GB2322062A

GB2322062A - Butterfly poultry escalopes

Info

Publication number: GB2322062A
Application number: GB9703198A
Authority: GB
Inventors: Mostafa Kalbassi
Original assignee: PADLEY G W HOLDINGS Ltd
Current assignee: PADLEY G W HOLDINGS Ltd
Priority date: 1997-02-15
Filing date: 1997-02-15
Publication date: 1998-08-19
Anticipated expiration: 2017-02-15
Also published as: GB9703198D0; GB2322062B

Abstract

Previous butterfly-shaped poultry escalopes have been formed from many, finely divided pieces of meat pressed together to form a single item. The invention relates to a method of manufacturing a natural, butterfly escalope from eg. chicken or turkey meat, comprising the steps of incising a breast fillet 10a from one side towards the other, such that a hinge (12a) is formed along one edge of the fillet. The fillet is then unfolded and pressed before subsequent treatment such as seasoning, coating with batter, breading, frying, cooking and chilling or freezing.

Description

IMPROVEMENTS IN AND RELATING TO FOOD PRODUCTS This invention relates to improvements in and relating to food products.

In particular, the invention relates to improvements in the manufacture of so-called "butterfly" poultry escalopes.

A butterfly poultry escalope is one in which poultry meat is formed into a shape resembling the outline of a butterfly. Such escalopes are attractive to the consuming public.

It is possible to cut a double fillet comprising two poultry breast portions joined by the keel cartilage. Such a fillet resembles an enlarged, butterfly escalope but is too costly to manufacture on a commercial scale.

Hitherto, it has only been possible to manufacture butterfly escalopes on a commericial scale by so-called "forming" of poultry meat such as chicken or turkey meat. The forming process involves cutting the meat into a large number of small pieces, and subsequently compacting (ie.

forming) the pieces in a mould to create the desired shape. The structure of the resulting food product is self-sustaining by virtue of the tendency of the pieces of meat to cohere. However, formed products are generally regarded as inferior to so-called "natural" products, in which a meat piece remains substantially intact during the manufacturing process.

Hitherto, it has not been possible to manufacture a natural, poultry butterfly escalope from a single piece of meat such as a fillet of chicken breast.

Also, formed butterfly escalopes tend to have an appearance that is regular and hence contrary to some consumers' expectations; and a texture that differs from that of a natural fillet.

According to a first aspect of the invention there is provided a method of manufacturing a food product comprising the steps of: incising a meat fillet to form a hinge in the fillet; unfolding the fillet along the hinge and flattening it; and further treating the unfolded, flattened fillet to stabilise it for consumption, storage or distribution.

Preferably the meat is poultry breast meat. Nonetheless the term "meat" is herein taken to mean any of a range of foodstuffs including (but not limited to) red meats such as beef, pork and lamb/mutton; speciality meats such as kangaroo, ostrich and alligator; fish meat or meat from other aquatic creatures; and game.

This method advantageously permits the manufacturing of a natural, butterfly-shaped escalope from eg. turkey, chicken or other poultry fillets.

Such a product has a superior "mouth feel", taste and appearance to formed (i.e. man-made), butterfly escalopes.

Preferably the step of incising the poultry breast fillet includes the step of making an incision transversely of the fillet from one longitudinal edge towards an opposite longitudinal edge, whereby to define the hinge along said opposite longitudinal edge.

This step takes advantage of the natural shape of the poultry fillet in forming the butterfly shape of the escalope. However, other directions of incision may be used, whereby to create other escalope shapes if desired.

Advantageously the step of incising the fillet includes the sub-steps of engaging the fillet with a fixed cutter disposed to make an incision at a predetermined location in the fillet; and advancing the fillet relative to the cutter to make the incision.

Conveniently the fillet is gripped along one longitudinal edge during cutting. This also takes advantage of the natural shape of the fillet in its uncut condition.

In preferred embodiments the step of flattening the unfolded fillet includes the step of pressing the fillet, eg. in a suitable meat press. This tends to flatten the hinge, and ensures that the escalope is of uniform thickness throughout.

Preferably the step of further treating the unfolded, flattened fillet includes one or more of the following substeps: marinading; seasoning; applying batter to; breading; frying; and cooking the unfolded, flattened fillet.

The term "seasoning" is herein taken to mean addition of any of a range of flavourings, including condiments, herbs, spices, and sauces.

In preferred embodiments, the cooking step involves frying of the unfolded, flattened fillet; however, other cooking processes such as oven baking may additionally or alternatively be used.

When the method includes the sub-step of cooking the unfolded, flattened fillet, it may also preferably include one or more of the steps of: chilling or freezing the cooked fillet.

These steps advantageously render the food product suitable for packing, distribution and/or storage.

The method also preferably includes the step of weight grading the fillet.

This step preferably occurs before incising of the fillet, whereby to ensure consistency of the weights of the resulting escalopes.

The invention is also considered to reside in a food product obtainable by the method defined hereinabove; and further in a one-piece, natural, butterfly poultry escalope.

There now follows a description of a preferred embodiment of the invention, by way of example, with reference being made to the accompanying drawings in which: Figure 1 is a plan view of a poultry breast fillet before undergoing the method steps of the invention; Figure 2 is an end elevational view of the Figure 1 fillet along line 2-2; Figure 3 shows the fillet of Figure 1 after incision, unfolding and pressing; and Figure 4 is an end elevational view of the Figure 3 fillet, along line 3-3.

