat and less greasy than breaded foods that are deep fried. Controlling the viscosity of the fat emulsion batter assures that the desired low percentage of fat in the lS finished product can be achieved consistently.
Other advantages and features will become apparent from the following description, and from the claims.
Description We first briefly describe the drawings.
; 20 Fig. 1 is a block diagram of a processing line for preparing breaded fish foods.
~ Fig. 2 is a schematic, cross-sectional view, ` enlarged, of a fragment of breaded food.
Cutting Referring to Figs. 1 and 2 (reference numerals lower than 100 refer to Fig. 1, those above 100 to Fig. 2), in a breaded food processing line 10, uncooked white fish with a fat content of less than 1.5%, such as cod, deep-skinned ~ Alaskan pollock or haddock, 110 is cut into pieces ~
¦~ 30 (suitable, e.g., for fish sticks or fish fillets) using two ll~ band saws 11, 12, and a slicer 14. The pieces serve as the ¦~ core food 110 and are covered with a multiple layer breaded - ` 2 ~ ir 7 1 coating system 112. The fish comprises 40%-65% (pre~erably 54%) by weight of the finished product in the case of a fillet, and 40%-65% (preferably 51.5%) in the case of a stick.
5 ~ The flrst stage of the coating system i5 a precoating that includes a two-stage process: prewash followed by predust.
Prewash The prewash component 114 of the precoating comprises from 5% to 10% (preferably 6.5S) by weight of the finished breaded fish stick or fillet. The prewash is an aqueous phase mixture, high in starch, comprising 40% to 60%
(preferably 53.6%) water, 25% to 40% (preferably 35.7%) of a mixture of flour, corn flour, and starch (Newly Weds ~2872), and 6% to 25% (preferably 10.7%) of National Starch Batter Bind. The prewash can be prepared in any suitable mixing device, for example a Wilevco Mixer. A Zahn cup can be used to monitor the viscosity of the prewash mixture.
The prewash is applied using a commercial batter table 16 (e.g., a Stein). The batter table has a single curtain and is modified with upper and lower air knives and a scraper bar to insure an even application of prewash.
This assures that enouqh solids from the prewash remain on the uncooked food to bind any excess water in the core food and prevent seepage of moisture from the core food during preparation and cooking.
Predust The prewash covered Pollock, while still wet, is coated with a predust 118 comprising 4% to 7% (preferably 5%) by weight of the finished breaded fish stick otr fillet.
The predust comprises a fine crumb breading (such as Newly Weds ~6162), which serves as a further moisture barrier to prev-nt vater fro= being dravn out of the core food.
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The predust i8 applied using a commercial breader 18 (for example, a Stein L5 Breader) that includes two blowers for even application.
The prewash/predust coating should be thoroughly dried before the fat-emulsion batter 120 i9 applied (see below) to ensure that the precoatings are not scraped off during application of the fat-emulsion batter. A long transfer belt i8 provided for this-purpose.
The two-stage precoating reduces the amount of water which can leak from the core food during the batter coating, breading, and freezing processes, and especially during the cooking process. This helps to prevent the breading from becoming soggy and crumbling or peeling away from the core food. Given the relatively low percentage of fat in the coating system, the precoating also helps to prevent the finished product from sticking to the cooking pan as a result of fish proteins being drawn to the surface by escaping moisture.
Fat-Emulsion Batter Next, the precoated fish pieces are covered with a fat-emulsion batter 120 (fat, caramel color, an emulsifier, and an emulsion stabilizer dissolved in an aqueous phase) that will comprise from 13~ to 30% (preferably 21.5%) by weight of the finished breaded fish stick or fillet.
The Fat The fat is canola oil, but any edible low saturated fat oil which is liquid at room temperature can be used, e.g., soybean, safflower, or peanut oil. The liquid fat is from 20-40% (preferably about 25%) by weight of the fat-emulsion batter. The fat content of the finished~food product is directly related to the percentage of fat in the fat-emulsion batter and the amount of batter used in the coating process. When the canola oil is 25% of the batter, 2~03 11l7l~
and the batter is 21.5% of the finished product, the oil comprises only 5.38% Or the ~lnished rood product, yielding a low fat, healthy product having less than the 30% of its calories in fat and less than 1% of its fat as saturated -fat. The amount of fat may be ad~usted to achieve both the low fat percentage desired and a proper mouth feel. In general the amount of fat is at least 3% and no more than 8%
(preferably no more than 6%, most preferably no more than 5.5% by weight of fat.
