GB2493287A

GB2493287A - Meat patty with raised outer rim for retaining filling

Info

Publication number: GB2493287A
Application number: GB1213457.3A
Authority: GB
Inventors: Andrew Lytle
Original assignee: Moy Park Ltd
Current assignee: Moy Park Ltd
Priority date: 2011-07-27
Filing date: 2012-07-27
Publication date: 2013-01-30
Anticipated expiration: 2032-07-27
Also published as: GB201213457D0; GB2493287B; GB2519213A; GB201112923D0; GB2519213B; GB201414543D0

Abstract

A meat product comprises a first patty (1) having a central portion (2) and a raised rim (3) surrounding the central portion (2). The raised rim (3) is tapered and sized and structured so as to retain the filling on the first patty. A filling 16 may be placed on the central portion (2). A second patty 4 may be placed on the first patty (1). The tapering of the raised rim (3) results in a side-by-side, overlapping contact 20 between the patties, which provides a good seal and a pleasing domed shape. The meat product may be a chicken kiev formed from two chicken patties, a garlic butter filling and a breadcrumb coating. An apparatus for producing a meat product comprises a mould shaped to form a first patty having a central portion and a tapered, raised rim; means for placing a filling onto the central portion of the first patty; and means for at least partially cooking the product.

Description

Meat Product and Method and Apparatus for making a Meat Product The present invention concerns a meat product, and a method and apparatus for making a meat product. More particularly, but not exclusively, the present invention concerns a meat product containing a filling, and a method and apparatus for making such a product.

Meat products having a filling are typically made by providing a flat base patty of meat, placing the filling on the centre of the base patty, and placing another patty of meat on top, so that the filling is covered. The two patties are sealed together by crimping around the edges. The product is coated, for example with breadcrumbs, and then fried. The product is then frozen for shipping to consumers. An example of such a product is a chicken Kiev.

An important aspect of the manufacture of such meat products is obtaining a product with a good finished appearance.

Obtaining a good shape of product is a very Important factor in the overall appearance: in the case of this meat product, the desired shape is oval, even, and well-domed.

Typically, joining of the patties has been by hand, with mixed results. Automation of the manufacture and joining of the patties has also had mixed results, with poor seals and/or poor product shape (e.g. a flattened rather than domed shape) Products made in the manner described above may suffer from leakage of the filling during cooking by the consumer. That is undesirable as the filling contributes significantly to the flavour of the product, and the leaked filling will typically affect the flavour of, for example, the breadcrumbs.

Moreover, when the consumer outs into the product, they want to see that the product contains a substantial amount of filling, which will not be the case if a significant quantity of the filling has leaked out. Leaking filling may also result in a dry taste and a soggy base to the product.

EP0641520A1 discloses a food product that comprises a base of meat, the base being provided with a cavity in the form of a shallow well or depression. A cover of meat is secured to the base around a peripheral line, a filling of the food product being located within the cavity, which is of a size sufficient to accommodate at least most of the filling. The cavity is partially defined by side walls of the base. The sidewalls are thick, presumably in an attempt to ensure a good seal between the cover and the side walls. However, the thick sidewalls limit the volume of the cavity available for a given size of base, and hence limit the quantity of filling that the food product can contain. Also, the shape of the product is less domed than is desirable.

The present invention seeks to mitigate the above mentioned problems. Alternatively or additionally, the present invention seeks to provide an improved meat product, and an improved method and apparatus for making a meat product.

According to a first aspect of the invention, there is provided a meat product comprising a first patty having a central portion and a raised rim surrounding the central portion and a filling on the central portion, the raised rim being tapered and sized and structured so as to retain the filling on the first patty.

The tapered rim is wider at the base of the rim than at the top of the rim. The slope of the taper has a significant effect on the appearance of the product. The rim may have an exterior side face that slopes at an angle of between 30 degrees and 80 degrees, for example between 60 degrees and 75 degrees. The slope of the exterior side face of the rim may vary around the circumference of the rim.

