GB2444117A - A food injection device - Google Patents

Abstract

A food treatment device comprises an injection assembly having a needle 110 with a food penetrating front end 118 and transverse protrusions 112. A tubular shroud 114 surrounds the needle with a spacing and is axially displaceable with respect to the needle. A conduit 130 communicates with the space within the shroud for passing a flowable composition into a rear end portion of the shroud. A tubular guide 120 surrounds the shroud with a spacing and is axially displaceable relative to the shroud and the needle. The guide has a cutting edge 125 at its front end and a fluid supply inlet 500 at a rear region. The needle may be solid and the shroud may also have a cutting edge at its front end. A method for the use of the device in injecting a flowable composition into a solid food substrate such as meat is also disclosed.

Description

FOOD TREATMENT

The pre5ent invention relates to the treatment of foods and food components, particularly (but not exclusively) meat. It relates to methods of treatment, apparatus for use in such methods, compositions for use in such methods, and the preparation of such compositions.

In a first aspect the invention provides a food-treatment device comprising an injection assembly comprising: (a) a needle (preferably solid) having a food penetrating front end having transverse protrusions; (b) a tubular shroud surrounding the needle with a spacing and axially displaceable relative to it; the shroud preferably having a cutting edge at its front ends; Cc) a conduit communicating with the space within the shroud for passing a flowable composition into a rear end portion thereof; (d) a tubular guide surrounding the shroud with a spacing, and being axially displaceable relative to the shroud and the needle, the guide having a cutting edge at its front end; and Ce) a fluid supply inlet at a rear region of said guide.

Preferably there are means for controlling the depth of penetration of the needle.

Preferably the device includes a multiplicity of injection assemblies, together either as multiple individual units or combined through a central manifold or similar so that multiple injections can be achieved at multiple sites simultaneously.

Preferably, there are means for enabling injection of a predetermined quantity of the flowable composition.

In a second aspect the invention provides a method of preparing a foodstuff comprising a solid food substrate, said method comprising a step injecting a flowable composition into said substrate using a food-treatment device according to the first aspect, the method having the following steps: (a) causing the needle to protrude forwardly of the shroud and guide, and to penetrate partially through the thickness of the substrate; (b) causing the guide to move forwardly and to penetrate the substrate, its depth of penetration being a minor proportion of the needle's depth of penetration, whereby the guide is caused to cut a plug of substrate; Cc) causing the needle to move deeper into the substrate while rotating, and causing the shroud to penetrate the substrate to a minor depth; (d) passing the flowable composition through the conduit and thence through the shroud into the substrate; (e) withdrawing the needle and shroud; and (f) withdrawing the guide from the substrate and passing fluid (generally gas) into the guide via the fluid supply inlet to expel the plug of substrate to seal the hole in the substrate.

Desirably, movements of some, and preferably all elements areontrollable, e.g. using a measure of individual resistance pressure (fat is easier to penetrate than muscle, and muscle easier than connective tissue/skin) and/or non-contact image analysis of the surface. For example, XY coordinates of differing materials are identified and the individual needles of a manifold equating to those XY coordinates are instructed accordingly.

Such a method may include a step of blending a composition with meat proteins and fat and, optionally, sodium chloride and/or sodium phosphate to produce said flowable composition, which is then passed into the substrate without substantial delay.

Such a method may employ a flowable composition which contains one or more of a food supplement (e.g. calcium or other mineral or a nutraceutical) or a drug.

The flowable composition may be injected at an elevated temperature at which its flow properties are more suitable (e.g. lower viscosity), and the substrate may be chilled so that the injected composition is chilled so that its tendency to leak out is reduced.

Some further aspects and features of embodiments are outlined below.

The present invention relates to a method of formulating and preparing sauces and fillings capable of controlled direct injection into any suitable foodstuff, but especially red or white or fish meat, meat pieces and meat products.

It also relates to methods of adapting said sauces and fillings so as to maintain or improve the properties of the sauce or filling during storage and/or coolsing.

It further relates to methods of adapting said sauces and fiuings so as to maintain or improve the eating qualities and properties of the injected product, especially meat tenderness, texture, flavour and juiciness.

Additionally it relates to methods of adapting said sauces and fillings so as to maintain or improve the keeping properties of injected product by reducing water activity, reducing microbial load, and reducing or minimising the formation of oxidation products.

It additionally relates to methods of adapting said sauces and fillings with additives, nutrients, medications, or similar so as to enhance the nutritional, physical and chemical composition of the foodstuff to suit the nutritional needs of consumers both individually and as groups.

It also relates to the methodology of selectively injecting into meat so as to precisely locate and place the chemical tenderizing agent, sauce, additive, nutritional supplement, or other required material (all of which hereinafter will be referred to as the injectate'), in the desired location(s) for controlled optimum effect.

It further relates to automated methodologies that will precisely locate and place each individual injector mechanism into the foodstuff and to precisely control the depth to which the injector is driven so as to initiate a mechanical tenderi.satjon of the foodstuff, with or without the addition of a chemical injectate, thus providing a controllable mechanism for less tender, unusual, novel or less expensive cuts not normally suitable for consumption without extensive further processing.

It also relates to methods of adapting said sauces and fillings so as to enhance the rate and evenness of heating or cooling when placed within the foodstuff without causing denaturation, precipitation or deterioration of the said sauces and making such injected products suitable for fast food applications without the need for additional technology or processes to enhance the heating or cooling process.

It further relates to methods of injecting said sauces and fillings directly into foodstuffs particularly meat, meat pieces and meat products and eliminating subsequent leakage by automatically plugging the injection sites with meat or suitable alternative edible materials on completion of the injection cycle.

Finally, the methodologies and technology can equally be applied to any foodstuff, raw, processed or cooked, capable of accepting the injectate by the described methods. However the proceeding will concentrate its application to red, white and fish meat, their intermediate products and finished meat based products. I0

Description of the Background and

State of the Art Almost since the origination of culinary art, there have been many attempts to change, modify, improve or enhance the tenderness, taste and flavour of food, especially meat, by the use of additives. This can be as simple as adding herbs and spices to the surface before, during or after the cooking process or wrapping the foodstuff in vegetable leaves such as vine or papaya to induce a flavour as well as a textural change.

Another common approach is to prepare a separate sauce or gravy and serve that with the foodstuff. In more modern times, with faster methods of cooking, especially for large scale catering or rapid food service production, there has been an increasing use of externally applied sauces to cook with the meat.

Current animal production methods result in highly efficient, rapid growth of the animal and, for the most part, the deposition of large quantities of lean muscle. Unfortunately the meat from animals produced in this manner while often very tender, has frequently been criticized for a lack of taste and flavour, while modern slaughter practices often give rise to meat with a lack of juiciness. The process of basting is well known in the culinary art. The introduction of fats or oils, usually in the form of butter, margarine or butter/oil emulsions acts as a means of reducing moisture loss and increasing the perception of juiciness in the cooked product. Such a comniercial process is described in GB2260071. 0S3399063 to Armour also includes additives such as sodium phosphates and salt suspended in a non-aqueous basting mixture such as oils or fats which it is claimed enhances the water holding capability of their formulation. However they also teach that a preferred embodiment is to entrain air or gas in the mix and the injection sites are deliberately left open to encourage self-basting of the external surfaces on cooking. The perceived lack of flavour in modern meat has also led to a further increase in the use of herbs and spices especially those with more intense flavours

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and aromas. Frequently meat from older animals has a stronger natural flavour, however such flavours are often considered too earthy' and the meat excessively tough. As a consequence, meat from older animals is rarely used in its native form but merely used as components for lower value, further processed products; this also applies to many cuts from prime meat animals which tend only to be used in processed products due to a variety of problems such as muscle toughness, excessive connective tissue and/or unsuitable appearance.

In all of these methodologies the additional flavourings, herbs, spices, etc. are added to the outside of the meat in the form of a topical rub, spray or sauce mix. Prior art is typified by Parsons (US4732137) which discloses an apparatus for liquid dispersion in the form of a delivery tube with spray nozzles suspended along its length. Sauce is delivered by a pressurized system in a timed manner. However it can only be used for external supply of sauce for basting, smoking or flavouring.

This type of approach frequently results in a highly flavoured exterior to the meat but for a variety of reasons including but not limited to physical status, viscosity, molecular weight and most frequently a lack of time, this flavour has very limited ability to permeate into the meat and so the flavour profile is rapidly lost during the early stages of eating with the remainder of the meat often tasting bland and insipid, especially if the cooking process used was rapid, such as microwaving with resulting minimal generation of cooked meat flavours.

