GB2530323A

GB2530323A - Improved Process For Producing Pork Rind Products

Info

Publication number: GB2530323A
Application number: GB1416634.2A
Authority: GB
Inventors: Matt Carter
Original assignee: HOLMESTERNE FARM CO Ltd
Current assignee: HOLMESTERNE FARM CO Ltd
Priority date: 2014-09-19
Filing date: 2014-09-19
Publication date: 2016-03-23
Also published as: GB201416634D0

Abstract

A process for preparing a pre-packaged pork crackling precursor, the process comprising: sealing one or more pork rinds in a container such that an interior surface of the container is in thermal contact with at least one pork rind; and exposing an exterior surface of the container to a steam atmosphere such that the steam is in thermal contact with the portion of at least one pork rind, thereby to produce a flexible pork crackling precursor. The process may further comprise removing air from the container, possibly so that the container encloses a vacuum and also freezing the flexible pork crackling precursor. Further disclosed is a process for preparing a pork crackling product which comprises removing the pork crackling precursor from the container; thawing the pork crackling precursor to obtain a flexible pork crackling precursor and cooking the said precursor to obtain the pork crackling product.

Description

IMPROVED PROCESS FOR PRODUCING PORK RIND PRODUCTS

TECHNICAL FIELD

The present invention relates generally to a process of preparing pork rind products, and to a process for producing high quality pork crackling.

BACKGROUND

Pork rind products are well known and widely sold, both in isolation as snack goods and as an addition to wider offerings or products. "Pork crackling" products are generally prepared from raw pork rind, or skin, with or without a fat portion adjacent to the rind. The pork rind often has a leathery consistency prior to any cooking and must be roasted or fried in hot oil to produce a pork crackling snack with a crunchy texture. The roasting or frying stage is generally conducted at around 200°C or higher. This high temperature renders some of the fat attached to the rind such that the rind reduces in size to form a crisp final product.

Pork crackling products are popular in the commercial market and the domestic market, where they can be readily prepared in the home in a hot oven, to accompany a roasting joint, for example. However, the usual method for producing pork crackling products has a number of disadvantages associated with it.

A pork crackling product, especially one that is prepared commercially, should have a consistent texture and colouring. Using common roasting and frying methods it can be difficult to evenly cook the pork rind to provide the best result and the desired reproducibility. In conventional high-temperature cooking, variation in temperatures within an oven or a frying pan may cause the pork rind to be exposed to temperature levels that are much higher than the desired cooking temperature. If removed from the heat of the oven or frying pan too late in the cooking process, overcooking of sections of the pork rind may result, whereas undercooking of sections of the pork rind may occur if the pork rind is removed too early from the heat. Portions of the pork rind being undercooked or overcooked may reduce the quantity of the pork rind which is of a sufficient quality to be used commercially. In the case that the final pork crackling product is to form part of a larger meal in a restaurant, as an example, a chef may have to throw away, and thus waste, a significant portion of the pork crackling.

It is therefore desirable to be able to more uniformly and reliably cook pork rinds to provide a consistently good pork crackling product.

A particular difficulty in cooking pork rind products is avoiding the infiltration of moisture into the rind, It is well-known that the required crunchy texture cannot be achieved if too much moisture is present. For example, methods for cooking pork rinds that include softening the rind in a pressure vessel prior to cooking in a conventional oven have been attempted; however, the pork rind tends to adopt a gelatinous consistency, which is not conducive to forming a crisp final product. A dehydration stage can be added prior to roasting or frying, in order to remove moisture in the pork rind. However, this adds a further costly processing stage, is not always an available solution, and is not always effective.

Other methods for cooking pork rinds include the use of microwave ovens, although, as with the use of conventional ovens, it can be difficult to control the temperature at which the pork rinds are cooked.

Pork crackling products can add complexity to a meal, particularly when the process parameters for preparing the pork crackling may differ from the process parameters for preparing other components of the meal. For example, the oven temperature and cooking time required for preparing the pork crackling may be different to the oven temperature and cooking time required for preparing a joint of meat with which the pork crackling is to be served. In catering environments, such as restaurants, it is generally advantageous for food preparation to involve as few stages and complexities as possible and the steps required to prepare the pork crackling may complicate the process of preparing the meal.

In commercial environments in particular it may be further desirable to prepare pork crackling products of a desired aesthetic appearance. It has been noted, however, that because raw pork rind is tough and difficult to shape, this can be very difficult to achieve. Also, deformation during the cooking process means that any shape provided to the raw pork rind is likely to be significantly distorted. Of course, the final pork crackling product is then too rigid and brittle to be moulded.