The rim may have a rounded top, for example a rounded top having a radius of ourvature of between 1 mm and 8 mm, preferably between 2 mm and 6 mm and more preferably between 3 mm and 4 mm. For example, the radius of curvature may be around 3.6 mm.

The rim may have an interior side face that slopes at an angle of between 60 degrees and 90 degrees, for example between 80 degrees and 75 degrees. The slope of the interior side face of the rim may vary around the circumference of the rim.

The product may further comprise a second patty covering the filling and contacting the raised rim. The second patty may contact the raised rim of the first patty around substantially the entire raised rim. In that way a seal may be formed between the raised rim of the first patty, and the second patty. The seal may prevent the filling form escaping during cooking by the consumer. Thus, an inner surface of the second patty may be in contact with the exterior side face of the rim. Preferably, the second patty overlaps the first patty across 15mm to 25 mm of the height of the exterior side face of the rim, more preferably across 20 mm to 24 mm.

Preferably, the second patty overlaps the first patty over more than 50% of the height of the exterior side face of the rim, more preferably more than 60%, more than 70%, more than 80% or more than 90%-. The second patty may overlap the first patty over the whole of the exterior side face of the rim.

By placing the filling on the central portion of the first patty, which is surrounded by the raised rim, leakage of the filling from the meat product during cooking by the consumer may be reduced. For example, the raised rim surrounding the central portion of the first patty may form a bowl-like structure having sufficient volume to contain the filling.

Where the second patty contacts the raised rim, the join between the first and second patty may be above the level of the filling when it melts during cooking by the consumer.

The first patty may have an area of between 5 cm2 and 200 cm2, preferably between 10 cm2 and 150 cm2, more preferably between cm2 and 100 cm2. In some embodiments, the first patty may have an area of between 100 cm2 and 200 cm2, between 30 cm2 and 70 cm2, or between 10 cm2 and 20 cm2. The first patty may have an uncooked mass of between 5 g and 100 g, preferably between g and 50 g. In some embodiments, the first patty may have an uncooked mass of between 9 g and 18 g, or between 80 g and g. The second patty may have an uncooked mass of between 5 g and 100 g, preferably between 30 g and 50 g. In some embodiments, the second patty may have an uncooked mass of between 9 g and 18 g, or between 80 g and 75 g. It may be that the height of the lowest point of the top surface of the central portion is between 3 mm and 10 mm, for example between 5 mm and 7 mm. It may be that the difference in height between the top of the rim and the lowest point of the top surface of the central portion of the first patty is not less than 3 mm, preferably not less than 5 mm, more preferably not less than 7 mm. It may be that the difference in height between the top of the rim and the lowest point of the top surface of the central portion of the first patty is not more than 30 mm, preferably not more than 20 mm and yet more preferably and not more than 15 mm. The width of the rim may be between 2 mm and 20 mm, preferably between 5 mm and 15 mm, more preferably between 7 mm and 12 mm, and yet more preferably 9 mm and 10 mm. It may be that the difference in height between the top of the rim and the lowest point of the top surfaoe of the central portion of the first patty is between 1 and 1.5 times the height of the lowest point of that top surface. A wider rim may be structurally stronger and may support the weight of the seoond patty better during cooking.

The raised rim may be around the periphery, or outer edge, of the first patty. It may be that the second patty tapers from its oentre to its edge; for example, the second patty may reduce in thickness by a factor of between 70% and 80%, for example by between 64% and 76%. For example, the edge thickness may be 3 mm, and the centre thickness between 8 mm and 12.5 mm.