This shortcoming was identified a very long time ago and cooks and chefs developed marination processes to try to more evenly distribute flavour compounds within the meat but with only modest success due to the physical limitations in diffusing or infusing the marinade into the internal meat structures. A very similar process introducing salt or brine and other compounds into meat for preservation and curing processes has been commercially used for several centuries and is typified by Russian patent 1789170.

As a consequence, and in an effort to accelerate the process, many traditional cooking methods incorporate mechanical methods of introducing additives. An example described in Victorian cookbooks creates multiple slit-like pockets within a meat cut, such as a leg of lamb or pork, using a knife and then forcing the additive, which may herb, spice, fat or other, into these slits with the knife blade. However the method is slow, labour intensive and inefficient. It is also often difficult to get the additive into the slit or remain there in any consistent quantity when the inserting blade is withdrawn. The device of Hunter (US6692783) locks the flavourings between two surfaces with the insertion of the flavourings undertaken in a single operation claiming a more even distribution. However the device is intended to essentially remain within the meat during the cooking phase, plugging the hole created by the insertion process and it has to be manually removed on completion. More importantly, herbs and spices have complex aroma and flavour profiles, which rapidly lose their intensity when they become wet, frequently resulting in undesirable changes to their flavour profiles. However the greatest problem remains getting the herb, spice or flavouring into the internal meat structures and evenly distributing it.

There are several disclosures in prior art that have attempted to improve the process. Bieser (US 4211160) discloses a method of introducing solid seasonings into meat via a reservoir and a hollow cylinder section that does not plug with meat as it enters the meat (also compare DeSeversky US 2887035) and thus allows a freer flow of spices. The larding spike (US 2473191) introduces additives via a groove in a tube that has a sharp end for insertion. Material is passively introduced and Ii the material is scraped off as the tube is withdrawn. The spiked cornet of Risco (US 2652765) improved on this basic process with a reservoir for the additives and a simple method for controlling amount and flow. However, distribution was limited as was effective control and such technology is both unsuitable and impractical for liquid or gel injection.

The patent of Davis (US 2761305) shows a device for injecting and compacting material into openings in brick and concrete but no method of penetrating the surfaces, while those of Sundholm (US 3286887) and Moline (US 3717222) show different mechanisms for dispensing materials such as grease using a plunger assembly and a nozzle. However neither device has any means of penetrating the material into which the liquid is to be IS dispensed, merely using already existing surfaces fractures.

With little progress having been made on the even introduction and distribution of solids and high viscosity materials into meat, together with an increasing demand for higher volume production capabilities, large scale further meat processing operations have adopted the addition of additives in liquid form as an easier method of ensuring more even distribution. A further advance in the process is to apply positive force to embed the additive mix.

Olney et al (US 4178660) describes several variations of the hypodermic needle approach, in its basic form an apparatus that includes a detachable pointed tip for piercing the meat, a cylinder for holding the additive to be introduced and a plunger for forcing additives that do not flow easily into the meat, via hollow needles. They also highlight common problems associated with such an approach including drip, uneven distribution (in its worst case the formation of concentrated areas of additives such as pickle pockets), clogged needles, the need for excessive pressure, poor take-up and excessive waste. When the openings of the maririation device are made large enough to hold solids or viscous liquids, the openings tend to become filled with meat.

There are also major issues with regard to sanitation and contamination especially in larger scale production. The process developed within this patent deliberately generates small plugs of meat that are used to help seal the injection sites against exudation. Equally importantly, this process does not use hollow needles as the medium by means of which liquid or solid materials move from the outside to the internal structures of the foodstuff.

Attempts have been made to alleviate some of these problems through variation in needle form and function. Lagares-Corominas (TJS550722].) describes prior art for needle design and its use for injecting additives into meat. There are two general types.

Low pressure single site needles that pierce the meat and deposit the additive in the pocket created. This is subsequently dispersed by further mechanical action ranging from the application of gentle massaging to more vigorous tumbling or vacuum tumbling. High pressure techniques use needles with multiple radial holes along a tubular body resulting in better additive dispersion with reduced damage to the meat structure.

JO However clogging of needles. reduces efficiency and increases contamination issues. He discloses a modified needle design that ensures the lowest part of the needle is both tapered and shaped in the form of an inclined trough thus reducing clogging at the lower end closest to the tip. The design of our process ensures that needle clogging is not an issue. Additionally, the technique described in this invention does not need any massaging or tumbling to ensure even distribution or dispersion of any injected materials. More importantly it allows for the automatic plugging of any injection site preventing the exudation of the injected material to the outside.

Hunter (0S6692783) discloses the reason for poor performance or failure of prior art intended to introduce additives into meat in a pressurized manner and sumrnarises technology and processes that use variations of a barrel containing an elongated piston. The holes these devices generate remain unsealed when the device is withdrawn. This leaves a pathway for injected additives and meat juices to exude from and over the surface both after injection, as pressures equilibrate, and during cooking, when the meat juice volume expands.

One possible solution to the problem of exudation is disclosed by Rubinstein (Israeli patent 43297). He adds other components to the emulsion that bind it so that it does not exude as it cools.

However the process does not seal the injection sites so there will be exudation as the injected mixture expands on cooking. Additionally the process does not teach any process or formulation to enhance shelf-life nor reduce oxidation processes in the injected project while introducing the additive mixture through hollow needles. Hendricks (US5053237) also uses a binder, in this case methyl cellulose, to achieve a reduced level of exudation but the injection process is a high pressure, nozzle delivery approach which does not attempt to close the injection sites.

A further problem with injection techniques is highlighted by Kish (US Patent Application 0030224093). This teaches that conventional injection techniques result in pockets of fluids being formed rather than being evenly distributed and excess fluid can be removed by a combination of compressive pressure and surface penetration by fine solid needles. The methods described here do not result in the formation of any such undesired, localized concentrations of additives. Without such additional mechanical procedures to assist in dispersion, Olander (US 4957756) teaches the need for holding for up to 40 hours and at temperatures of +4 to +7 C to ensure adequate passive dispersal of injected pickle solution in pork bellies.

To improve fluid uptake, Townsend (US Patent Application 0040109923) discloses a variation to conventional injection technology utilizing needles with a roughened outer surface to create a generally larger hole than with a needle of constant external diameter. In addition, while inserted in the meat, the needles are vibrated to further widen the hole. It is claimed this improves total fluid intake during the injection cycle.

However my invention uses a different injection principle to achieve the necessary volume uptake. North (US3955490), while principally concerned with the mechanism of and ability to accurately control the amount of liquid injected into as meat product, also discloses that the approach can be used to inject precise amounts of flavourings into meat fowls. The current invention accurately measures product volume and determines status before calculating and dispensing optimum volumes for each injector and, because of its ability to individually control, does not rely on a fixed measured volume per cycle.

Gundlach et al (US Patent Application 0030044496) have attempted to further refine the process and improve the process economics by utilising compression as a method of recovering expensive brining solution and reducing production and financial losses due to brine exudation. However such recovered brine will likely have higher microbial counts than once only injected additive. My invention utilizes injected materials that exhibit a very low capability of exudation after injection and generate minimal excess in use and thus no need for recovery nor generate a financial loss.

Finally before we move on to reviewing prior art covering the area of control once injectates have been successfully introduced into meat, we need to look at two other aspects, namely the use of mechanical means to tenderize meat and automating and controlling the location, insertion and depth of insertion of mechanical devices and injectors into meat.

Most needle based injection systems use a method of indiscriminately driving the needles, with or without attached cutting knives or blades e.g. Langen (US Patent 4680832, 1986) Rocha and Daniel (US Patent 5035672, 1990) describe a toothed upper plate and plunger mechanism which allows the distance travelled by the upper plate to be adjusted. However, only the whole plate can be adjusted and to change the adjustment the system has to be stopped. The tapered sharpened outer surfaces of the cutting device in my invention make the severing of connective tissue more decisive and effective.

The injection devices detailed by Langen (1976 and 1986) and others have one common feature. The needles are mounted on a manifold and when the manifold is moved downward, all the needles move in a fixed fashion so as to impale the meat and push downward into the meat. However this indiscriminate action results in all tissues being equally cut or scored by the needles or attached blades. In this patent application, while all the needles will come in contact with the meat, only those selected needles will be further activated to push deeper into the meat. Likewise, needles not in contact with a meat surface are not activated. The decision making as to which needles are activated for further downward motion and/or an injection cycle is determined by use of either manual selection for a single needle or small manifold with 1-5 needles, or by image analysis for larger or more complex manifolds, thus imparting a substantial degree of control on the precision of both mechanical tenderisation and/or the application of injectate.