An alternative means of preparing pork crackling precursors and pork crackling products would therefore be advantageous.

The present invention aims to provide a process for producing pork rind products which overcomes or mitigates one or more of the problems and disadvantages in the

prior art.

SUMMARY OF THE INVENTION

The invention relates generally to processes for producing pork rind products and precursors for producing pork crackling, which provide an improvement over known processes. The pork crackling precursors of the invention may improve the production of edible pork crackling products, such as by simplifying or otherwise aiding the reproducibility of preparing good quality pork crackling. The invention also relates to pre-packaged pork crackling precursors and to improved processes of producing pork crackling. The processes and products of the invention may be suitable for commercial and non-commercial applications.

According to a first aspect of the present invention, there is provided a process for preparing a pre-packaged pork crackling precursor, the process comprising: sealing one or more pork rinds in a container such that the container is in thermal contact with at least a portion of at least one pork rind; and exposing the container to a steam atmosphere such that the steam is in thermal contact with the container, thereby to produce a flexible pork crackling precursor. Beneficially, the step of exposing the container to a steam atmosphere pre-cooks the one or more pork rinds to give a flexible pork rind that may subsequently be cooked to produce a pork crackling product. Exposing the container to steam may also evenly cook the pork rind pieces, such that this stage may be carried out at a lower temperature than would be necessary within a conventional oven.

Advantageously, the one or more pork rinds may be vacuum sealed within the container. Vacuum sealing the container may have the advantage of improving thermal penetration into the pork rinds while the container is exposed to the steam atmosphere, and may also assist in more even cooking of the pork rinds. This may increase the quantity of the pork crackling precursor which is able to produce good quality pork crackling, thus reducing wastage of the pork crackling product relative to conventional processes.

Suitably, the container has at least one flexible wall which seals closely I tightly around the pork rinds when a vacuum is applied. The tight seal between the flexible wall and the pork rinds may increase the portion of an outer surface of the one or more pork rinds that is in thermal contact with the container, improving thermal penetration into the pork rinds and allowing the pork rinds to be more evenly cooked during exposure of the container to the steam atmosphere. In other words, a vacuum sealed container may advantageously be in close (thermal) contact with a larger surface area of pork rind than would otherwise be the case.

In preferred embodiments the container is a bag. Beneficially, the bag may have water vapour permeability of less than approximately 20 g1m224h, less than approximately 10 g1m224h, or more suitably, less than approximately 5 g1m224h, such that the bag has a high moisture barrier and thus guards against moisture contacting the outer surface of the pork rinds. This assists in preventing the pork crackling precursor from absorbing moisture during the first pre-cooking stage, and thus, helps in producing a higher quality, crisp final pork crackling product. The bag may also have oxygen permeability of less than approximately 100 cc/m224hatm, less than approximately 85 cclm224hatm, less than approximately 75 cclm224hatm, or more suitably, less than approximately 65 cclm224hatm to assist in maintaining a substantial vacuum in the bag. It will be appreciated that the water vapour permeability and oxygen permeability may be varied according to preference or the properties of commercially available containers I bags for packaging purposes.

Any suitable steam atmosphere may be used, which softens the pork rind precursors and renders them flexible, but which does not damage the pork rinds rendering them unsuitable for use. Thus, the temperature of the steam atmosphere may be between approximately 100°C and 120°C, and preferably, the temperature of the steam atmosphere is approximately 110°C.

Similarly, the container may be exposed to the steam atmosphere for any period of time sufficient to render the pork rinds flexible, but which does not damage the pork rinds rendering them unsuitable for use. For example, a steaming I cooking stage of between approximately 3 hours and S hours may be used. Preferably, the container is exposed to the steam atmosphere for approximately 4 hours.

If the pork cracking is not to be immediately produced, the flexible pork crackling precursor should be chilled or frozen shortly after the steam pre-cooking stage.

If the flexible pork crackling precursor is to be chilled, the chilling is typically carried out prior to freezing the flexible pork crackling precursor. Suitably the chilling is to a temperature of less than 5°C. In one example, the chilling is to a temperature of approximately 4°C or less within a period of approximately 90 minutes after steaming.