The first patty may take a wide variety of shapes when viewed from above, for example, the first patty may be circular, the first patty may be an oval, the first patty may be a square, a rectangle, or a multisided regular or irregular shape. The second patty may have substantially the same shape as the first patty when viewed from above. In other words, the footprint of the second patty may be substantially the same as the footprint of the first patty. In some embodiments the footprint of the second patty may extend beyond the footprint of the first patty. For example, the footprint of the second patty nay extend by not more than 10 mm, preferably not more than 5 mm and even more preferably not more than 2 mm beyond the footprint of the first patty. lit may be that the footprint of the second patty extends by not less than 1 mm beyond the footprint of the first patty. In some embodiments, the second patty may be substantially flat, that is, it may be that the second patty has no protruding rim. Advantageously, the second patty may have a domed shape. The second patty may be at least partially fused with the first patty, for example as the result of a cooking process.

The first and second patties may comprise one or more types of meat. The patty may comprise mechanically processed meat, which may have been formed into the patty. In a broad aspect of the invention, the first and second patty may comprise meat such as poultry (for example chicken or turkey), beef, pork, lamb or sausage meat. The meat product may be coated, for example with breadcrumbs. The meat product may be frozen.

The filling may be a flavoured infill. The filling may be a fatty filling. For example, the filling may comprise butter, preferably garlic butter. The filling may melt below the intended cooking temperature of the product by the consumer.

It may be that the infill protrudes over an upper surface of the rim of the first patty by more than 1.2 times the height of the rim. For example, the infill may protrude over the upper surface of the rim by more than 5 mm.

The product may be a Kiev, for example a chicken Kiev. The product may be an escalope or a nugget.

In some embodiments, the product may comprise a coating, for example a coating comprising breadcrumbs. In some embodiments, the product may comprise a slab or layer of edible foodstuff, for example a slice of cheese, advantageously a high-melt cheese, covering the filling and contacting the raised rim. Such a product may further comprise a coating, for example a coating comprising breadcrumbs.

According to a second aspect of the invention, there is provided a method of producing a meat product, the method comprising forming a first patty having a central portion and a tapered, raised rim surrounding the central portion; placing a filling onto the central portion; and at least partially cooking the meat product.

By forming a first patty having a central portion and a raised rim surrounding the central portion, and placing the filling onto the central portion, a product is created in which the filling is contained by the rim surrounding the central portion of the first patty. Leakage of the filling from such a product during cooking by the consumer may be substantially reduced compared to a product manufactured using a flat patty.

The method may comprise the step of placing a second patty on top of the first patty such that the second patty rests on the raised rim and covers the filling. The method may include a step of moulding the second patty around the raised rim of the first patty so as to at least partially seal the first patty to the second patty. Such a step may result in a product that is more aesthetically pleasing and also that is less prone to leakage.

The method preferably comprises a step of coating the product, for example in breadcrurnbs. The process may comprise a step of freezing the product, for example for storage and transport to the consumer. The at least partial cooking of the product may be carried out by frying the product, preferably flash frying.

The method may comprise a step of placing a slab or layer of edible foodstuff, such as a slice of cheese, on top of the first patty such that the slab or layer of edible foodstuff rests on the raised rim and covers the filling.

The first patty may be formed from mechanically processed meat. For example, the mechanically processed meat may be contained in a vat and fed to a roller having a plurality of mould shapes thereon. The mould shapes may be configured such as to produce a patty having a central portion and a raised rim surrounding the central portion. The roller may form a plurality of patties on a conveyor, which may carry the patties through at least part of the remainder of the process.

The method may therefore be a method of mass producing meat products, the method comprising forming a plurality of patties each having a central portion and a raised rim surrounding the central portion, the raised rim being tapered and sized and structured so as to retain the filling on the first patty; placing a filling onto the central portion of each of the plurality of patties; optionally placing a second patty on top of each of the plurality of patties such that the second patties rest on the raised rims and cover the fillings; optionally coating the products; at least partially cooking the products, preferably in a flash fryer, and optionally freezing the products.

It may be that the method is carried out partially or solely by hand. It may be that the method is carried out partially or solely using automated apparatus.