The foregoing are examples of the many problems associated JO with the various methodologies used to infuse or inject flavourings into meat and the further problems encountered in trying to evenly disperse those additions. Once the components have been successfully introduced into the meat, a whole series of new problems are encountered both trying to keep those additives within the meat and ensuring the additives achieve the functionality required of them without adversely changing any of the desirable physical or chemical characteristics already present in the meat. The following examples of prior art will illustrate some of these major problems.

It has long been identified that increasing the water activity (aw) of meat, while increasing the apparent juiciness of the meat by maintaining or improving water holding capacity, reduces meat keeping quality primarily through an over-softening of the muscle protein structure and its resultant accelerated tissue breakdown. It also generates an environment ideal for both microbial growth and the formation of undesirable oxidized flavour components. Examples of prior art which have attempted to alleviate or solve one or more of these problems and effects include}lardman et al (US5972408) which describes a process that substitutes part of the fat component in the sauce with water and reduces water activity to less than 0.95 with the addition of hurnectants such as sucrose, whey, glycerol, sorbitol, potassium phosphate, sodium chloride etc. The resultant sauce is then processed using continuous steam in a manner not to cause burning or degradation or product sticking to the heated surfaces. The current invention deliberately uses sauces and fillings with a higher rather than lower fat/oil content and does not require any form of cooking process to maintain or extend shelf-life.

Tsuji et al (US4851241) describes a process for treating meat through simple marination or injection with raw soy sauce tenderizing it preferentially through connective tissue breakdown rather than myofibrilar breakdown thus reducing the softening of the meat. However such a mixture usually has a pH value of between 4.0 and 5.5; such acidity would cause the precipitation of several specified sauce components. It would also taint the taste of many sauces especially those that are milk or cream based. The sauces and fillings developed in this invention are at a pH higher than that of the post rigor meat that is to receive them (i.e. greater than 5.5).

Ludwig (0S6730341) claims an improvement in water holding capacity through a combination of temperature elevation and massaging after injection of a treatment solution which may contain phosphates, nitrite, nitrate salt, flavour enhancers, proteins, fat binders or preservatives. The temperature of the meat is elevated within the range 45-60 F while the fluid is injected at a temperature slightly lower than the meat itself.

Little is mentioned of the microbial numbers that develop by holding or raising meat to these temperatures. My current invention utilises an elevated temperature significantly in excess of 60 F for the injectable sauce or filling but the meat receiving the injected sauce or filling is significantly cooler than these meat temperatures. Bailey et al (US 6680077) claim similar effects with specific starter cultures without additional phosphates. Thrasher et al (US Patent Application 0030203079) utilize the benefits of marination usually through contact and tumbling, cooking and maintaining within a low pH regimen, followed by cooking within a vacuum packed environment to enhance the keeping qualities of treated meat without freezing. The marinade itself contains some or all of the well known usual components known to meat science to enhance water holding, improve water binding and inhibit microbial growth.

It is also well known in meat science that reducing water activity to less than 0.9 will extended shelf life. Troller (1980) states that products with water activities be1ow 0.85 are essentially non-perishable as most spoilage and pathogenic organisms cannot grow under such conditions. A simple way to achieve this state in meat is to cook the product but for uncooked meat different approaches have to be adopted. In US 6726943, Priosise details products with a lowered water activity through the addition of other protein sources such as soy.

However these additions can impact the generation of off-flavours. Processes like Suspentec', Cozzini mc, Chicago IL and the technology disclosed by Norre in US 5142971 utilize complimentary animal proteins in very fine particulate form to increase overall protein content while attempting to minimize the generation of off-flavours but as they are suspended in a water base they do not lower water activity. Additionally, because they utilize materials generally classified as waste or reject, it is difficult for such material not to be in an enhanced oxidised state and/or have an elevated microbial count prior to injection. onagle (US Patent Application 0030232121) uses extracted protein in the form of a low viscosity, salt tolerant gel, dissolved in a typical meat brine and injected into meat pieces so that on cooking, and as a consequence of the resultant denaturation, it forms firm, sliceable meat-like pieces. An additional major problem with all such products is that they have to be considered meat products rather than meat under the labelling laws of most western countries.

Priosise (US 6726943) also states that use of fats improves the flavour of meat and if those fats are non-digestible then the rate of generation of off-flavours is reduced. A further problem of using fat is highlighted by the prior art of Haggerty (US4472448) . He discloses that the emulsification and stabilization of fat is necessary to minimize the problem of fat separation and fat/water dissociation in precooked or heat-processed foods containing meat in sauce and meat in gravyapplications. Prior art disclosed in US 3615689 utilises emulsifiers to stabilize a predominantly high fat to low water emulsion injected at a temperature of 25 C-43 C. However this process does not teach the incorporation any solid materials nor components to reduce oxidation. Other prior art solutions include fat skimming, fat replacement with oils, thickening agents such as starches, also fat absorbers such as flour or potato starch. Haggerty's solution is the use of a fat emulsifier and stabilizer such as soy protein. The current invention specifically uses sauces without the need to reduce the fat content, emulsify the fat components or necessarily stabilise them prior to injection or during any holding and/or cooking phase.

Olofsson et al (US Patent Application 0010016219) describe other problems associated with high water activity sauces in food mixtures and which raise basic problems with using sauces in general. High water content and high water activity sauces heat up rapidly and, if allowed to heat up too quickly, can separate changing in both consistency and flavour and thus human intervention and/or stirring action is needed to prevent this from happening by better dissipating the added heat especially to prevent boiling. The problem is even more acute with cream based sauces as they can irreparably curdle and separate.

Olofsson et al disclose a method of using frozen sauce pellets to enhance the heating rate of other food components such as meat and vegetables. By careful external placement of the pellets, they contend that the high water activity of the sauce results in the sauce heating faster than other components and then passing that heat by conduction to other components. The current invention specifically utilizes materials that evenly distribute the heat without the need for pelletising or the need to be specifically located relative to other food components thus permitting the use of component materials capable of separation and/or change if excessively heated but does so in a manner that prevents such occurrences.

One further major practical problem of high moisture content materials in a complex foodstuff is described in US Patent 6503546, that of rapid moisture migration between different components detrimentally changing the physical state of one by the undesirable actions of the other. They describe a method of preventing excessive moisture within a filling from penetrating the pastry layers of a product so as to induce a crisp external layer on rapid cooking. They further disclose that increasing the moisture content of the filling, i.e. increasing the overall water activity of the filling, slows down the rate of cooking of the filling, while the fat/oil barrier allows the pastry layer to more rapidly brown and crisp. Similar approaches are disclosed in prior art relating to filled product as diverse as chocolate and doughnuts. However, this approach is completely opposite to the current invention which requires the injected or filled product to cook at an accelerated rate and is modified accordingly to achieve this.

Preferred embodiments of the invention may comprise one or more of the following elements, each of which may be used independently of, or in conjunction with any other element.

Combination of all the elements produces product of the highest quality and synergistic interactions with regard to keeping quality and microbial load. Preferred embodiments of the present invention will enable one or more of the following to be achieved.

1) A method of formulating and preparing injectates, which may be any combination of sauces, 10 liquid or semi-solid fillings, gels, tenderizing agents, nutritional additives, medication and other flowable materials, for controlled, direct injection into meat, meat pieces and meat products.

ii) A method as in i) but without the necessity for hollow needles to provide a guide and/or method of internal access for the injectate.

iii) A method of controlling the degree of penetration of the injection device and introducing such injectates in a manner that optimizes their effect.

iv) A method of identifying suitable sites for mechanical action and/or physical application of cutting devices and/or injectates and controlling the activation of each individually based on a decision making process.

v) A method of adapting said injectates so as to maintain or improve the properties of the injectate during storage and/or cooking.

vi) A method of adapting said injectates o as to maintain or improve the eating quality and properties of the injected product, especially but not limited to, meat tenderness, meat texture, flavour and juiciness.

IS vii) A method of adapting said injectates so as to maintain or improve the keeping properties of injected product especially by, but not limited to, reducing water activity, reducing microbial load, reducing or minimising the formation of oxidation products.

viii) A method of adapting said injectates so as to enhance the rate of heating when placed within the meat product without causing denaturation, precipitation or deterioration of the said sauces.

ix) A method of adapting said sauces and fillings so as to enhance both the rate of heating and the ability to better retain that heat when placed within the meat product making such injected products suitable for fast food applications without the need for additional heat enhancing, heat distribution or heat retention technology.

x) A method of modifying the composition of the injectate so as to specifically improve the nutritional content of and/or add specific medication at a defined concentration to a single portion to meet those specifically required for an individual such as a single hospital or care home patient or elderly person.

xi) A method of modifying the composition of the injectate added to a single portion so as to meet the specific physical textural requirements of an individual such as a single hospital or care home patient or elderly person.

xii) A method of injecting said injectates directly into meat, meat pieces and meat products and plugging the injection sites with meat on completion of the injection cycle, preventing exudation of 15 injectate from its injection sites.