The Emulsifier The emulsifier in the batter is dried egg white solids (Cutter t4000) in an amount which is about 1.5 to 4.0% (preferably 3.0%) by weight of the fat-emulsion batter.
Not only do the egg whites serve to emulsify and stabilize the fat-emulsion, they solidify when the breaded food is baked, binding the oil and water, and thus, adding to the integrity and adhesion of the breading.
The Stabilizer ~;~ The stabilizer is a water soluble gum, preferably Xanthum gum, in an amount which is about 0.3-0.5%
(preferably 0.4%) by weight of the fat-emulsion batter.
Both the emulsifier and stabilizer can be used to control the viscosity of the batter. Controlling the viscosity of the batter is one important mechanism for regulating the fat content of the finished food product. Fat percentage in the finished product varies with the amount of batter and the amount of breading applied ~more batter means higher fat content; more breading means a lower percentage of fat ~
content). The amount of emulsion batter that adheres during the coating process and the amount of breading that adheres to the batter during breading depend upon the viscosity of the batter. Thus, the batter viscosity can be optimized to maintain the desired level of adhesion, and hence, fat :
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content. The emulsion batter contains 0.3%-0.5% (p~eferably 0.4%) stabilizer by weight for a viscosity that results in a coating of emulsion batter which comprises only about 18% to 25% (preferably 21.5%) by weight of the finished food product.
Preparation The fat-emulsion batter can be prepared in any suitable mixing device (e.g., a Stephan Vertical Cutter Mixer operating at 1200 RPM) which disperses the liquid fat in the aqueous medium as fine globules or droplets. First, the emulsifier, stabilizer, and caramel color are mixed (for about 1.5 minutes) with the water, which comprises from 55%
to 75% (preferably 71.525%) by weight of the fat-emulsion batter, to form an agueous solution. The fat-emulsion batter is made by vigorously mixing or combining the fat with the aqueous solution, for about 45 seconds, and then pumping the batter through a diaphragm pump to the applicator 20.
Application The fat-emulsion batter has good stability for recirculation in a commercial batter applicator fitted with a diaphram pump for recirculation of the emulsion batter to maintain the desired viscosity. (As the belt on the batter table moves it whips air into the emulsion causing it to thicken; if the viscosity of the emulsion rises, the pickup of emulsion will rise, thus increasing the amount of fat in the product.) A Zahn cup can be used to monitor the -viscosity of the batter.
For example, a Stein Tempura batter applicator may be used to apply the emulsion batter. As they are designed for more viscous batters. The batter applicator is modified with upper and lower air knives and three scraper bars to insure an even distribution of batter coating on each food 2 ~ ~ 1 q~
portion. The air knives and scraper bar~ on the ba~ter applicator (and on the prewa~h applicator) enable equal amounts of batter (or prewash) to be removed from both the top and bottom of the flsh portion. If too much emulsion S ~prewash) remains on the bottom, the product may be soggy.
These tools also allow the prewash to be run very thick so that plenty of solids stay on the raw fish.
Breading The batter coated fish is then coated with a first layer of breading 122 that will comprise 7% to 10%
(preferably 8.64%) by weight of the finished breaded fish stick or fillet. A second layer of breading 124, is then applied over the first breading, comprising 3% to 5%
(preferably 3.36%) by weight of the finished breaded fish lS stick or fillet. The breadings can be colored (e.g., caramel colored), flavored, seasoned, pretoasted, and sized as to particular shape and granulation. The crispness of the finished food product varies with the type of crumbs used for the breading. Crisp, very crunchy crumbs are preferred. For the first layer of breading, the crumbs preferably are round and coarse with less than 5% moisture (such as Newly Weds t6524). For the second layer of breading, the crumbs preferably are spindly and fine crumb with less than 5% moisture (such as Newly Weds ~6517). The so-called Japanese-style of breading can be used to augment the crisp, crunchy character of the breaded food. The breading should be colored to enhance the appearance of the finished food product.