According to the third aspect of the invention there is provided an apparatus for producing a meat product, the apparatus comprising a mould for forming a first patty having a central portion and a tapered, raised rim surrounding the central portion, and means for placing a filling onto the central portion. The apparatus may further comprise means for placing a second patty on top of the first patty, such that the second patty rests on the raised rim and covers the filling. The apparatus may also comprise of one or more of

B

means for coating the meat product, for example in breaclcrumbs, means, for example a fryer, preferably a flash fryer, for at least partially cooking the meat product and means, for example a freezer, for freezing the meat product.

It will be appreciated that the cup-shape of the first patty is an important aspect of the invention in its own right.

Therefore, in a broad aspect of the invention, there is provided a meat product comprising a base portion having a shape suitable for containing a volume of filling. The product may comprise a top portion resting on the base portion and covering a filling contained in the base portion. The base portion may have a cup-shape. The base portion may have a central portion and a raised rim surrounding the central portion. The raised rim may be tapered and sized and structured so as to retain the filling on the first patty.

It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the meat product of the invention and vice versa.

Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which: Figure 1 is a view of a patty having a raised rim; Figure 2 is a plan view of the patty of Figure 1; Figure 3 is a cross-sectional view of the patty of Figure 1; Figure 4 is another cross-sectional view of the patty of Figure 1; Figure 5 is a view of a patty for placing on top of the patty of Figure 1; Figure 6 is a plan view of the patty of Figure 5; Figure 7 is a cross-sectional view of the patty of Figure 5; Figure 8 is another cross-sectional view of the patty of Figure 5; Figure 9 is a schematic diagram of a method of making a meat product; and Figure 10 is a cross-sectional view of the finished meat product.

Referring to Figures 1, 2, 3 and 4, a patty 1 has a central portion 2 surrounded by a raised rim 3. The central portion 2 is 75 mm in length 5 and 35 mm in width 6, while the overall length 7 of the patty 1 is 96 mm and the overall width 8 of the patty 1 is 55 mm. The width of the raised rim 3 is therefore between 10 and 11 mm. The top of the raised rim 3 is 15 mm in height 10 and the central portion 2 of the patty 1 is 7 mm in height 11. The difference in height between the top of the raised rim 3 and the lowest point of the top surface of the central portion 2 of the patty 1 is therefore 8 mm. The raised rim 3 is tapered, and has a radius of curvature 9 of around 3.6 mm at the top.

Turning now to Figures 5, 6, 7 and 8, a second patty 4 has a length 12 of 105 mm and a width 13 of 65 mm. The second patty 4 therefore has a footprint that extends by between 9 and 10 mm beyond the footprint of the first patty 1. The patty 4 has a domed shape and is around 9 mm in height 15 in the centre and around 3 mm in height 14 at the edge.

Referring to Figure 9, to form a meat product 5, a filling 16 is placed into the central portion 2 of the first patty 1 and the second patty 4 placed on top. The outer edges of the second patty 4 are moulded around the raised rim 3 of the first patty 1 to at least partially seal the first patty 1 to the second patty 4. The first patty 1 has a mass of around 44 grams and the second patty 4 has a mass of around 36 grams, resulting in a total mass of around 80 grams. After moulding, the product 5 has a length of around 104 mm, a width of around 67 mm and a height of around 36 mm. The product 5 is coated in breadcrumbs 17 and placed in a fryer 18. On exiting the fryer 18, the product 5 is frozen 19 and stored.

In the finished product (Fig. 10), the filling 16 protrudes above the rim of the first patty 1, thus supporting the second patty 4 and helping to form an aesthetically pleasing domed structure. There is a steeply sloped overlap 20 where the first patty 1 and the second patty 4 are in contact with each other. The first patty 1 and the second patty 4 lie side-by-side where they overlap, with the second patty 4 outside the first patty 1, which further contributes to the domed shape of the product. The overlap 20 extends over the major part of the height of the rim of the first patty 1, thus helping to ensure a good seal.