Detailed Description of the Invention

It is stated at the outset that while the examples detailed are specifically for application to meat or meat pieces, it is obvious to anyone skilled in the art that simple modifications to any of the apparatus, process and/or formulae will allow the principles disclosed here to be used for almost any suitable foodstuff requiring an injectate and/or a mechanical tenderization. I will now describe the principles of the invention and the embodiments by means of which they are achieved.

In conventional culinary processes, sauces generally fall into two basic categories, thin sauces which mix and permeate with foodstuffs and thick sauces which tend to coat and cling to the surfaces over which they are poured. However sauces for injection need to be relatively thin so they can both flow into the injection site with minimal pressure or force so as to limit damage to the internal structures, allow for a rapid process cycle and diffuse through and into the meat or food structures.

Yet ideally they need to thicken both after injection with cooling and/or refrigerated storage to prevent or minimize diffusion to the extent required, and on cooking, to both adhere to the surfaces without denaturation nor exude to make the exposed food surface either tacky or wet to the touch for ease S of dispensing or serving.

In addition, the sauce needs to have properties such that it will not heat so rapidly that it boils, denatures or in any physical way deteriorates so that the need for any manual intervention in controlling the cooking process is avoided.

It is therefore a preferred embodiment to this patent that the sauce contains one or more components that thicken when cold (cold in this application is defined as any temperature at or below 25 C but not lower than -2 C) and yet assume properties that increase flow capabilities when above these temperatures.

Components with these properties include but not limited to animal gelatin, Carragheenan (vegetable gelatin), medium length chain animal and vegetable fats including lard, beef suet, butter, margarine, stearic acid, etc. It is a further embodiment of this patent that in the preparation of the sauces, where components are not water soluble or miscible, they are dissolved in lipid carriers with which they are miscible so as to improve the flow characteristics of the resultant mixture. Examples include but are not limited to edible oils which preferentially have minimal flavour, such as olive oil, sunflower and safflower oil and canola oil. These oils may be used singly or as a blend.

After injection into the refrigerated meat cuts, joints or pieces, the sauce cools and the flow capabilities of the sauce become significantly reduced. Similarly, when the product is JO cooked, the liquid volume will expand and, if the injected volume is large relative to the meat volume, is likely to ooze or weep from the multiple injection sites. In some circumstances this is an undesirable product characteristic and needs to be minimized or eliminated.

It is a further embodiment of this patent that the sauce mixtures when heated to cooked meat temperatures (cooked meat temperatures are defined as any temperature above which the physical state of the product significantly changes such that the product cannot be considered raw. For meat this is generally considered to be around 60 C), contains one or more components which rethickeri the sauce such that the flow characteristics are considerably reduced compared with its flow characteristics when above 25 C but below 60 C. Components with these properties include but are not limited to alginate, soluble food starches and flour extracts such as potato starch, wheat flour, cornflower, edible gums, and protein compounds such as milk protein, potato protein, egg albumin, egg yolk, etc. It is a further aspect to this patent to use larger diameter, insoluble solid particle components in these formulations both in sauce and in filling formats (for the purpose of definition and clarification, fillings contain solid and semi-solid components of a larger diameter than found in sauce formulations and require larger diameter needles to permit their transfer and larger diameter cavities to contain them) . To enable this to be carried out satisfactorily in a production environment, these components need to be evenly distributed within the sauce or filling formulation. It is therefore a further embodiment of this patent to utilize one or more liquid components (or at least liquid at injection temperatures) that have a density during the injection phase sufficiently high to retain the solid components of the formulation in a substantially suspended state. Components with these characteristics include but are not limited to corn syrup, sucrose or other sugars in solution, edible animal and vegetable fats and oils, edible gums, glycerin.

There are a number of sauce properties that can be affected by fresh or frozen storage. These include but are not limited to, denaturation, precipitation, oxidation, microbial degradation, change or loss of flavour profile, change or loss of aroma profile. It is a further aspect of this patent that I have found that the combination of formulation components and process specification described in this application can used to minimize or eliminate one or more of the above listed storage problems. I0

Flavour and aroma components can be either predominantly water soluble or fat soluble. Fat soluble flavour and aroma compounds are often commercially available as an oleoresin concentrate but they tend to be expensive. Much lower cost and more cost effective variants are also available. However these are water soluble and tend to rapidly lose their flavour and aroma intensity through oxidation and/or hydrolysis. We have found that aroma or flavour compounds that are principally water soluble can be better preserved by suspending in non aqueous solvents or dissolving in concentrated sugar solution or sugar syrup and then immobilizing them with a compound of lower water activity.

It is therefore an embodiment to this patent that water soluble flavour and aroma compounds are initially dissolved in the concentrated sugar solution or sugar syrup and then immediately mixed with any suitable compound to effectively eliminate sources of oxidation and/or hydrolysis. However the selection of such compounds is limited because of the need to assume the required flow characteristics during the injection phase. Components with these properties include but not limited to animal gelatin, agar, carragheenan (vegetable gelatin), medium chain length animal and vegetable fats including lard, beef suet, butter, milk, cream, margarine, stearic acid, etc. In a preferred embodiment, that compound is animal or vegetable fat or oil.

It is a further embodiment that to further minimize the oxidation and/or hydrolytic activity such flavour/aroma compounds mixed with animal or vegetable fat or oil contain a small amount of a suitable emulsifying compound to stabilize the formed emulsion. In a preferred embodiment that compound is lecithin for strongly water soluble aroma and/or flavour compounds and animal or vegetable fat or oil for poorly water soluble or water insoluble aroma and/or flavour compounds, added to achieve a water activity (aw) value less than 0.89 and ideally 0.85.

It is well known to those skilled in the art that eating quality is the cumulative effect of three meat properties, namely meat texture, flavour juiciness. Meat texture, specifically tenderness is a consequence of the magnitude of three different reactions namely the amount and degree of solubility of the connective tissue, the degree of contraction of muscle fibres at and after death and the degree of proteolysis within the inyofibrilar proteins between slaughter and consumption.

Flavour is a very complex series of chemical reactions but primarily derived from the volatile aroma compounds during cooking and interactions between proteins and protein breakdown products and carbohydrates, especially sugars and to a lesser degree fats. Juiciness is a combination effect derived from the ability of the meat to retain its natural liquids, predominantly water (water holding capacity) and its ability to retain any extraneous liquids added to it (water binding capacity) especially during and after any cooking period. Because of the very specific property requirements of the formulations for injection, it is not possible to utilize any of the well known components such as tenderizing enzymes and low pH marinades for tenderness; water based marinades, salt, and/or phosphates for juiciness or water based herbs, spices or flavourings for enhanced flavour, in a conventional manner as these are all predominantly water soluble and will increase the water activity of the overall mixture.

However, we have found that inducing a small increase in muscle proteolysis combined with an increase in soluble lipid will significantly increase tenderness, flavour and juiciness.

In a further embodiment to this patent, meat proteins and natural fat (derived from the same species as the meat) and sodium chloride and sodium phosphate (added both as solids) are finely blended together and added to the chosen injection or filling formulation in a inacerated or homogenized form (depending on maximum particle size requirements), immediately prior to injection. In a preferred embodiment the homogenized mixture as detailed is adjusted (by modifying the ratios of the components but without the addition of any additional acid or alkali), to be as close to the iso-electric point of the chosen meat species, i.e. pH 6.4 for poultry and pH 6.2 for pork).

It is well known to those skilled in the art that the keeping quality of a product is predominantly a combination of the effects of the temperature at which the product is stored before use, the atmosphere in which the product is stored, the effects of water activity, particularly hydrolysis, on the various components, initial microbial load and its rate of increase, and the initial level of oxidation products and their rate of increase. Methods to control the deleterious effects of high water activity have already been addressed by earlier embodiments to this patent.

One of the major causes of reduced keeping quality with injected products is the level of surface microbial contamination. The injection process not only forces contaminated meat into the non-contaminated sub-surface, it also causes needles to become contaminated and they and the contaminated meat become excellent sources of further contamination. Additionally, if excess injected material Is recovered and recycled, a common practice in commercially marination processes, this further increases overall microbial numbers.