The breading may be applied with any commercial breading unit 22, e.g., a Stein J-Breader which includes two b}owers angled such that the breading crumbs are neither compressed down into the emulision batter, nor blown off the surface o~ the food. The rollers must either be eliminated or cbecked to make sure their spring loaded mountig mechanisms are working effectively. This technique produces a crispness in the breading of the finished product when served. ~y contrast, compression of the crumbs into the 5 _emulsion batter would produce a soggy final product while excessive blowing would result in an insufficiently coated product.
For application of the sec~nd layer of breading, a second breading unit 24, e.g., a Stein J-Breader may be used which includes two blowers and a roller to insure an even distribution of breading on the surface of the food. The second breading layer fills the voids that remain after application of the first breading layer. In order to avoid dislodging or damaging the breaded coating, it is important to provide a mechanically smooth transfer to the sprayer.
Spray The batter coated and breaded fish pieces are sprayed with a starch solution, which also helps to prevent the breading from falling off. It is the uniform coating of 20 starch on the breading which holds the breading on. Recall ~ -~ that the breading is applied to the batter without ¦ compression and so would not necessarily stay together without the starch coating. This technique assures that the breading will not become soggy fro~ having been pushed into the emuls?ion batter. The starch spray comprises 1% to 3%
(preferably 1.5%) by weight of the finished breaded fish stick or fillet. The spray solution is preferably a solution of 8% to 15% (preferably 10%) tapioca dextrin,-Crystal Gum (National Starch ~52-2550). The starch solution can be prepared in any suitable mixing device. The mixer should contain a heater and recirculating pump such that the starch solution is heated to 150 F before being pumped (via a filter) to a holding tank connected to a spraying device.
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The final starch spray i9 applied over the breading by a fine mist sprayer 26 to achieve a uniform and complete coating 130.
The purpose of the starch is to hold the cru~b to 5 ~the core food during processing, handling, and cooking of the coated food product.
E~r~hçr Processin~ and Preparation for Servina The finished coated product is frozen and packaged for distribution.
The frozen product is prepared for serving by baking in a conventional hot air oven for 20-30 minutes in a 375 F
oven. The heat cooks the uncooked fish and congeals the emulsion batter. Microwave preparation is possible but may not provide as much crispness.
lS Note that all of the equipment throughout the process is operated with extended noses and adjusted angles to assure smootn transfer of product from one belt to another, preventing the coating from being scraped off. If portions of the coating are scraped off the product may be soggy and may stick to the cooking pan.
Pxoperties The resulting breaded food is comprised of preferably about 51.5-54% Pollock, about 21.5% batter coating, about 12% breading, and about 11% undercoating by weight, and has the desirable characteristics of a breaded food while limiting fat and saturated fat to acceptable, health-oriented levels. Limiting the fat content also results in a lower calorie breaded food that is less fattening. The product may have, for example, less than 30%
of its calories as fat and less than 1% of its fat as saturated fat.
The oven baked breaded food appears golden brown, has a uniform coating of breading with no bare spots, and r 21~1 L~ 7 ~1 ~ 11 ~
appearcs crisp with no wet or fatty surface areas. .The coating on the food has good adhesion and cohesion (imparted by the composition of the ingredients and the even ~Sspplication of each ingredient to the core food product) 5 -which are discernible during preparation of the breaded foods for serving and in handling or prodding with a fork.
The eating qualities of the breaded food of the invention are similar to a deep frled food, i.e. crisp and crunchy, although not as greasy. The food is moist and tender, but not soggy or doughy. Since the core food is not precooked, a fresher taste is achieved when the frozen product is cooked.
Other embodiments are within the following claims.
I The breading system is applicable to core foods other than I lS fish, for example, meat, seafood, poultry, and vegetables.
It i8 especially effective for foods with high water content.
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The predust i8 applied using a commercial breader 18 (for example, a Stein L5 Breader) that includes two blowers for even application.
The prewash/predust coating should be thoroughly dried before the fat-emulsion batter 120 i9 applied (see below) to ensure that the precoatings are not scraped off during application of the fat-emulsion batter. A long transfer belt i8 provided for this-purpose.
The two-stage precoating reduces the amount of water which can leak from the core food during the batter coating, breading, and freezing processes, and especially during the cooking process. This helps to prevent the breading from becoming soggy and crumbling or peeling away from the core food. Given the relatively low percentage of fat in the coating system, the precoating also helps to prevent the finished product from sticking to the cooking pan as a result of fish proteins being drawn to the surface by escaping moisture.