Figure 1 shows a poultry breast fillet (such as a chicken breast fillet) after it has been cut from a poultry carcass, and, inpreferred embodiments, trimmed to a predetermined weight using e.g. a known water cutter machine. As illustrated, the poultry fillet 10 generally has a tear-drop shape in plan view. The tear-drop shape has two longitudinal edges 11,12 that diverge from one another in the embodiment shown, but that are nonetheless generally opposite one another on the periphery of the fillet.

According to the method of the invention, the fillet 10 is incised to create a cut extending in the direction of the arrows I, ie. transversely from the edge 11 towards the edge 12.

The resulting incision 13 extends from edge 11 towards edge 12, but terminates a short distance from edge 12 so that the fillet 10 is not completely sliced in two.

As is shown in Figure 2, the incision 13 is made approximately half way between the upper surface 14 and the lower surface 15 of the fillet.

The incision 13 can be made using a suitable, hygienic cutting apparatus.

In preferred forms of the method, the incision is created by firstly gripping the uncut fillet 10 between a pair of parallel, moveable belts that are spaced one from another by a distance short enough to grip the fillet 10 firmly, without damaging it. The belts are powered to advance the fillet towards a fixed blade (not shown) that lies generally parallel to the line 13 of Figure 2, at the correct height for the incision 13 to be preferably equi-spaced from the upper 14 and lower 15 surfaces of the fillet 10. Clearly the height of the fillet 10 relative to the blade during cutting determines the position of the incision 13.

Since the edge 12 of the fillet is in its uncut condition slightly thicker along edge 12 than along edge 11, the preferred method of gripping and advancing the fillet 10 involves gripping only along edge 12 and advancing the fillet 10 in a direction perpendicular to arrows I into engagement with the fixed blade.

The cutting apparatus may be accurately controlled to create the desired cut.

Incising of the fillet 10 in the manner described results in a hinge 12a that extends along edge 11 opposite that on which the incision commenced.

The fillet 10 may be unfolded along hinge 12a to defme a butterfly-shaped escalope 10a shown in Figure 3.

Although the invention has been described with reference to forming of a butterfly escalope, it will be appreciated that other directions and starting points for incision 13 may be used to create different escalope shapes, by virtue of positioning of hinge 12a in other locations than that shown.

The escalope 10a is in accordance with the method pressed in meat press to flatten it, and to ensure that its thickness is substantially uniform as shown in Figure 4.

The escalope 10a may then be seasoned, coated with batter (or any other flavouring/cooking enhancing medium), cooked and chilled or frozen.

The cooking step may include baking, frying or a combination of baking and frying. The preferred cooking method is frying followed by oven baking. Other cooking processes are also possible.

The resulting escalope if chilled to a temperature of 0 to 2"C may be packed eg. in a sealed tray or under inert gas in a sealed pack for chilled distribution to supermarkets and other retail food outlets; to restaurants; caterers; airlines; schools and local authorities.

Alternatively, after cooking, the escalope 10a may be deep frozen eg. to -18 C in order to provide a longer storage life of the product.

As is evident from the method described herein, it is necessary to make only a single incision into the fillet 10, thereby retaining the natural characteristics of the meat, ie. the appearance, taste and mouth feel that are generally regarded as superior.

Also, the escalope 10a is of a larger area than previous, formed escalopes the sizes of which are limited by the dimensions of the moulds in which the cut pieces of meat are pressed.

It is advantageous for meat products to have a large surface area, since good "plate coverage" is regarded as desirable within the food industry.

Claims

1. A method of manufacturing a food product comprising the steps of: incising a meat fillet to form a hinge in the fillet; unfolding the fillet along the hinge and flattening it; and further treating the unfolded, flattened fillet to stabilise it for consumption, storage or distribution.

2. A method according to Claim 1 wherein the step of incising a meat fillet includes the step of making an incision that extends transversely of the fillet, from one longitudinal edge towards an opposite longitudinal edge, whereby to define the hinge along said opposite longitudinal edge.

3. A method according to Claim 1 or Claim 2 wherein the step of incising the fillet includes the sub-steps of engaging the fillet and a fixed cutter disposed to make an incision at a predetermined location in the fillet; and advancing the fillet relative to the cutter to make the incision.

4. A method according to Claim 3 wherein the fillet is gripped along one longitudinal edge during cutting.

5. A method according to any preceding claim wherein the step of flattening the unfolded fillet includes the step of pressing the fillet.

6. A method according to any preceding claim wherein the step of further treating the unfolded, flattened fillet includes one or more of the following sub-steps: seasoning; apply batter to; breading; frying; and cooking the unfolded, flattened fillet.

7. A method according to Claim 6 including the said sub-step of cooking the unfolded, flattened fillet and one or more of the further substeps of: chilling the cooked fillet; freezing the cooked fillet.

8. A method according to Claim 6 or Claim 7 wherein the step of cooking the fillet includes the step of frying the fillet.

9. A method according to any preceding claim including the step of weight grading the fillet.

10. A method according to any preceding claim wherein the meat is poultry breast meat.

11. A food product obtainable by the method of any preceding claim.

12. A one-piece, natural, butterfly poultry escalope.

13. A method generally as herein described, with reference to or as illustrated in the accompanying drawings.

14. A food product generally as herein described, with reference to or as illustrated in the accompanying drawings.

15. A natural, butterfly poultry escalope generally as herein described, with reference to or as illustrated in the accompanying drawings.