It is therefore a further embodiment of this patent that the injection process is carried out in an essentially aseptic atmosphere and the meat (or foodstuff) to be injected is itself essentially free of surface microbial contamination. This is achieved by exposing the foodstuff to a level of IN-C sufficient to achieve acceptable minimal surface microbial contamination level. Alternatively, a mixture of nv wavelengths including UV-B, C and A can be used. In addition, this decontamination step is undertaken in an inert atmosphere so as to limit any tJV induced oxidation. Such at atmosphere can be any suitable mixture of nitrogen and/or carbon dioxide. Preferentially it is 100% carbon dioxide. In a further embodiment, if the product is not to be stored in a frozen state, it is preferentially packaged within the same atmosphere in which it is treated and stored at a temperature preferentially between +1 C and -2 C. I0

It has been further discovered that adding oxidation prevention measures to the sauce recipes themselves significantly reduces the rate of increase of oxidation products within the injected product, either from the injected product or from the sauce or filling injected.

It is a further embodiment to this patent that the sauce or filling mixes be essentially deaerated at any suitable step in their manufacturing but certainly prior to injection.

It is also a further embodiment to this patent that anti-oxidants be added as necessary to the sauce or filling mixture prior to injection. These can be any of the compounds known to impart such protection such as BHA, BHT, Vitamin A, Vitamin C, Vitamin E, or natural anti-oxidants including herbs such as Rosemary, Thyme or Oregano and/or spices such as peppers or onions!! In a preferred embodiment, the preferred compound is Vitamin E dissolved in oil at a level of between 100mg and 2000mg per Kg of finished product.

Table 1

Effect of Sauce Formulation and Injection Environment on Product shelf life Product -Beef steak Not Injected Not Injected Injected Injected No exposure to Exposure to No Exposure to Exposure to UVorCO2 UV+C02 UV+C02 UV+C02 8.2 days 12.8 days 11.9 days 17.4 days Days to i. * i6 total plate counts Storage conditions -overwrapped in trays at +4 C in the dark.

The rate at which products heat or cool is a function of its rate of heat transfer. If the rate of energy input to a product exceeds its maximum rate of heat transfer then the outside of the product heats or cools at a faster rate than its internal surfaces. Where the product is essentially composed of a single component such as lean meat, that rate is totally predictable dependent upon the energy source, the energy level and its duration. Such a constraint limits the use of thick pieces or chunks of meat in fast food applications where meat, if it is used as a major component, is cut so as to present a very large surface area to the heat source, usually either as very thin slices or small chunks.

It is therefore a further aspect of this invention that we have found that injecting the formulated sauces and fillings described in this patent into solid pieces of meat in very defined patterns, can substantially improve the rate of heating and the evenness of the distribution of that heat, reduce the overall heating time to cook the meat and the refrigeration time to cool the meat.

Following injection and cooling of the injected material, and unlike water based marinades and curing solutions which distribute themselves initially through the application of pressure and subsequently through diffusion, the material injected forms solid or semi-solid thin columns within the meat in defined patterns and at defined distances as determined by the injection process and equipment. When energy is applied to the meat, these columns act as cores along and through which heat travels at a much faster rate than through meat alone. This results in a rapid and even distribution of the heat throughout the meat piece. The product acts in a similar manner when refrigeration is applied resulting in a more rapid and even cooling. To demonstrate the heating properties, beef fillet steaks, with and without injections, were heated in a conventional convection oven at 220 C.

Size of steaks = 8cm x 6cm x 4cm; weight of Steaks 207g, 237g with injection.

The injections were in a grid pattern, with 1.5cm between centres.

Temperatures were measured periodically, (a) 5mm below the surface and (b) 20mm below the surface, i.e. in the centre. The results are shown in Table 2.

Table 2

Non-Injected Injected Time (a) (b) (a) (b) 1 mm 41 C 9 C 52 C 19 C 3 mm 72 C 16 C 98 C 36 C mm 112 C 24 C 134 C 49 C 7 mm 153 C 31 C 178 C 62 C 9 mm 177 C 39 C 201 C 73 C 11 mm 194 C 49 C 221 C 80 C 13 mm 211 C 58 C 229 C 85 C It is therefore a preferred embodiment to this patent that the composition of the injected sauces and fillings contain materials that accelerate the transfer of energy into and within the injected foodstuffs, in a manner which enhances the rate at which the product cooks or cools and makes that heat distribution more even than can be achieved by non injected product or products injected with conventional marinades or cures. The preferred materials are animal and vegetable fats and oils in defined proportions with gelatin or other homogenized proteins.

Of equal importance is the manner in which we find ourselves able to control the rate of temperature increase at which the sauce heats and thus eliminating the problem of denaturation, precipitation or decomposition of the sauce due to a rapid temperature rise and an uncontrolled heat induced reaction.

It is therefore a preferred embodiment of this patent that the formulation of the sauce or filling is controlled so that the heating rate of the sauce or filling is optimized to match the required cooking conditions of the treated foodstuff but still further controlled so as to prevent any unplanned denaturation, precipitation or decomposition of the sauce, eliminating the need for intervention in the cooking process.

The preferred materials are animal and vegetable fats and oils in defined proportions in the presence of gelatine or other homogenized proteins.

There are many reasons why hospitals, health care practices, nursing homes and similar establishments rarely have meat on the menu. To many the cost of meat protein is too high for regular inclusion on the menu and when it does appear it is poor quality or cheap cuts, e.g. minced/ground meat or meat leaf. However, apart from cost, textural properties and/or special dietary needs have a major effect.

Many elderly people or ill patients find meat difficult to chew, many also find it unpalatable. It also induces digestive problems, especially constipation, in inactive elderly recipients. And finally, many patients of this type require dietary modification and/or supplementation and/or medication; the latter often being difficult to take in tablet or solid form.

Later quoted examples show how the technology and approach covered in this application address many of these issues.

Example 1 addresses both the cost issue and the chewing tO issue by showing how to tenderize cheaper cuts and tougher cuts both in bulk manufacture or as a specific product.

Examples 2 and 3 additionally help make the meat softer and more chewable as well as the ability to change the taste of the meat on a mass production basis or as a specific one-off' menu item for a single patient.

Integrated with all these examples is the ability to use the injection process to supplement the food of these special needs patients. Example 4 is a simple one, supplementing the Calcium needs of an elderly patient suffering from two common but related ailments, a loss of muscle mass and muscle strength and accelerated Calcium solubilisation (osteoporosis), additionally the person is lactose intolerant so milk/dairy is not a suitable source. However, it is obvious to anyone skilled in the art that the principle can easily be adapted to virtually any drug, supplement or additive combination suitable for ingestion in this manner.

While the formulations and the process described allow all of the described embodiments to take place, none can occur without the ability to inject the sauces and/or fillings into the meat or other foodstuff in the desired volume within the required timescale. l0

Conventional injection systems are not practical as they do not allow for the holes generated by the needles to be closed off without additional processes such as massaging or tumbling to occur. If the holes are not closed after the completion of the injection process then back pressure generated by the injection process will cause the injected material to exude from the holes. In a further embodiment, the injection process includes a mechanism that allows the injection hole to be sealed once the appropriate amount of sauce or filling has been injected. In a preferred embodiment, the sealing is accomplished with a plug of the same foodstuff that is injected.

Additionally, conventional injection processes rely on the application of high pressure to force the injected materials in the form of a marinade or a cure into the matrix of the meat between and/or along the muscle bundles resulting in physical damage to the internal structures of the foodstuff. In a preferred embodiment, the low pressure injection process uses only sufficient pressure to discharge the required volume of sauce or filling for each injection cycle. Also, conventional injection techniques use very narrow diameter needles making it difficult if not impossible to inject viscous and/or particulate materials. In a preferred embodiment, the material to be injected is not injected through hollow needles nor by pressure jets but by means of sleeves around the needles, such an arrangement allows much larger particle materials to be injected than can be achieved through a hollow needle with the same external diameter. In a further preferred embodiment, whenever practical and when a mechanical tenderisation step is not required, the injection hole is created parallel to the meat fibres.

A novel method has had to be developed which overcomes all of these problems and restrictions and the technology and its mode of application will now be described. For the purposes of clarity, the sequencing for a single needle will be outlined.

However, for anyone skilled in the art it will be understood that this sequence can be used singly or in unlimited multiples and/or unlimited configurations to achieve different volumes, injection patterns and the ability to control the rate at which the treated foodstuffs of varying thickness will cook or cool.

The detailed structure of a single needle assembly is shown in Figure 2. Again it should be obvious to anyone skilled in the art that components may be varied or substituted to achieve the same performance. For example, the mechanical springs 300 and 310 could be replaced with hydraulic or gas operated valves.