Fat-Emulsion Batter Next, the precoated fish pieces are covered with a fat-emulsion batter 120 (fat, caramel color, an emulsifier, and an emulsion stabilizer dissolved in an aqueous phase) that will comprise from 13~ to 30% (preferably 21.5%) by weight of the finished breaded fish stick or fillet.
The Fat The fat is canola oil, but any edible low saturated fat oil which is liquid at room temperature can be used, e.g., soybean, safflower, or peanut oil. The liquid fat is from 20-40% (preferably about 25%) by weight of the fat-emulsion batter. The fat content of the finished~food product is directly related to the percentage of fat in the fat-emulsion batter and the amount of batter used in the coating process. When the canola oil is 25% of the batter, 2~03 11l7l~
and the batter is 21.5% of the finished product, the oil comprises only 5.38% Or the ~lnished rood product, yielding a low fat, healthy product having less than the 30% of its calories in fat and less than 1% of its fat as saturated -fat. The amount of fat may be ad~usted to achieve both the low fat percentage desired and a proper mouth feel. In general the amount of fat is at least 3% and no more than 8%
(preferably no more than 6%, most preferably no more than 5.5% by weight of fat.
The Emulsifier The emulsifier in the batter is dried egg white solids (Cutter t4000) in an amount which is about 1.5 to 4.0% (preferably 3.0%) by weight of the fat-emulsion batter.
Not only do the egg whites serve to emulsify and stabilize the fat-emulsion, they solidify when the breaded food is baked, binding the oil and water, and thus, adding to the integrity and adhesion of the breading.
The Stabilizer ~;~ The stabilizer is a water soluble gum, preferably Xanthum gum, in an amount which is about 0.3-0.5%
(preferably 0.4%) by weight of the fat-emulsion batter.
Both the emulsifier and stabilizer can be used to control the viscosity of the batter. Controlling the viscosity of the batter is one important mechanism for regulating the fat content of the finished food product. Fat percentage in the finished product varies with the amount of batter and the amount of breading applied ~more batter means higher fat content; more breading means a lower percentage of fat ~
content). The amount of emulsion batter that adheres during the coating process and the amount of breading that adheres to the batter during breading depend upon the viscosity of the batter. Thus, the batter viscosity can be optimized to maintain the desired level of adhesion, and hence, fat :
:
210~/~7~
content. The emulsion batter contains 0.3%-0.5% (p~eferably 0.4%) stabilizer by weight for a viscosity that results in a coating of emulsion batter which comprises only about 18% to 25% (preferably 21.5%) by weight of the finished food product.
Preparation The fat-emulsion batter can be prepared in any suitable mixing device (e.g., a Stephan Vertical Cutter Mixer operating at 1200 RPM) which disperses the liquid fat in the aqueous medium as fine globules or droplets. First, the emulsifier, stabilizer, and caramel color are mixed (for about 1.5 minutes) with the water, which comprises from 55%
to 75% (preferably 71.525%) by weight of the fat-emulsion batter, to form an agueous solution. The fat-emulsion batter is made by vigorously mixing or combining the fat with the aqueous solution, for about 45 seconds, and then pumping the batter through a diaphragm pump to the applicator 20.
Application The fat-emulsion batter has good stability for recirculation in a commercial batter applicator fitted with a diaphram pump for recirculation of the emulsion batter to maintain the desired viscosity. (As the belt on the batter table moves it whips air into the emulsion causing it to thicken; if the viscosity of the emulsion rises, the pickup of emulsion will rise, thus increasing the amount of fat in the product.) A Zahn cup can be used to monitor the -viscosity of the batter.
For example, a Stein Tempura batter applicator may be used to apply the emulsion batter. As they are designed for more viscous batters. The batter applicator is modified with upper and lower air knives and three scraper bars to insure an even distribution of batter coating on each food 2 ~ ~ 1 q~
portion. The air knives and scraper bar~ on the ba~ter applicator (and on the prewa~h applicator) enable equal amounts of batter (or prewash) to be removed from both the top and bottom of the flsh portion. If too much emulsion S ~prewash) remains on the bottom, the product may be soggy.
These tools also allow the prewash to be run very thick so that plenty of solids stay on the raw fish.