While the pork crackling precursor may also be chilled at a stage after a freeze-thaw cycle, chilling the flexible pork crackling precursor prior to freezing may allow for more efficient reduction of the temperature of the pork rind pieces. Chilling the flexible pork crackling precursor removes an initial component of the heat from the flexible pork crackling precursor, with an additional component of heat removed through freezing.

Advantageously, the flexible pork crackling precursor may be frozen. This may allow the pork rind pieces / pork crackling precursors to be stored (in a frozen state) for a relatively long duration; e.g. for up to approximately 12 months, until the final product is required. Any suitable freezing temperature can be used. In a preferred embodiment, the flexible pork crackling precursor is frozen to a temperature of approximately -18°C or below.

In preferred embodiments, the flexible pork crackling precursor is sealed within the container in which the rinds were steamed during chilling of the pork crackling precursor and/or freezing of the pork crackling precursor. Beneficially, this allows for the pork rind pieces to be easily transferred between apparatus and between areas of the facility in which they are being prepared. However, it is envisaged that the pork rind pieces may be removed from the container in which they were steam-cooked prior to chilling and/or freezing if this is desirable. The pork rinds may be transferred to a new container for storage when chilled or frozen.

Any appropriate size of pork rind may be used, depending on requirements. In some embodiments, the one or more pork rinds may have length and width dimensions between approximately 50 mm and 400 mm, or between approximately 100 mm and 300 mm. In a preferred embodiment, the one or more pork rinds have length and width dimensions between approximately 200 mm and 250 mm. The one or more pork rinds may have a thickness that is somewhat dependent on the anatomy of the animal from which it was obtained. For example, the pork rind may have a thickness of between approximately 3 mm and 7 mm. Suitably, the pork rinds may be pre-prepared to have substantially the same thickness, which may assist with providing a consistent and reproducible product, especially when a plurality of pork rinds are packaged in the same container. In a preferred embodiment the thickness of the pork rinds is approximately 5 mm. Suitably, the pork rinds are comprised of a skin layer which is substantially free from fat: therefore, any pre-processing step may remove all or substantially all of the fat layer from the skin of the pork rind.

In a preferred embodiment, there is a plurality of pork rinds and the pork rinds are arranged in the container in one or more layers. For example, pork rinds may be arranged side by side in stacks (e.g. 1, 2, 3,4 or more stacks). In some embodiments pork rinds are arranged in the container (or bag) in two stacks. Each stack may contain 2, 3, 4, 5, 6 or more rinds.

The invention also encompasses a pre-packaged pork crackling precursor produced by the processes of the invention.

According to a second aspect of the invention, there is provided a pre-packaged pork crackling precursor, comprising a sealed container and at least one pork crackling precursor, the or each pork crackling precursor being a flexible steam-cooked pork rind and at least one pork crackling precursor being in thermal contact with the container. The pre-packaged pork crackling precursor may be produced through any or all of the process steps described in connection with the first aspect of the invention.

According to another aspect of the present invention, there is provided a process for preparing a pork crackling product from the pre-packaged pork crackling precursor as described herein. Suitably, the process comprises: removing the pork crackling precursor from the container; optionally thawing the pork crackling precursor to obtain a flexible pork crackling precursor; and cooking the pork crackling precursor to obtain the pork crackling product. Suitably, the step of cooking the pork crackling precursor may transform the pork crackling precursor into a crisp pork crackling product, able to be used for domestic or commercial purposes. Cooking the pre-prepared pork crackling precursor to produce the pork crackling product is relatively quick and simple, when compared to traditional methods for producing pork crackling, and thus offers a more efficient process for producing pork crackling products.

The cooking may be at any suitable temperature: for example, at a temperature of between approximately 175°C and 225°C, and, in preferred embodiments, at a temperature of approximately 20000. The cooking may be carried out for any appropriate period of time, as determined by the cooking means used, the desired temperature for the cooking, and the desired result (product texture and appearance) to be achieved. In some embodiments, therefore, the pork crackling is cooked for a period of approximately 30 minutes, for approximately 25 minutes or, more suitably, for approximately 20 minutes. A preferred cooking regime is approximately 20 minutes at approximately 200°C.

Advantageously, the flexible pork crackling precursor may be thawed, or tempered, prior to cooking, and, in preferred embodiments, may be shaped prior to cooking.

The tempering process may comprise changing the temperature of the pork crackling precursor such that the temperature lies between approximately 4°C and 8°C. The tempering process is beneficial since it may give the flexible pork crackling precursor a more rubbery and pliable consistency, such that the flexible pork crackling precursor may be cut or shaped to a desirable geometry.

