FI130475B

FI130475B - Method of producing a food product for human consumption

Info

Publication number: FI130475B
Application number: FI20216206A
Authority: FI
Inventors: Santtu Vekkeli
Original assignee: Ne Innovations Oy
Priority date: 2021-11-25
Filing date: 2021-11-25
Publication date: 2023-09-25
Also published as: FI20216206A1

Abstract

It is disclosed a method of producing a food product for human consumption by using extrusion from gutted and plucked poultry comprising bones, hard tissues, tendons, skin and/or cartilages.

Description

METHOD OF PRODUCING A FOOD PRODUCT FOR HUMAN CONSUMPTION

FIELD OF THE INVENTION

The present invention relates to a method of producing a food product.

More particularly, the invention relates to a method of producing a food product by extrusion from poultry including undervalued parts of poultry.

BACKGROUND OF THE INVENTION

Extrusion is widely used in the manufacture of various food products.

Broadly, extrusion is a continuous process which uses an extruder having one or two screws. The extruder provides transport, compression, mixing, cooking, shear- ing, heating, cooling and shaping of raw material to final products.

US 5853790 discloses a method for commercial preparation of poultry meat for human consumption by using extrusion. The method effectively maxim- izes the use of poultry meat from an entire poultry carcass, and enhances the value of all of the meat from a bird carcass. The meat portions of whole birds are de- boned in the method.

US 2012/0237642 Al discloses a method for production of a meat- based, cereal-free semi-moistanimal food product by extrusion. Meat may be poul- try.

US 2008/0268115 A1 discloses a process for processing poultry —wherein a hot boned poultry meat is provided, ground or macerated and blended with salt. The term “hot boned poultry meat” refers poultry meat that is deboned.

US 2014/0087044 A1 discloses a method of preparing a food or feed ingredient for incorporation into a human food or animal feed by extrusion.

Deboned meat, e.g, from poultry, is used in the method.

S 25 RU 2223673 C2 discloses a method for producing an extruded product

N from mechanically deboned poultry meat material and vegetable raw materials.

S US 4022915 discloses a method of producing a food product from cereal 5 grains and a protein source using extrusion. The protein source may include pro- = teinous by-products from the processing of meat, poultry and fish, including bones. + 30 EP 2011404 A1 discloses a method for producing an extruded food

S product comprising vegetable protein and meat including bones. The method com- = prises continuously introducing components comprising meat and vegetable pro- a tein to an extruder, mixing the components to produce a mixture, heating, extrud- ing and cooling the mixture.

It has now been found that a food product for human consumption with appealing taste and good mouthfeel may be produced from poultry by effectively using whole bird except gut and feathers. Undervalued value parts of birds, and poultry meat from an entire poultry carcass may be effectively used including bones, hard tissues, tendons, skin and/or cartilages. The method of the invention produces a ready-to-consume product. Additionally, the food product can be used as an ingredient or extender and combined with other food materials to produce a wide range of foodstuffs.

The food product produced by the method of the invention is also suit- able as an animal feed.

BRIEF DESCRIPTION OF THE INVENTION

In an aspect, the present invention provides a method for producing a food product from poultry meat material. The method effectively utilizes all meat from bird carcass and also bones, hard tissues, tendons, skin and/or cartilages. The invention is as defined in claim 1.

The invention thus provides a sustainable method in which whole gut- ted and plucked bird may be effectively used in the production of a food product for human consumption providing environmental benefits.

The invention also provides a method in which undervalued parts of a bird or of low hygienic quality may be used providing economic benefits in that the product can be offered at a lower cost.

The invention further provides a method of producing a food product with an increased nutritional value.

Further, the invention provides a method of producing a food product — which enables reduction of global meat production providing environmental ben-

N efits.

N In another aspect, the invention provides use of a food product pro-

S duced by the method of the invention as an ingredient in the production of food-

S stuffs. x = 30 BRIEF DESCRIPTION OF THE DRAWINGS

S Figure 1 generally illustrates a process flow diagram of an embodiment

N of the method of the invention. i

DETAILED DESCRIPTION OF THE INVENTION

In an aspect, it is disclosed a method of producing a food product,

comprising - providing gutted and plucked poultry meat material comprising bones, hard tissues, tendons, skin and/or cartilages, - grinding the gutted and plucked poultry meat material to provide ground poultry mass, - subjecting the ground poultry mass to an extrusion at a temperature of at least 100°C to provide an extruded mass as a food product.