Breading The batter coated fish is then coated with a first layer of breading 122 that will comprise 7% to 10%
(preferably 8.64%) by weight of the finished breaded fish stick or fillet. A second layer of breading 124, is then applied over the first breading, comprising 3% to 5%
(preferably 3.36%) by weight of the finished breaded fish lS stick or fillet. The breadings can be colored (e.g., caramel colored), flavored, seasoned, pretoasted, and sized as to particular shape and granulation. The crispness of the finished food product varies with the type of crumbs used for the breading. Crisp, very crunchy crumbs are preferred. For the first layer of breading, the crumbs preferably are round and coarse with less than 5% moisture (such as Newly Weds t6524). For the second layer of breading, the crumbs preferably are spindly and fine crumb with less than 5% moisture (such as Newly Weds ~6517). The so-called Japanese-style of breading can be used to augment the crisp, crunchy character of the breaded food. The breading should be colored to enhance the appearance of the finished food product.
The breading may be applied with any commercial breading unit 22, e.g., a Stein J-Breader which includes two b}owers angled such that the breading crumbs are neither compressed down into the emulision batter, nor blown off the surface o~ the food. The rollers must either be eliminated or cbecked to make sure their spring loaded mountig mechanisms are working effectively. This technique produces a crispness in the breading of the finished product when served. ~y contrast, compression of the crumbs into the 5 _emulsion batter would produce a soggy final product while excessive blowing would result in an insufficiently coated product.
For application of the sec~nd layer of breading, a second breading unit 24, e.g., a Stein J-Breader may be used which includes two blowers and a roller to insure an even distribution of breading on the surface of the food. The second breading layer fills the voids that remain after application of the first breading layer. In order to avoid dislodging or damaging the breaded coating, it is important to provide a mechanically smooth transfer to the sprayer.
Spray The batter coated and breaded fish pieces are sprayed with a starch solution, which also helps to prevent the breading from falling off. It is the uniform coating of 20 starch on the breading which holds the breading on. Recall ~ -~ that the breading is applied to the batter without ¦ compression and so would not necessarily stay together without the starch coating. This technique assures that the breading will not become soggy fro~ having been pushed into the emuls?ion batter. The starch spray comprises 1% to 3%
(preferably 1.5%) by weight of the finished breaded fish stick or fillet. The spray solution is preferably a solution of 8% to 15% (preferably 10%) tapioca dextrin,-Crystal Gum (National Starch ~52-2550). The starch solution can be prepared in any suitable mixing device. The mixer should contain a heater and recirculating pump such that the starch solution is heated to 150 F before being pumped (via a filter) to a holding tank connected to a spraying device.
2 ~ ` 7 ~
The final starch spray i9 applied over the breading by a fine mist sprayer 26 to achieve a uniform and complete coating 130.
The purpose of the starch is to hold the cru~b to 5 ~the core food during processing, handling, and cooking of the coated food product.
E~r~hçr Processin~ and Preparation for Servina The finished coated product is frozen and packaged for distribution.
The frozen product is prepared for serving by baking in a conventional hot air oven for 20-30 minutes in a 375 F
oven. The heat cooks the uncooked fish and congeals the emulsion batter. Microwave preparation is possible but may not provide as much crispness.
lS Note that all of the equipment throughout the process is operated with extended noses and adjusted angles to assure smootn transfer of product from one belt to another, preventing the coating from being scraped off. If portions of the coating are scraped off the product may be soggy and may stick to the cooking pan.
Pxoperties The resulting breaded food is comprised of preferably about 51.5-54% Pollock, about 21.5% batter coating, about 12% breading, and about 11% undercoating by weight, and has the desirable characteristics of a breaded food while limiting fat and saturated fat to acceptable, health-oriented levels. Limiting the fat content also results in a lower calorie breaded food that is less fattening. The product may have, for example, less than 30%
of its calories as fat and less than 1% of its fat as saturated fat.
The oven baked breaded food appears golden brown, has a uniform coating of breading with no bare spots, and r 21~1 L~ 7 ~1 ~ 11 ~
appearcs crisp with no wet or fatty surface areas. .The coating on the food has good adhesion and cohesion (imparted by the composition of the ingredients and the even ~Sspplication of each ingredient to the core food product) 5 -which are discernible during preparation of the breaded foods for serving and in handling or prodding with a fork.