According to another aspect of the present invention, there is provided a process for producing a pork crackling product, the process comprising any or all of the process stages for preparing a pre-packaged pork crackling precursor as previously described, in combination with any or all of the process stages for preparing a pork crackling product from a pre-packaged pork crackling precursor as previously described.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination.

Features described in connection with one aspect or embodiment are applicable to all other aspects and embodiments, unless disclosed otherwise or unless such features are incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a flowchart illustrating a general method for processing pork rinds according to one embodiment of the invention.

DETAILED DESCRIPTION

Figure 1 depicts a flowchart for an improved process for preparing pork crackling products from pork rind. The pork rind may optionally be supplied to the process as a pork rind precursor, wherein the pork rind precursor is an arbitrarily-sized portion of a skin layer from a pig, with an adjacent layer of fat attached. The raw pork rind or pork rind precursor may therefore be pre-processed in order to prepare the pork rinds for use in the present invention. Thus, the term "pork rind" is used herein to refer generally to the skin layer with at least a substantial portion of the adjacent fat layer removed. In some cases the fat layer is completely removed so that the rind comprises substantially only a skin layer; however, it will be appreciated that it can be difficult to remove the entirety of the fat from the skin. The pork rind used in accordance with the invention therefore has a thickness largely determined by the skin layer, which may be between 3 and 7 mm, and is preferably about 5 mm.

A process for producing a flexible pork crackling precursor from a pork rind or pork rind precursor in a pre-cooking stage is described. The pork crackling precursor may subsequently be reliably and easily cooked to form pork crackling in a final cooking stage.

The pre-cooking stage comprises: removing a layer of fat adjacent to the pork rind or pork rind precursor; steam cooking at least one pork rind in a sealed container such that the container is in thermal contact with at least a portion of at least one of the pork rinds, and such that the steam is in thermal contact with the container. The final cooking stage comprises cooking the at least one pork rind in an oven to produce the pork crackling.

In the process of the present invention, the pork rind or pork rind precursor may be natural, salted, or otherwise preserved or smoked. Furthermore, the pork rind or pork

S

rind precursor may be fresh, chilled or frozen. It may be taken from any suitable area of the pig, and may in particular be taken from the belly or back of a pig.

In more detail and with reference to Figure 1, where necessary, a portion of the fat layer adjacent to the pork rind precursor is removed (20), such that the rind is the desired thickness (for example, approximately 5 mm or less in thickness).

Alternatively, the pork rind may also be provided with the adjacent fat layer already removed. Typically, the pork rind precursor is cut (30) to an appropriate size for processing. In cutting the pork rind it is desirable to produce similarly sized pieces, which may help in consistent preparation and reproducible cooking of each piece, especially when more than one pork rind is prepared simultaneously. For example, the pork rind precursor is cut into substantially rectangular pieces having approximate dimensions 250 mm by 200 mm, or other size which is convenient having regard to the container / bag in which the rinds are to be pre-cooked.

According to the embodiment exemplified, the pork rind pieces are then arranged within a vacuum bag (40). Beneficially, the pork rinds are arranged in an ordered fashion, for example, six pork rind pieces are arranged on top of one another in the vacuum bag. The vacuum bag may be of any suitable dimensions and material. For example, in the described embodiment, the vacuum bag comprises two sheets sealed at their peripheral edges, the sheets being manufactured from a combination of polythene and nylon, and having approximate dimensions 300 mm by 400 mm.

The primary function of the vacuum bag is to guard against moisture contacting the outer surface of the pork rinds, which may otherwise result in a pork rind with an undesirable gelatinous consistency. To this end, the vacuum bag has a high moisture barrier, with water vapour permeability of less than approximately 20 g/m224h.

Preferably, the water vapour permeability of the vacuum bag is less than approximately 10 g/m224h, and, more preferably, the water vapour permeability of the vacuum bag is less than approximately 5 g/m224h.

Likewise, the vacuum bag will desirably reduce oxygen (and air) transmission, which may increase the rate at which the pork rind degrades. Thus, the bag may have an oxygen permeability of less than approximately 85 cc/m224h atm. Preferably the oxygen permeability of the vacuum bag is less than 75 cc/m224h atm, and more preferably the oxygen permeability of the vacuum bag is less than 65 cc/m224h atm.