In an example product 5, the first patty 1 and the second patty 4 are formed from chicken and the filling 16 is garlic butter. The product 5 is a chicken Kiev.

Where in the forgoing description, integers or elements are mentioned which have known, obvious or foreseeable eguivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the tike are optional and do not limit the scope of the independent ciaims.

Moreover, it is to be understood that such optionai integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.

Claims

<claim-text>Claims 1. A meat product comprising a first patty having a central portion and a raised rim surrounding the central portion, and a filling placed on the central portion, the raised rim being tapered and sized and structured so as to retain the filling on the first patty.</claim-text> <claim-text>2. A meat product according to claim 1, wherein the product comprises a second patty on top of the first patty, the second patty contacting the raised rim and covering the filling.</claim-text> <claim-text>3. A meat product according to claim 2, wherein the rim has an exterior side face that slopes at an angle of between 30 degrees and 80 degrees.</claim-text> <claim-text>4. A meat product according to claim 2 or ctaim 3, wherein the rim has a rounded top.</claim-text> <claim-text>5. A meat product according to any of claims 2 to 4, wherein the rim has an interior side face that slopes at an angle of between 60 degrees and 90 degrees.</claim-text> <claim-text>6. A meat product according to any of claims 2 to 5, wherein the second patty comprises one or more of chicken or turkey.</claim-text> <claim-text>7. A meat product according to any of claims 2 to 6, wherein the second patty has an uncooked mass between 5 and 100 grams.</claim-text> <claim-text>8. A meat product according to any preceding claim wherein the first patty comprises one or more of chicken or turkey.</claim-text> <claim-text>9. A meat product according to any preceding claim, wherein the filling comprises butter, preferably garlic butter.</claim-text> <claim-text>10. A meat product acccrding to any preceding claim wherein the first patty has an uncooked mass between 5 and 100 grams.</claim-text> <claim-text>11. A meat product according to any preceding claim wherein the raised rim has a width of between 2 and 20 mm.</claim-text> <claim-text>12. A meat product according to any preceding claim wherein the difference in height between the top of the raised rim and the lowest point of the top surface of the central portion of the first patty is not less than 3 mm.</claim-text> <claim-text>13. A method of producing a meat product, the method comprising forming a first patty having a central portion and a tapered, raised rim surrounding the central portion, placing a filling onto the central portion of the first patty, and at least partially cooking the product.</claim-text> <claim-text>14. A method according to claim 13, wherein the method comprises a step of placing a second patty on to the first patty such that the second patty contacts the raised rim and covers the filling.</claim-text> <claim-text>15. A method according to claim 14, wherein the method comprises a step of moulding the second patty around the raised rim so as to at ieast partially seai the first patty to the second patty.</claim-text> <claim-text>16. A method according to any of claims 13 to 15, wherein the method comprises a step of coating the meat product, preferably in breadcrumbs.</claim-text> <claim-text>17. An apparatus for producing a meat product, the apparatus comprising a mould shaped to form a first patty having a central portion and a tapered, raised rim surrounding the central portion, means for placing a filling onto the central portion of the first patty, and means for at least partially cooking the product.</claim-text> <claim-text>18. An apparatus according to claim 17 wherein the mould is on a roller which passes through a vat suitable for containing meat, the roller being configured to form the first patty on a conveyor after the mould has passed through the vat.</claim-text> <claim-text>19. An apparatus according to claim 17 or 18, the apparatus comprising means for placing a second patty onto the first patty such that the second patty contacts the raised rim and covers the filling.</claim-text> <claim-text>20. A meat product substantially as herein described with reference to the accompanying drawings.</claim-text> <claim-text>21. A method of producing a meat product substantially as herein described with reference to the accompanying drawings.</claim-text> <claim-text>22. An apparatus for producing a meat product substantially as herein described with reference to the accompanying drawings.</claim-text>