The invention is as defined in claim 1.

Figure 1 illustrates an embodiment of the method of the invention. The dotted line illustrates an optional method step. The method may include further optional method steps not shown in the figure.

Poultry meat material suitable for use in the method of the invention includes, but is not limited to, chickens, turkeys, ducks, and geese. In an embodi- ment of the invention, the poultry is chicken.

In an embodiment, the gutted and plucked poultry meat material com- prises bones, hard tissues, tendons, skin and/or cartilages. In an embodiment, the gutted and plucked poultry meat material, comprising bones, hard tissues, tendons, skin and/or cartilages, comprises legs, necks, skin and/or heads of poultry. The main portion of the gutted and plucked poultry meat material is meat based on weight of the poultry meat material.

The gutted and plucked poultry meat material is ground to crush bones and other hard tissues and to provide ground poultry mass which is in a suitable form to be fed to the extrusion. The grinding may be carried out, e.g., with a meat grinder having a hole size of 2-5 mm.

In an embodiment, the ground poultry mass further comprises a plant- n based food material. Any food-grade plant-based food material is suitable to be

N added to the ground poultry mass. The plant-based food material includes, but is

N not limited to, a food material which is rich in protein, carbohydrate and/or fibre. < In an embodiment, the plant-based food material comprises soy protein, pea pro-

S 30 tein, cereal proteins, broad bean protein, maize protein, potato starch, maize

E starch, or any mixture thereof. In an embodiment, the plant-based food material is o provided as finely ground powder.

N In an embodiment, the plant-based food material is thoroughly mixed

N with the ground poultry mass to provide a uniform poultry/plant mass mixture. If

N 35 desired, the poultry/plant mass mixture is ground again, e.g., with a meat grinder with a hole size of about 5 mm, whereby the ground mixture exhibits a thread-like structure.

In an embodiment, the amount of the ground poultry material is in the range of about 10% w/w to about 95% w/w of the food product. In another em- bodiment, the amount is in the range of about 25% w/w to about 60% w/w of the food product. In a further embodiment, the amount is in the range of about 50% w/w to about 60% w/w.

In an embodiment, the amount of the plant-based material is in the range of about 5% w/w to about 90% w/w. In another embodiment, the amount is in the range 40% w/w to about 75% w/w. In a further embodiment, the amount is in the range of about 40% w/w to about 50% w/w.

In an embodiment, the ground poultry mass is cut to pieces having a diameter of about 0.5 to about 15 mm, e.g, about 2 mm, before the pieces are fed to the extrusion.

In an embodiment, compressed air is used to facilitate feeding of the — ground poultry mass to an extruder and to avoid clogging of the extrusion nozzles.

In an embodiment, the ground poultry mass is cooled to a temperature of about -25°C to about 6°C. Cooling of the mass facilitates the feeding of the mass to an extruder. Further, cooling provides structural strength to the mass, while for- mation of a gel-like structure is avoided.

In an embodiment, the extrusion is performed at a moisture of at least 20%. The extrusion may be carried out with a single-screw or twin-screw extruder.

Shearing and tearing combined with moisture in the extrusion step causes soften- ing of the hard tissues of poultry and provides a unique structure to the final food product.

In an embodiment, the extrusion is performed at a temperature of n about 100°C to about 400°C. Depending on the extruder used in the method, the

N extruder has to contain at least one heating segment where the temperature is at

N least 100°C. In addition, there may be further heating segments where the extru- < sion may be performed below 100°C, e.g. at 70°C. In an embodiment of the inven-

S 30 tion, an extruder is used which contains several heating segments each operated at

E a different temperature. In an embodiment, the temperature of the heating seg- o ments increases when the mass moves forward in the extruder.

N In an embodiment, the extrusion is performed using about 100 rpm to

N about 1000 rpm speed. In another embodiment, the extrusion is performed using

N 35 about 200 rpm to about 600 rpm speed. In an embodiment, about 500 rpm is em- ployed in the extrusion.

In an embodiment, the extrusion of the ground poultry mass provides an extruded mass having a temperature of at least 100°C.

In an embodiment, the extruded mass is cooled to a temperature of about +60°C to about -30°C. In an embodiment, cooling of the extruded mass is per- 5 formed in an extruder before the extruded mass is discharged from the extruder.