The nitrogen permeability of the vacuum bag may be less than approximately 15 cc/m224h atm and carbon dioxide permeability may be less than approximately 200 cc/m224h atm. However, it is envisaged that the vacuum bag may take any other suitable form. For example, the vacuum bag may be manufactured from any other material with suitable water vapour permeability and oxygen permeability characteristics. A preferred vacuum bag is a 300 mm by 400 mm blue tint, seven-layered vacuum pouch, manufactured from a polyethylene and nylon co-extruded blown film.

Once the pork rinds have been suitably arranged in the vacuum bag (40), a vacuum is applied (50) to an opening of the vacuum bag to remove substantially all of the air from within the vacuum bag. In this way, the vacuum bag seals tightly around the pork rind pieces so that the outermost surfaces of the pork rinds within the bag are in contact with the inner surface of the vacuum bag. In a preferred arrangement, a portion of the outer surface of each pork rind piece within the bag is in contact with a portion of the inner surface of the vacuum bag. This contact allows for thermal penetration into the rinds during the subsequent steam-cooking process, as will become apparent later. The term vacuum' is given its normal meaning in the art to refer to a space from which substantially all of the air has been removed, as is possible using commercial vacuum bags, for example.

The vacuum bag containing the pork rind pieces is then placed into a steam oven for the pre-cooking stage such that the vacuum bag is exposed to a steam atmosphere (60). Exposing the vacuum bag to the steam atmosphere pre-cooks the pork rinds in the vacuum bag. In the preferred embodiment, the pork rinds are pre-cooked at approximately 110°C for 4 hours. However, it will be appreciated that the cooking time and cooking temperature at the steam cooking stage (60) may be varied according to personal preference, and to this end, any suitable temperature and time may be used. The result of the steam-cooking process should be the production of flexible pork crackling precursors.

The flexible pork crackling precursors are still sealed within the vacuum bag so as to provide a pre-packaged pork crackling precursor product.

Advantageously, the steam cooking process (60) evenly pre-cooks the pork rind pieces so that when finally cooked to become pork crackling, the result is consistent.

Vacuum sealing the vacuum bag (50) assists in allowing water vapour or steam to come into thermal contact with a portion of the outer surface of each of the pork rind pieces. Furthermore, the vacuum sealing (50) tightly packs the pork rind pieces together, such that the pork rind pieces maintain a substantially planar configuration during the pre-cooking stage. Minimal deformation at the pre-cooking stage means that the pork rinds may be provided with a desired shape in the final cooking stage.

In addition, vacuum packing of the pork rinds may improve thermal transfer between the pork rinds, resulting in a more consistent pre-cooking stage.

The steam cooking process may also allow for greater control over the cooking temperature of the pork rind pieces, and helps to prevent local temperature variations in the oven. In this way, the possibility of portions of a pork rind being overcooked or undercooked is reduced. It is believed that the steam in the steam cooking process may help to control the temperature of the oven, such that a substantially precise, consistent and uniform temperature is provided throughout the oven for cooking the pork rind pieces. Thermal contact between the steam (through the container) and the outer surface of the pork rind pieces allows for quick heat transfer into the pork rind pieces, which may allow for steam cooking to be carried out at a lower temperature than may be possible in a conventional oven.

A further advantage of the steam pre-cooking process of the invention is that any fat that remains adjacent to the rind is rendered, such that a crisp pork crackling product is more readily formed during the final cooking stage. Additionally, the vacuum bag contains all of the juices and aroma released during the steam cooking process, which may result in an improved, more flavoursome final product.

It will be appreciated that in some embodiments the steam cooking temperature and time may be varied according to preferences. For example, the cooking temperature may be between approximately 85°C and 150°C, between approximately 9000 and 140°C, between approximately 95°C and 130°C, or between approximately 100°C and 120°C. In some embodiments the cooking temperature may be varied during the steam cooking stage. Typically, the length of the cooking time may be selected in proportion to the selected temperature. For example, as the temperature is increased, the cooking time may be reduced. Typically, the cooking time at this stage is between approximately 2 hours and 6 hours, between approximately 2.5 hours and 5.5 hours, between approximately 3 hours and 5 hours, or between approximately 3.5 hours and 4.5 hours.

After removing the vacuum bag containing the pork rind pieces from the steam oven, the pork crackling precursor is frozen (80). This may be carried out directly, after steaming (60), or the rinds may first be chilled (70) prior to freezing (80). The term chilling' is used herein to describe a reduction in the temperature of the pork rinds to a temperature that is typically between 5°C and 0°C. Legal requirements may determine to what temperature and over what time period it is necessary to chill the pork rinds for commercial use. The term freezing' is used herein to describe a reduction in the temperature of the pork rinds to 0°C or below, and preferably to a temperature of approximately -18°C or below, such that the flexible pork crackling precursors are in a frozen state. Again, legal requirements may determine to what temperature and over what time period it is necessary to freeze the pork rinds for commercial use.