In the rest position, the solid needle (110), hollow needle shroud(114) and guide (120) are fully retracted above the surface of the foodstuff, e.g. cuts of meat (240) to be injected (Fig la). Prior to commencement of operations, the thickness of the foodstuff is either manually (visual inspection and measurement) or automatically (for example by image analysis or IS by weight) assessed. From this data, the overall distance the whole assembly moves is predetermined, as are the individual distances of the needle and the guide. The edges of the guide (125) are both tapered (narrowest at the distal end) and concave shaped to produce a cutting surface. Also predetermined for each product (either manually by the user or automatically by the system) is the diameter of the needle (110), the external diameter of the needle protrusions (112) and the diameter of the guide (120). These physical system parameters are principally controlled by the volume of injectate to be injected, the absence or presence of particulates in the injectate, and the size of the meat plug required to seal the hole formed by the injection operation.

In a first motion (Fig ib) the solid needle (110) moves downwards a predetermined distance, to the initial penetration position. This is achieved by applying pressure to the top plate (400) situated at the proximal end of the needle shroud (114) which partially compresses the attendant spring (300). This causes the needle tip (118) to penetrate the surface. In a second motion (Fig ic) pressure is applied to plate (410) which fully compresses spring (310) and sealing washer (450) against fixed plate (420). This causes the cutting guide (120) to also break through the surface of the foodstuff.

The needle forms a small hole while the guide cuts a small plug (220) that moves up into the tapered inner surface of the guide. This plug although now separate from the rest of the meat in the XY planes remains intact in the Z or thickness plane except when the external diameter of the needle protrusions (112) closely matches that of the guide internal diameter. In such circumstances, the spiral motion of the protrusions will often additionally separate the meat plug (220) in the thickness plane from the meat piece (240).

In a third downward motion, caused by further pressure applied to the plate (400), the guide (120) remains stationary but the needle (110) and the shank to needle shroud (113) continue downward in a spiral motion as it passes through the fixed coarse threaded cam (210) . The distance travelled is predetermined by the product type and thickness and controlled by the preset stop (350). Protrusions (112) located along the long axis of the needle at defined intervals form a spiral such that as the needle moves downwards it also rotates. This causes the initial hole (140) made by the needle tip to become widened. The overall shape of the protrusions is not critical.

However it has been found by trial and error that the more rounded the surface the better the hole forming capability.

However the undersurface of the protrusions needs to be relative flat so that it makes good contact with the coarse threads on the cain, both of these features are included as embodiments to this patent. The amount of rotation imparted is just sufficient to widen all surfaces of the initial hole created by the needle tip. The more protrusions on the needle, the less the total rotation needed. However more protrusions cause greater resistance when the needle is withdrawn.

In a preferred embodiment, rotation is limited to between i and li per injection cycle.

At the end of its predetermined travel, the needle stops and as much pressure as is necessary is applied to force the sauce or filling (230) from its reservoir (130) along the needle shroud long axis and exits at its slightly concave distal end into the preformed hole (Fig ld). The pressure is applied for a predetermined amount of time to ensure the required volume is injected. The total pressure required is dependant upon a number of physical parameters of which the primary factors are the iniectate viscosity, the presence and size of any particulates in the injectate and the total injected volume required. In a preferred embodiment the ideal range is 20 - 45psi. The time taken from the start of the needle's rotation to the completion of the fill is sufficiently short that the muscle fibres that have been laterally displaced by the needle protrusions (112) do not have time to recover and return to their original position. This ensures sufficient hole volume into which the injectate can be deposited.

We have found that the diameter of the needle shaft (110) can be quite narrow, ideally between 1mm and 3mm, preferably l.5mrn-2.Omni. The diameter of the needle together with its protrusions can be between 3mm and 12mm and the diameter of the barrel (114) of the needle shroud that will deliver the additive between 4mm and 14mm. However in applications that use sauces with no large solid particles, the preferred overall diameter is 3mm -6mm with the needle shroud internal diameter of similar size. Where large particles are used in filling applications, the diameter of the needle and its protrusions needs to be 4x the maximum particle size, e.g. if the maximum particle size is 2mm, the diameter of the needle plus protrusions needs to be 8mm; this will lower the required injection pressure and eliminate blockages. For ease of assembly and replacement, the distal end of the needle shroud shank (113) screws into the proximal end of the needle shroud barrel (114). A shear pin (117) located through the distal end of the needle (110) fits into a milled slot (100) located near the proximal end of the needle shroud (114) . The separate tapered end of the needle shroud (111) screws on to the proximal end of the shroud, locking the needle shear pin (117) in place and sealing the exposed slot (100) The needle is then withdrawn from the now filled hole in with a controlled reverse rotation by the release of pressure on plate 400 and the action of the compression spring (300) . The presence of the meat plug (220) within the inner surface of the guide (120) and the slow rotation speed of the needle, both preferred embodiments to this patent, prevent the sauce or filling from being withdrawn from the hole as the needle and shroud are retracted. It is allowed to travel to its fully rested position above the base of the meat plug (Fig le) Sufficient air pressure is then applied to the guide via an inlet at its proximal end (500) to blow the meat plug (220) out from the internal surfaces of the guide (125) back into the hole (140). The typical range is 60-l5Opsi with 75-90psi being the preferred values. The guide is allowed to return to its rest position by releasing pressure on plate (410) and the action of compression spring (310) and the cycle can repeat. Plates 400, 410, 420 are common surfaces which action all needles, needle shrouds and guides attached to them. However, it should be further appreciated that the common surfaces can be attached to needle banks of 1-20 needles, thus providing significant independent operational flexible to individual needles as necessary.

In a preferred embodiment to this patent, the shape of the needle tip/blade (118) can be changed to suit operational requirements. Where the injection device is to be used solely for the purpose of mechanical tenderisation, a needle tip of the type (119) shown in Fig 2a can be used. This replaces the solid needle tip with one that has an extended bicuspid cutting surface. This ensures that any material that is trapped between the fingers of the blade is subjected to a positive cutting motion in the downward travel of the needle rather than the incision and displacement effect of the standard needle tip.

This will have the effect of cutting connective tissue, tendon and other tough components into much smaller lengths and exposing the cuts surfaces to chemical and/or physical action during holding and cooking. When a combination of mechanical and chemical tenderisation is required, a combination of needle types should be used.

However, cutting needle tips (119) cannot be easily rotated because of the volume of material trapped between the cusps. In a further embodiment, the vertical distance travelled by the needle shaft can be still be controlled by pressure to plate (400) but the 2 piece coarse threaded cam (210) can be withdrawn by unscrewing end stop (350) and replaced with an unthreaded cam (211) . Fig 2c. shows a further embodiment for preferable use with the hand held unit. The auxiliary blades (117) swing out as the body of the injector is rotated turn. This creates the cavity for the injectate with minimal motion. In addition, in this configuration the needle shaft (110) is devoid of protrusions as the auxiliary blades (117) accomplish the same function.

It is a preferred embodiment that where the injectate is not a filling, each plate is flat so that holes are created parallel with each other. However in a further embodiment in applications where the injectate is a filling, these plates are concave So that while each needle has an equal pressure applied to it, such pressure can be applied in a manner that allows the distal end of each formed hole to be concentrated around a single focus resulting in a concentration of filling at this point.

In some applications, there is a requirement for the formed holes not to be sealed. In such cases, and in a further embodiment, the inner diameter of the tapered guide is reduced so that it closely matches but always exceeds the outer diameter of the protrusions on the needle by at least 0.25mm. This ensures that while the cutting motion can still occur, there is no room for a plug to be formed, only the hole formed by the downward and rotational movement of the needle.

For most applications, and as an embodiment to this patent, spacings between needles of 10mm and 25mm are practical and effective. However in a preferred embodiment, spacings between adjacent needles of 18mm by 18mm have proven optimally efficient. With each injection cycle taking approximately 2 seconds, a bank of needles numbering 3 long and 14 wide (covering 60mm * 250mm of product per cycle) will process approximately llOOKgs (or 25001bs) of product per hour and allow for up to 15% -20% w/w of injectate addition to the product during the injection process.

In a preferred embodiment, It has also been found that with JO tapered product such as chicken breasts, to apply pressure by means of a roller or similar mechanism immediately prior to injection will minimize variation in product thickness during the injection cycle.

We have also discovered that when using the process for injectates that are fillings, while changing the needle configuration so that the formed holes appear to radiate from a focal point can generate the necessary concentration of filling, in a preferred embodiment wherever practical, holes are formed parallel with the meat fibres rather than perpendicular to them.