Cooling in the extruder is conveniently carried out in the cooling die. When the ex- truded mass is cooled in the extruder, the temperature of the mass discharged from the extruder may range from about 1°C to about 60°C, e.g. about 30°C to about 60°C.

In another embodiment of the invention, the ground poultry mass in the extruder is pressed thorough a hole, which may be smaller than or equal to the cylinder area in the end of the extrusion cylinder. Extruded mass loses a portion of water steam when it exits the process, if the temperature is more than 100°C. The mass has a different taste, smell, structure (viscosity, cutting properties etc.), and — itreacts differently in post-processing compared with a process involving a cooling die step.

The extrusion provides a food-grade product which is ready to be con- sumed as such.

Extrusion process decreases microbial load of poultry carcass enabling use of poultry of low hygienic quality. Microbial load is reduced by approximately 1000-1012 fold during the process.

The extruded food product produced by the method of the invention may imitate the texture, flavour, and mouthfeel of meat.

The method of the invention provides a food product which exhibits an increased nutritional value. By using calcium-containing parts of poultry, i.e, n bones, hard tissues, tendons, and/or cartilages, the calcium content of the food

N product produced by the method is increased compared with typical poultry meat

N products. In an embodiment, the food product has a calcium content of about 0.2% < w/w to about 0.7% w/w. In an embodiment, the calcium content of the food prod-

S 30 uctis about 0.5% w/w, such as 0.52% w/w.

E In an embodiment, the extruded mass is heat-treated at a temperature o ranging from about 110°C to about 400°C to improve sensory properties and

N mouthfeel of the product. The heat treatment may be carried out, e.g., by cooking

N in oil, e.g, at 150-300°C, grilling, pan frying, drying by heat, e.g., at 200-400°C,

N 35 freeze drying below -70°C, microwaving or infrared radiating.

Extrusion of a poultry meat material with bones and other hard tissues together with heat treatment provides a ready-to-eat food product for human con- sumption which shows unique, appealing taste and structure, and mouthfeel.

The sensory properties of the food product may be further improved by adding ingredients typically used in food manufacture to the food product pro- duced by the method of the invention, e.g, flavouring agents, aromas, salt, stabi- lizers, emulsifiers, carbohydrates, fibres, oils and fats, etc.

The extruded mass may be combined with other food materials to pro- vide a wide variety of foodstuffs having different appearance, taste and structure.

Thus, in an aspect, the invention provides use of a food product produced by the method of the invention as an ingredient or extender in the production of food- stuffs. The food product may be combined, for example, with a plant-based food raw material or poultry meat material without bones, hard tissues, tendons, skin and/or cartilages. The food product produced by the method of the invention may beincluded in the foodstuff in an amount up to about 50% w/w without imparting any negative effect on the sensory properties of the foodstuff.

The following examples are presented for further illustration of the in- vention without limiting the invention thereto.

The calcium content of the food product was measured according to — standard SFS-EN ISO 11885, 2009.

The level of aerobic microorganisms was measured according to stand- ard NMKL 86:2013.

Example 1 58 kg of poultry carcass (with bones and skin) was minced with a meat grinder with a hole size of 2 mm. The ground poultry mass was then properly mixed n with 42 kg of a mixture consisting of 21 kg of a soy concentrate powder (protein

N content of 66 wt.%) and 21 kg of a pea concentrate powder (protein content of 79

N wt.%). The mixture was kept at approximately 4°C. The mixture was fed to a meat < grinder with a hole size of 5 mm. The resultant ground mixture was then cooled to

S 30 approximately 2°C and cut to pellets with a length of approximately 5 mm. The pel-

E lets kept cooled were fed to an extruder as a constant feeding process using air o pressure bursts to avoid stops in the feeding.

N The extrusion process was performed with a twin-screw extruder with

N a temperature profile of a cylinder (from feeder to cooling die): 65-70-80-100-

N 35 120-140-150%, and the cooling die with temperature of 25°C. The extrusion was performed using approximately 400 rpm speed to provide an extruded mass. The extruded mass showed a temperature of about 35°C at the exit.

The extruded mass was collected and cooled to +4°C whereby a ready- to-eat food product was obtained. The food product had a calcium content of 0.52% w/w.