In a preferred embodiment the chilling stage (70) is carried out prior to freezing, since this allows for an initial heat component to be removed from the pork rind pieces. A blast chiller (or any other suitable refrigeration means), may be used for this purpose, before a second heat component is removed from the pork rind pieces within e.g. a blast freezer (or any other suitable freezing means). It is believed that this two-stage approach (70), (80) is more efficient for temperature reduction, and reduces the costs associated with the freezing process (80). In a preferred embodiment, the vacuum bag containing the pork rinds is placed into a blast chiller and the pork rinds cooled to a temperature of approximately 4°C over a period of around 90 minutes. It is envisaged that the pork rinds may alternatively be cooled to approximately 5°C or less in 90 minutes, as required by legislation. The vacuum bag containing the pork rinds is then placed in a blast freezer and frozen to a temperature of approximately -18°C or lower.

The pork rind pieces are preferably left in the vacuum bag throughout the chilling and freezing process, for convenience in transfer of the pork rind pieces between the apparatus and also for improved hygiene. However, it is envisaged that the pork rind pieces may be removed from the vacuum bag (or other container) prior to insertion into the blast chiller or the blast freezer. In this event, the pork rinds may be first placed in an alternative container for the purposes of chilling and/or freezing and storage.

The pork rind pieces may be held in the freezer for up to approximately 12 months until the final pork crackling product is required. This allows for a significant portion of the pork rind preparation to be carried out in advance of the final product being required, which increases the efficiency with which the final product can be prepared.

This may be particularly beneficial in the event that the pork crackling is to be an addition to a larger meal in a restaurant, where reduced time and effort allocated to preparing the pork crackling allows a chef to allocate a greater portion of time and effort to the preparation of other fresh food products. The pork rinds may also be readily transported in a frozen state, allowing for transfer of the pork rind pieces between different facilities and establishments, such as restaurants.

To provide the finished pork crackling product, one or more of the pork crackling precursors are removed from the freezer and firstly thawed in a controlled manner (e.g. tempered) (90). For example, the pork rind pieces are placed in a refrigerator and the temperature of the pork rind pieces is thus slowly raised to a temperature between approximately 0°C and 5°C. Alternatively, the tempering stage (90) may be executed in any other such suitable temperature-controlled environment. At the end of the tempering process (90), the pork rind pieces have a soft and pliable consistency, such that they are supple relative to the raw pork rind precursor and may be relatively easily cut or moulded into a desired shape (100), as may be desired. For example, the pork rind pieces may be shaped by cutting into smaller circle-shaped pieces, heart-shaped pieces or any other such shape as required. It is envisaged that three-dimensional shapes may also be produced from the flexible pork crackling precursor of the invention.

After tempering (90), and optionally shaping (100), the pork rind pieces are subjected to a final cooking stage (110) in order to produce the edible pork crackling product.

Accordingly, the pieces (removed from the container in which they were stored or steamed) are placed into an oven or fryei for cooking. Suitably, the pork crackling precursor is placed on a baking tray in a pre-heated oven at approximately 200°C, and is cooked for up to approximately 20 minutes or until crisp. It will of course be appreciated that the cooking temperature and time at this cooking stage may be varied according to preference. For example, the cooking temperature may be a temperature between approximately 160°C and 240°C, between approximately 170°C and 230°C, between approximately 180°C and 220°C, or between approximately 190°C and 210°C. In some embodiments the cooking temperature may be varied during the cooking stage (110). As with the steam cooking stage (60), the length of the cooking time may be selected in proportion to the selected temperature, with the cooking time reduced proportionally to any rise in cooking temperature, for example. Typically, the cooking time at this stage is between approximately 10 minutes and 30 minutes, between 14 minutes and 26 minutes, or between approximately 17 minutes and 23 minutes.

After completion of the final cooking stage, the pork rind pieces are removed from the oven, in the form of the final pork crackling product, with a crisp / crunchy texture.

Any additional seasonings or flavourings may be added at this stage, before the pork crackling pieces are packaged, consumed individually or added to a larger meal. It is also envisaged that the final pork cracking product may then be freezed for later use.