This allows larger diameter needles to be used to further displace the meat fibres without causing mechanical destruction, creating larger holes that, in turn, allow fillings with larger particulates to be included in the filling formulation and a larger volume of such fillings to be injected. The injection orientation of this preferred embodiment also has substantial benefit when the injectate contains a tenderizing solution. We have shown that introducing the injectate parallel to rather than perpendicular to muscle fibres and/or connective tissue significantly improved both rate of diffusion and total diffusion area/volume.

All of the preceding description of the invention has described the function of a single needle within a multiple needle arrangement and the process involved in a single operational cycle. It has also concentrated on an equipment set-up manually configured. Two further variants are now described and included as embodiments to this patent, namely automated control of the multiple needle configuration and a hand-held manually operated arrangement.

For a fully automated operation, the device needs to be told specifically what type of meat or foodstuff is being presented, where the meat or foodstuff is located on the production conveyor and what operation needs to happen for each piece or area of product? Other refinements such as individual product thickness could be added but in a typical operation, simple product levelling devices can ensure an even distribution of material at a uniform thickness.

The location of meat or foodstuff on a conveyor can be achieved by many means including visual light, ultrasound, IR reflectance, etc. However the preferred method is Video image analysis (VIA) which can effectively used in two ways. Firstly, with visible or structured light, the location of the meat can be determined and knowledge of the conveyor speed will allow that image information to be used to locate individual structures. Secondly, using Ultra violet illumination, particularly in the UV-B range and specifically blacklight blue' lamps, will cause both fat and connective tissue to fluoresce, connective tissue a steel blue colour and fat, bright white.

For effective injection of any injectate, injection into fat should be avoided. For mechanical and/or chemical tenderisation, connective tissue needs to be specifically targeted.

Conventional mechanical techniques use knives or needles to penetrate the surface of the meat cut and cut through, damage or perforate meat structures likely to cause toughness, primarily connective tissues over, on and within the meat piece but also to some degree, to mature muscle protein structure8. It is also used to prevent toughness during cooking such as through shrinkage of the connective tissue structures surrounding the meat piece. However these conventional techniques are purely random and uncontrolled and lead to damage to tissues such as muscle proteins, producing cell content loss, protein loss and reduced meat quality properties.

Similarly, conventional injection tenderizing techniques are similarly random. Most injected enzyme and/or additive mixtures are relatively non specific so they attack structures that need little or no tenderisation with the same level of activity as the structures that do need tenderizing. The use of the technology described in this patent allows for very specific targeting of both mechanical damage and tenderisation solutions.

The muscle and connective tissue locations of most meat animals are well known and well defined. Obviously with this knowledge it is possible for a single needle device to be used so as to specifically locate the most needed or suitable areas.

Where a commercial injection manifold is used, the footprint of that manifold can be modified so as to optimally suit the product to be injected. This may be through manual control and/or product orientation. Additionally it may be through automation. Through manual control or the use of some method of surface analysis, such as Video Image Analysis (VIA) it will be possible to automatically recognize the orientation and rotation of the product piece. This information can be used to either control which of the injectors are activated and pushed into the piece and/or the depth to which each is driven into the meat cut and/or the volume of injectate that is applied to the piece. In this way, a superior and optimized mechanism for tenderizing is achieved which is piece specific.

Using the results of the VIA, the specific actions of individual injectors can be controlled. The pressure applied to drive plates 400 and 410 can be controlled in both intensity and duration. This provides precise individual control on the activation of each needle device, the depth of its penetration IS and the rate of rotation while automatic in-line valves located between the injectate reservoir (130) and the shank to needle shroud (113) as well as at the shroud inlet (500) control the discharge of the injectate, the volume discharged and the repositioning of the meat plug. VIA data and/or a lack of positive pressure is used to cancel any action on injectors that have no product under them. Activation and deactivation of a cycle or part of any cycle can be through electrical, hydraulic or mechanical means. To anyone skilled in the art, the principles and requirement are fully defined but may be achieved by variants to the described process.

The commercial multiple needle units described function as a consequence of centrally available services and/or components such as a central reservoir for the injectate or a central gas or hydraulic line to provide pressure. For a hand held single injection device to be fully functional requires all the necessary components and the means to operate those components to be present and functional within or upon the unit. The JO following embodiment describes the necessary modifications undertaken to produce such a fully functional hand held unit (Figure 4) . Unless otherwise stated construction, configuration and mode of action are generally as previously stated.

The device is held in a vertical position over the meat piece using adjustable hand grip (570). The injection sequence is initiated by applying pressure to trigger (550) . This causes food grade, oil free, compressed air or Carbon Dioxide or other suitable gas to be released from the gas cylinder (520) through the Schrader type valve (540) screwed into the fixed plate (560) causing the plate (300) to move downward. All other actions remain as previously described until plate 410 is fully pressed against fixed plate 420. In the commercial version, the necessary rotation is achieve by the downward movement of the needle shaft passing through the coarse thread (210). In another version of the hand held unit, the downward pressure and/or necessary rotation can be achieved using the appropriate hand motions in place of the gas pressure for the downward motion or the coarse thread for the rotation. Plate 420 is located and fixed as previously described but is tubular rather than solid to provide an inlet on its lower surface (500) for the injectate and then for compressed air. Additionally, to reduce the amount of revolution to no more than of a turn, a modified blade can be used. In addition to the normal blade, it has two smaller additional folded blades (117). These are folded back against the main blade (118) as the blade penetrates the meat. However as the injector is given a clockwise iturn, they open out and make the cavity for the sauce previously accomplished by the protrusions (112). Other blade types may also be used as needed.

Once moving plate 410 presses against fixed plate 420 contact is made with stud (430) which completes a low voltage (1.5v) circuit causing current to flow to valve (530) which opens allowing causes food grade, oil free, compressed air or Carbon Dioxide or other suitable gas to be released from the gas cylinder (520) through the Schrader type valve (530) screwed into the fixed plate (532) causing the plate (545) to move downward. The reservoir of injectate is contained within a flexible refillable container (130) or a replaceable ampoule (132) and is displaced from the base of the reservoir to the top of the needle (110) via the tubular chamber within fixed plate 420 and the now fixed needle shroud 114. This displacement continues until moving plate (545) contacts the preset stop (565). The gas continues to be released and when the pressure inside chamber (510) reaches a suitable pressure, preferably between 85-lOOpsi, Schrader type valve (535) opens and the release of high pressure gas into the cutting guide (120) through the chamber in fixed plate (420) . This in turn blows the meat plug (220) back into its originating hole (140) . At this point the combined effect of the release of the pressurized gas causes valve (535) to close and the release of the fully compressed spring (310) breaks the contact at stud (430) and valve (530) closes.

As previously described, we have found that operating the injection process within an atmosphere of inert gas, preferably mixtures of Nitrogen and Carbon Dioxide, and more preferably Carbon Dioxide alone, with or without the use of narrow range UV-C or broader range rJV-B & UV-C, will result in significantly lower contamination of injected product and injection equipment.

Therefore, in an embodiment to this patent, wherever practical, injetion operations are carried in the presence of one or the other. In a preferred embodiment, both inert gases and UV are incorporated into the operating environment in which the injection procedures are carried out.

Finally, we will demonstrate some of the claims of this patent with four examples. The first is the use of the device as a mechanical tenderizer or a combined mechanical tenderizer and chemical tenderizing injectate. The second is using the device to inject a prepared particulate injectate into a chicken breast; the third is using the device to inject a filling into a beef steak and finally, the preparation and use of the device to add a combined nutritional supplement and medication to a meat portion.

Example 1 As a mechanism for mechanical and/or chemical tenderising cuts of meat Slices of pork shoulder, approximately l4cms * 9cms * 2 cms weighing approximately 260 grams are randomly placed flat on a conveyor belt. They are illuminated by tJV-A light (such as a black light blue) and pass under a camera. This causes the connective tissue to fluoresce and the attached imaging system identifies the orientation of the cut, its'XY location on the conveyor and the location of the connective tissue on the exposed surface structures; it may also make use of a database of information which contains further information on the location of such structures sub-surface. This information is passed to the controller of the injector manifold and at the appropriate time the valve (540) controlling the air or liquid pressure to each injector is activated or not so as to achieve a selected and controlled activation of each valve and the depth to which it penetrates each meat piece. Where only mechanical action is needed using the bicuspid blade (119), only those injectors are preferentially activated. Where mechanical and chemical tenderisation is required, additionally, the valves (530 and 535) controlling the flow and duration of flcw of any injectate is similarly controlled based on the supplied or calculated information. This provides a very specific mode and level of action through a controlled combination of physical damage through mechanical injection and chemical degradation through a precise injection of tenderizing enzyme or additives.