The eating qualities of the breaded food of the invention are similar to a deep frled food, i.e. crisp and crunchy, although not as greasy. The food is moist and tender, but not soggy or doughy. Since the core food is not precooked, a fresher taste is achieved when the frozen product is cooked.
Other embodiments are within the following claims.
I The breading system is applicable to core foods other than I lS fish, for example, meat, seafood, poultry, and vegetables.
It i8 especially effective for foods with high water content.
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Claims (19)
1. A breaded food product comprising an uncooked piece of core food, and a breaded coating system on said core food, said coating system comprising bread crumbs and fat, said product comprising at least 3% and no more than 8% by weight of fat.
2. The product of claim 1 wherein said core food comprises fish.
3. The product of claim 1 wherein said core food comprises poultry.
4. The product of claim 1 wherein said core food comprises vegetable.
5. The product of claim 1 wherein said product comprises preferably less than 6% by weight of fat.
6. The product of claim 1 wherein said product comprises most preferably less than 5.5% by weight of fat.
7. The product of claim 1 wherein said breaded coating system comprises a precoating comprising starch and flour.
8. The product of claim 1 wherein said breaded coating system comprises a batter comprising a fat emulsion in an aqueous phase.
9. The product of claim 8 wherein said batter comprises an oil low in saturated fat.
10. The product of claim 9 comprising less than 1%
of fat in the form of saturated fat.
of fat in the form of saturated fat.
11. The product of claim 9 wherein said oil comprises canola oil.
12. The product of claim 1 wherein said breaded coating system comprises breading and a starch overcoat on said breading.
13. A breaded food product comprising an uncooked piece of core food, and a breaded coating system on said core food, said coating system comprising a precoating having starch and flour, a batter comprising a fat emulsion of low saturated fat oil in an aqueous phase, breading on said batter, and a starch overcoat on said breading, said product comprising no more than 8% by weight of fat.
14. A breaded food product comprising an uncooked core food, a breaded coating system on the core food, and a starch film overcoated on said breaded coating system.
15. A method for making a breaded food product comprising applying breading on an uncooked core food, and spraying a starch overcoat film on said breading.
16. The method of claim 15 further comprising prior to applying said breading, applying a fat-emulsion coating in amounts such that the finished product comprises less than 30% of calories in fat and less than 1%
of its fat in the form of saturated fat.
of its fat in the form of saturated fat.
17. The method of claim 16 further comprising preparing said fat-emulsion batter from a low fat oil, an emulsifier, and a stabilizer.
18. The method of claim 17 further comprising controlling the viscosity of said fat-emulsion batter to effect a desired pickup of breading on said batter in order to achieve a predetermined aggregate fat percentage in said finished product.
19. The method of claim 15 further comprising prior to applying said fat-emulsion coating, applying to said uncooked core food an undercoating of flour, starch and water.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002101474A CA2101474A1 (en) | 1993-07-28 | 1993-07-28 | Breaded food |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002101474A CA2101474A1 (en) | 1993-07-28 | 1993-07-28 | Breaded food |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2101474A1 true CA2101474A1 (en) | 1995-01-29 |
Family
ID=4151997
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002101474A Abandoned CA2101474A1 (en) | 1993-07-28 | 1993-07-28 | Breaded food |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2101474A1 (en) |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0746210A1 (en) * | 1994-03-02 | 1996-12-11 | Griffith Laboratories Worldwide, Inc. | Improved breading crumbs |
| EP1127496A1 (en) * | 2000-02-19 | 2001-08-29 | Wiesenhof Geflügel-Kontor GmbH | Method of producing a breaded meat product |