The following non-limiting Example is provided to illustrate the method for producing pork rind products and pork crackling in accordance with the invention.

EXAMPLE

Preparation of pork crackling precursors: The fat layer was first removed from a raw pork rind precursor, such that the rind had a thickness of approximately 5 mm. The pork rind was then cut into multiple pieces with dimensions of 250 mm by 200 mm and packed into a vacuum sealable bag with dimensions 300 mm by 400 mm. In this way, six pork rind pieces were positioned so as to be stacked on top of one another in the vacuum bag.

The vacuum bag was vacuum then sealed and a vacuum source applied to remove air from the bag and tightly pack the rinds on top of one another. The sealed vacuum bag was then inserted into a steam oven and cooked at approximately 110°C for approximately 4 hours.

On removal from the steam oven, the vacuum bag containing the pork rind pieces was placed into a blast chiller, and the temperature of the pork rind pieces reduced to approximately 4°C over a period of approximately 90 minutes. The vacuum bag containing the pork rind pieces was then transferred from the blast chiller to a blast freezer and the temperature of the pork rind pieces reduced to approximately -18°C for storage of the pork crackling precursors.

Preparation of pork crackling: The vacuum bag containing the frozen pork crackling precursors was removed from the freezer and placed into a refrigerator, such that the pork rind pieces could be slowly thawed to a temperature of approximately 5°C.

Before cooking, the pork rind pieces were cut into a number of smaller pieces of desired size and shape (e.g. rectangles, circles etc.). The smaller pieces were then positioned on a baking tray and inserted into a pre-heated oven and cooked at a temperature of approximately 200°C for 20 minutes. The pork rind pieces were then removed from the oven in the form of pork crackling.

The pork crackling products had a relatively uniform appearance, were uniformly crispy and ready to eat.

The above Example illustrates a preferred process according to the invention, but it is not intended that it should limit the scope of the invention. Thus, although a vacuum bag is used in the embodiments described, other containers are envisaged. For example, the container may take the form of a rigid layer and a flexible layer joined together along their peripheral edges, or a number of rigid layers joined together, where relative movement between the layers creates a seal around the pork rind pieces on application of a vacuum. The pork rinds may be removed from the container prior to chilling or freezing, such that individual pork rind pieces are placed into the blast chiller or the blast freezer. Thus, the pre-packaged pork crackling precursor of the invention may be pre-packaged in an alternative container to the container exposed to the steam atmosphere during the steam cooking stage.

It will be appreciated by a person skilled in the art that the invention could be modified to take many alternative forms to that described herein, without departing from the invention, which is defined by the scope of the appended claims.