Example 2

Chicken Breast with a cream and mushroom sauce.

The solid components of the sauce, sliced mushroom, onion, tomato and herbs, having been previously softened by heating in a pan with butter, chicken fat and olive p11, are then macerated to a very fine suspension and while still warm (at or near 55 C) are then further mixed with the remainder of the warmed butter, cream, dissolved gelatine (to a final volume of 5% of the total 35sauce) and Vitamin E dissolved in l0-20m1 of the olive oil to a final concentration of 300mg/Kg finished product.

The final temperature of the sauce 15 between 45 C - 50 C which is sufficient to keep all the components in a free flowing liquid form) but not above 55 C. The sauce is loaded JO into the temperature insulated reservoir of the needle injectors which itself has been pre-warmed to a similar temperature with circulating warm water.

Chilled chicken breasts (at 6 C) from broiler fowl (each breast trimmed and prepared weighs approximately 150 grams) are loaded on to the injector service conveyor, exposed to 1W-C to decontaminate the surfaces in the presence of Carbon Dioxide and the final height of the breasts is controlled at 4 cms by a pressure roller. Needle spacings are adjusted so that they are lOapproximately 1.5cm * 1.5cm between centers and needles with a diameter of 3.1mm are fitted. Cycle time is set at 2 seconds with a dwell time of approximately 1 second. Before commencing injection the needle shrouds are bled to ensure an even continuous flow.

At each injection cycle, as previously detailed, 12 -15 holes are formed in the chicken breast and approximately imi the slightly viscous liquid sauce is injected into each hole before the hole is closed by the chicken meat plug formed at the beginning of the injection cycle. The coolness of the meat rapidly causes the liquid sauce to initially become viscous and then solidify (approximately 60 seconds) and the product can then be further processed as required or packaged and stored until used. The data shown in Table 2 is typical of the extended shelf life encountered by this injected product compared with similarly non-injected product.

Example 3 Beef Steak with a wine based espagnole sauce.

A puree of vegetables, principally onion, celery, carrot is pre-prepared, as is a homogenate from bacon trimmings. Lard, butter and oil are preheated to a hot temperature and firstly the homogenised bacon, then the vegetable puree are sautéed in this mixture of oils and fats. Beef stock with additional beef fat is then added to this whole mix which is allowed to simmer for 30 minutes. The whole liquid mass is then macerated with warmed wine concentrate to which salt and sodium phosphate have been added together with any required herbs and spices, Vitamin E and sufficient corn flour suspended in a little water, to ensure the correct thickness when the injected meat is cooked.

The final Inaceration will ensure that no large particulates remain. No gelatine is required as the fats, vegetable puree and flour will ensure a rapidly thickening mix after injection.

Before injection, the final temperature of the sauce is again adjusted to between 45 C -50 C which is sufficient to keep all the components iu a free flowing liquid form) but not above 55 C. The sauce is loaded into the temperature insulated reservoir of the needle injectors which itself has been pre-warmed to a similar temperature with circulating warm water and then deaerated immediately before use.

Chilled thick slices of beef steak (approximately 8cms * 6cms * 5cms and weighing approximately 230 grams) are loaded on to the injector service conveyor and the final height of the breasts is controlled at 4.5 cms by a pressure roller. In this application the steak slices are positioned so that the long axis of the meat fibres is running parallel with the conveyor and the needles orientated so that they enter the meat from the sides and in the same plane as the meat fibres Needle spacings are adjusted so that they are approximately 1.5cm * 1.5cm between centers and needles with an overall diameter of 5.0mm (including protrusions) are fitted. Cycle time is set at 2.3 seconds with a dwell time of approximately 1.5 second. Before commencing injection the needles are again bled to ensure an even continuous flow.

At each injection cycle, as previously detailed, 9 -12 holes, each with a depth of approximately 50mm, are formed in the beef steak and approximately 2 ml of homogenized mix is injected into each hole before the hole is closed by a meat plug formed at the beginning of the injection cycle. Each steak now contains approximately 15% of filling by weight (different meat configurations will allow for a greater or lesser filling portion to be injected), The coolness of the meat rapidly causes the filling to initial become viscous and then a thick gel (approximately 60 seconds) and the product can then be immediately further processed as required or packaged and stored until used. Because the meat was injected parallel to the orientation of its major bundles, the surface holes are invisible especially if packed and presented as traditional steaks in a tray. When cooked, the enhanced cooking capabilities are typified by the accelerated cooking times as detailed in

Table 2.

Example 4: Food supplementation fox hospital patients and those with special dietary needs.

A single piece of pork shoulder of 2cm thickness and a raw portionweight of 150g is prepared ready for injection. A suitable water based thickened sauce is prepared, this is slightly more concentrated than normal to accommodate the extra liquid containing the added drug or supplement. At the final stage of sauce preparation and while being cooled (below 40 C), the necessary volume of a suitable Calcium supplement (in this case 300mg of soluble Calcium Citrate) or calcium rich medication, 150mg of Magnesium Chloride (known to enhance Calcium absorption) and 250 I.U. of a suitable Vitamin D source (in this case Vitamin D3) are added to the sauce and thoroughly mixed. The mix also contains any necessary tenderizing agents if chemical as well as mechanical tenderisation is deemed necessary.

The sauce/supplement/tenderisation mix applied and dispersed selectively throughout the meat portion as previously detailed using multiple injection device in free flow bulk form via the liquid reservoir (130) and inlet (500) or as a discrete ampoule (132) via the injector chamber (420) of a single hand held injector using pressurized air from the gas cartridge (520) to produce the necessary positive pressure.

This provides a very easy and digestible method of intake to alleviate the conditions especially in a relatively immobile recipient.

Claims (15)

CLAIMS -

1. A food-treatment device comprising an injection assembly comprising: (a) a needle having a food penetrating front end having transverse protrusions; (b) a tubular shroud surrounding the needle with a spacing and axially displaceable relative to it; Cc) a conduit communicating with the space within the shroud for passing a f lovable composition into a rear end portion thereof; Cd) a tubular guide surrounding the shroud with a spacing, and being axially displaceable relative to the shroud and the needle, the guide having a cutting edge at its front end; and Ce) a fluid supply inlet at a rear region of said guide.

2. A device according to claim 1 wherein said needle is solid.

3. A device according to claim 1 or claim 2 wherein said shroud has a cutting edge at its front end.

4. A device according to any preceding claim including means for controlling the depth of penetration of the needle.

5. A device according to any preceding claim which includes a multiplicity of said injection assemblies, together either as multiple individual units or combined through central manifold means so that multiple injections can be achieved at multiple sites simultaneously.

6. A device according to any preceding claim having means for enabling injection of a predetermined quantity of the f].owable composition.

7. A food treatment device substantially as described with reference to and as illustrated in the accompanying drawings.

8. A method of preparing a foodstuff comprising a solid food substrate, said method comprising a step of injecting a flowable composition into said substrate using a food-treatment device according to any preceding claim, the method having the following steps: (a) causing the needle to protrude forwardly of the shroud and guide, and to penetrate partially through the thickness of the substrate; (b) causing the guide to move forwardly and to penetrate the substrate, its depth of penetration being a minor proportion of the needle's depth of penetration, whereby the guide is caused to cut a plug of substrate; (C) causing the needle to move deeper into the substrate while rotating, and causing the shroud to penetrate the substrate to a minor depth; Cd) passing the flowable composition through the conduit and thence through the shroud into the substrate; Ce) withdrawing the needle and shroud; and (f) withdrawing the guide from the substrate and passing fluid (generally gas) into the guide via the fluid supply inlet to expel the plug of substrate to seal the hole in the substrate.

9. A method according to claim 8 wherein movement of at least some of the elements of said device are controlled using a measure of individual resistance pressure and/or non-contact image analysis of the surface.

10. A method according to claim 9 employing image analysis wherein XY coordinates of differing materials are identified and the individual needles of a manifold equating to those XY coordinates are instructed accordingly.

11. A method according to claim 8 or claim 9 which includes a step of blending a composition with meat proteins and fat and, optionally, sodium chloride and/or sodium phosphate to produce said flowable composition, which is then passed into the substrate without substantial delay.

12. A method according to any of claims 8-11 which employs a flowable composition which contains one or more of food supplements and/or drugs.

13. A method according to any of claims 8-12 in which said flowab].e composition is injected at an elevated temperature at which its viscosity is lower.

14. A method according to any of claims 8-13 in which the substrate is chilled so that the injected composition is chilled so that its tendency to leak out is reduced.

15. A method of preparing a foodstuff comprising injecting it with a flowable composition, said method being substantially as herein described with reference to and as illustrated in the accompanying drawings.