The level of aerobic microorganisms measured at 30°C/72 h was < 1000 pmy/g. The measured level of aerobic microorganisms indicates that a food grade product for human consumption was obtained.

The extruded mass of +4°C was torn to approximately 1-5 mm particle size. The particles were marinated with a mixture of rapeseed oil and spice at +4°C for approximately 2 hours. The marinated particles were cooled and formed to a patty by adding egg, spices, wheat flour and dried vegetable particles. The patty was cooked in rapeseed oil, cooled to 2°C, packed in vacuum package. The resultant food product exhibited an appealing taste and mouthfeel.

A similar cooked product may be produced from an extruded mass — which is frozen to below -18°C. The frozen extruded mass is first torn to smaller particles and then marinated and cooked as described above.

Example 2

Extruded mass was produced in a similar manner as in Example 1 from poultry carcass and a soy protein concentrate. The extruded mass was collected and frozen to -20°C.

The extruded mass of -20°C was thawed to about +4°C. The thawed ex- truded mass was torn to particles of about 1-5 mm particle size. Fresh grounded chicken meat was added to the particles in a ratio of 65:35 w/w. Beef fat was added to the obtained mixture in a ratio of 1:10 w/w followed by grinding by a meat grinder with 5 mm sieve to provide a dough. en 2.0% w/w of salt and spices including black pepper powder, hot pepper

S powder, cumin powder, garlic powder, onion powder and cayenne pepper were > added to the dough. The dough was kneaded for about 20 minutes until a smooth 3 mass was obtained. The mass was wrapped in an oil-coated aluminum foil, baked

S 30 inanovenat125*Cuntil the internal temperature of the kebab-like mass was 80°C.

E Product was cooled to +4*C and vacuum packaged. © The resultant kebab-like food product exhibited an appealing taste and

N mouthfeel.

N

N 35 It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims. ™

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Claims

1. A method of producing a food product for human consumption, com- prising - providing gutted and plucked poultry meat material comprising bones, and optionally hard tissues, tendons, skin and/or cartilages, - grinding the gutted and plucked poultry meat material to provide ground poultry mass, - subjecting the ground poultry mass comprising a plant-based food ma- terial to an extrusion at a temperature of at least 100°C to provide an extruded mass as a food product comprising about 25% w/w to about 95% w/w of the ground poultry mass and about 5% w/w to about 75% w/w of the plant-based food material, wherein the food product has a calcium content of about 0.2% w/w to about 0.7% w/w.

2. The method of claim 1, wherein the gutted and plucked poultry meat material is chicken.

3. The method of claim 1 or 2, wherein the gutted and plucked poultry meat material comprises legs, necks, skin and/or heads of poultry.

4. The method of any one of the preceding claims, wherein the plant- based food material comprises soy protein, pea protein, cereal proteins, broad bean protein, maize protein, or any mixture thereof.

5. The method of any one of the preceding claims, wherein the amount of the ground poultry mass is in the range of about 50% w/w to about 90% w/w, more specifically about 60% w/w to 80% w/w of the food product.

6. The method of any one of the preceding claims, wherein the amount plant-based food material is in the range of about 10% w/w to about 50% w/w, e more specifically about 20% w/w to about 40% w/w of the food product.

S

7. The method of any one of the preceding claims, wherein the ground o poultry mass is cooled to a temperature of about -25°C to about 6°C.

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8. The method of any one of the preceding claims, wherein the extrusion S 30 is performed ata temperature of 100°C to about 400°C.

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9. The method of any one of the preceding claims, wherein the extrusion © is performed at a moisture content of at least 20%. >

10. The method of any one of the preceding claims, wherein the temper- N ature of the extruded mass is at least 100°C. N 35

11. The method of any one of the preceding claims, wherein the ex- truded mass is cooled to a temperature of about +60*C to about -40°C.

12. The method of any one of the preceding claims, wherein the ex- truded mass is subjected to a heat treatment to a temperature ranging from about 150°C to about 400°C.

13. The method of any one of the preceding claims, wherein the food product has a calcium content of about 0.5% w/w.

14. Use of a food product produced by the method of any one of claims 1 to 13 as an ingredient in the production of a foodstuff.

15. The use of claim 14, wherein the food product is used in an amount up to about 50% w/w of the foodstuff. ™ Ql O N o S N O I a a © O N © N O N