| EP1411773A1 (en) * | 2001-07-12 | 2004-04-28 | Advanced Food Technologies, Inc. | Snack/convenience foods and the like having external and/or internal coating compositions |
| FR2911046A1 (en) * | 2007-01-09 | 2008-07-11 | Doux S A Sa | Non-fried foodstuff in which core is baked, comprises a substrate made of minced poultry meat, chopped fish, egg, textured vegetable protein and/or cheese fondue or a specialty cheese, and a coating in the form of agglomerates |
| EP2322450A1 (en) * | 2009-11-11 | 2011-05-18 | FRoSTA Aktiengesellschaft | System for preparing a fish product in a microwave |
| US7964231B2 (en) | 2001-07-12 | 2011-06-21 | Advanced Food Technologies, Inc. | Coated potato substrates having reduced fat content |
| US7998512B1 (en) | 2005-01-14 | 2011-08-16 | Advanced Food Technologies, Inc. | Dough-enrobed foodstuff |
| US8043643B1 (en) | 2000-09-21 | 2011-10-25 | Advanced Food Technologies, Inc. | Coated cereal pieces |
| US8048459B2 (en) | 2002-10-09 | 2011-11-01 | Advanced Food Technologies, Inc. | External coating composition for toaster pastries and other pastry products |
| EP3251528A1 (en) * | 2016-06-03 | 2017-12-06 | Nomad Foods Europe IPCO Limited | Coating composition |
-
1993
- 1993-07-28 CA CA002101474A patent/CA2101474A1/en not_active Abandoned
Cited By (21)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0746210A1 (en) * | 1994-03-02 | 1996-12-11 | Griffith Laboratories Worldwide, Inc. | Improved breading crumbs |
| EP0746210A4 (en) * | 1994-03-02 | 1998-04-15 | Griffith Lab Worldwide Inc | Improved breading crumbs |
| EP1127496A1 (en) * | 2000-02-19 | 2001-08-29 | Wiesenhof Geflügel-Kontor GmbH | Method of producing a breaded meat product |
| US8043643B1 (en) | 2000-09-21 | 2011-10-25 | Advanced Food Technologies, Inc. | Coated cereal pieces |
| US7906164B2 (en) | 2001-07-12 | 2011-03-15 | Advanced Food Technologies, Inc. | Snack/convenience foods and the like having external and/or internal coating compositions |
| US7294355B2 (en) | 2001-07-12 | 2007-11-13 | Advance Food Technologies, Inc. | Snack/convenience foods and the like having external and/or internal coating compositions |
| AU2002310428B2 (en) * | 2001-07-12 | 2008-04-24 | Advanced Food Technologies, Inc. | Snack/convenience foods and the like having external and/or internal coating compositions |
| US8486471B2 (en) | 2001-07-12 | 2013-07-16 | Advanced Food Technologies Inc. | Snack/convenience foods and the like having external and/or internal coating compositions |
| US8163321B1 (en) | 2001-07-12 | 2012-04-24 | Advanced Food Technologies, Inc. | Coated potato substrates having reduced fat content |
| EP1411773A4 (en) * | 2001-07-12 | 2005-12-14 | Advanced Food Technologies Inc | Snack/convenience foods and the like having external and/or internal coating compositions |
| EP1411773A1 (en) * | 2001-07-12 | 2004-04-28 | Advanced Food Technologies, Inc. | Snack/convenience foods and the like having external and/or internal coating compositions |
| US7964231B2 (en) | 2001-07-12 | 2011-06-21 | Advanced Food Technologies, Inc. | Coated potato substrates having reduced fat content |
| US8048459B2 (en) | 2002-10-09 | 2011-11-01 | Advanced Food Technologies, Inc. | External coating composition for toaster pastries and other pastry products |
| US7998512B1 (en) | 2005-01-14 | 2011-08-16 | Advanced Food Technologies, Inc. | Dough-enrobed foodstuff |
| WO2008107585A3 (en) * | 2007-01-09 | 2009-02-19 | Doux S A | Non fried food product |
| WO2008107585A2 (en) * | 2007-01-09 | 2008-09-12 | Doux S.A. | Non fried food product |
| FR2911046A1 (en) * | 2007-01-09 | 2008-07-11 | Doux S A Sa | Non-fried foodstuff in which core is baked, comprises a substrate made of minced poultry meat, chopped fish, egg, textured vegetable protein and/or cheese fondue or a specialty cheese, and a coating in the form of agglomerates |
| EP2322450A1 (en) * | 2009-11-11 | 2011-05-18 | FRoSTA Aktiengesellschaft | System for preparing a fish product in a microwave |
| EP3251528A1 (en) * | 2016-06-03 | 2017-12-06 | Nomad Foods Europe IPCO Limited | Coating composition |
| GB2550970A (en) * | 2016-06-03 | 2017-12-06 | Nomad Foods Europe Ipco Ltd | Coating composition |
| GB2550970B (en) * | 2016-06-03 | 2020-09-09 | Nomad Foods Europe Ipco Ltd | Coating composition |
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