Claims

CLAIMS1) A process for preparing a pre-packaged pork crackling precursor, the process comprising: sealing one or more pork rinds in a container such that the container is in thermal contact with at least a portion of at least one pork rind; and exposing the container to a steam atmosphere such that the steam is in thermal contact with the container, thereby to produce a flexible pork crackling precursor.
2) The process of claim 1, further comprising removing air from the container.
3) The process of claim 1 or claim 2, further comprising removing substantially all of the air from the container, such that the container encloses a vacuum.
4) The process of any previous claim, wherein the container comprises one or more flexible walls.
5) The process of any previous claim, wherein the container is a bag capable of being subjected to a vacuum.
6) The process of any previous claim, wherein the temperature of the steam atmosphere is between approximately 100°C and 120°C.
7) The process of any previous claim, wherein the temperature of the steam atmosphere is approximately 110°C.
8) The process of any previous claim, wherein the container is exposed to the steam atmosphere for between approximately 3 and 5 hours.
9) The process of any previous claim, wherein the container is exposed to the steam atmosphere for approximately 4 hours.
10)The process of any previous claim, further comprising freezing the flexible pork crackling precursor.
11) The process of claim 10, wherein the freezing is to a temperature of approximately -18°C.
12)The process of any previous claim, further comprising chilling the flexible pork crackling precursor.
13)The process of claim 10 or claim 11, wherein chilling the flexible pork crackling precursor is carried out prior to freezing the flexible pork crackling precursor.
14)The process of claim 12 or claim 13, wherein the chilling is to a temperature of approximately 4°C or less.
15) The process of any of claims 12 to 14, wherein after exposing the container to the steam atmosphere the flexible pork crackling precursor is chilled to a temperature of approximately 4°C or less within a period of approximately 90 minutes.
16) The process of any of claims 10 to 15, wherein the flexible pork crackling precursor is sealed within the container during freezing and/or chilling.
17) The process of any previous claim, wherein the one or more pork rinds have length and/or width dimensions between approximately 50 mm and 400 mm.
18) The process of any previous claim, wherein the one or more pork rinds have length and width dimensions between approximately 200 mm and 250 mm.
19)The process of any previous claim, wherein the one or more pork rinds are approximately 5 mm in thickness.
20) The process of any previous claim, wherein the pork rind is comprised of a skin layer which is substantially free from fat.
21)The process of any previous claim, wherein there is a plurality of pork rinds and the pork rinds are arranged in the container in one or more layers.
22) A pre-packaged pork crackling precursor produced by the process of any of claims 1 to 21.
23) A pre-packaged pork crackling precursor comprising: a sealed container and at least one pork crackling precursor therein, the or each pork crackling precursor being a flexible steam-cooked pork rind, and wherein at least one pork crackling precursor is in thermal contact with the container.
24) The pre-packaged pork crackling precursor of claim 23, wherein the sealed container encloses a vacuum.
25) The pre-packaged pork crackling precursor of claim 23 or claim 24, wherein the pork crackling precursor is frozen.
26) The pre-packaged pork crackling precursor of claim 23 or claim 24, wherein the pork crackling precursor is chilled to a temperature of approximately 4°C or less.
27) The pre-packaged pork crackling precursor of any of claims 23 to 26, wherein the pork crackling precursor has length and/or width dimensions between approximately mm and 400 mm.
28) The pre-packaged pork crackling precursor of any of claims 23 to 27, wherein the sealed container has at least one flexible wall.
29) The pre-packaged pork crackling precursor of any of claims 23 to 28, wherein the sealed container is a bag capable of being subjected to a vacuum.
30) The pre-packaged pork crackling precursor of any of claims 23 to 29, wherein the sealed container has a water vapour permeability of less than approximately 5 g/m224h.
31)The pre-packaged pork crackling precursor of any of claims 23 to 30, wherein the pork crackling precursor is between approximately 3 mm and 7 mm in thickness and comprises a skin layer.
32)A process for preparing a pork crackling product from the pre-packaged pork crackling precursor of any of claims 23 to 31, the process comprising: removing the pork crackling precursor from the container; optionally thawing the pork crackling precursor to obtain a flexible pork crackling precursor; and cooking the pork crackling precursor to obtain the pork crackling product.
33) The process of claim 32, wherein the cooking is at a temperature of between approximately 175°C and 225°C.
34) The process of claim 32 or claim 33. wherein the cooking is at a temperature of approximately 200°C.
35)The process of any of claims 32 to 34, wherein the cooking is for a period of approximately 20 minutes.
36) The process of any of claims 32 to claim 35, further comprising thawing the flexible pork crackling precursor prior to cooking.
37) The process of any of claims 32 to 36, further comprising shaping the flexible pork crackling precursor prior to cooking.
38)A process of producing a pork crackling, the process comprising the process for preparing a pre-packaged pork crackling precursor of any of claims 1 to 22, in combination with the process for preparing a pork crackling from a pre-packaged pork crackling precursor of any of claims 32 to 37.
39) A process for preparing a pre-packaged pork crackling precursor substantially as hereinbefore described.
40) A pre-packaged pork crackling precursor substantially as hereinbefore described.

41)A process for preparing a pork crackling product substantially as hereinbefore described.Amendments to the claims have been filed as follows:CLAIMS1) A process for preparing a pre-packaged pork crackling precursor, the process comprising: sealing one or more pork rinds in a container such that an interior surface of the container is in thermal contact with at least a portion of at least one pork rind; and exposing an exterior surface of the container to a steam atmosphere such that the steam is in thermal contact with the portion of at least one pork rind, thereby to produce a flexible pork crackling precursor.2) The process of claim 1, further comprising removing air from the container.3) The process of claim 1 or claim 2, further comprising removing substantially all of the air from the container, such that the container encloses a vacuum.4) The process of any previous claim, wherein the container comprises one or more flexible walls.5) The process of any previous claim, wherein the container is a bag capable of being subjected to a vacuum.6) The process of any previous claim, wherein the temperature of the steam atmosphere is between approximately 100°C and 120°C.7) The process of any previous claim, wherein the temperature of the steam atmosphere is approximately 110°C.8) The process of any previous claim, wherein the container is exposed to the steam atmosphere for between approximately 3 and 5 hours.9) The process of any previous claim, wherein the container is exposed to the steam atmosphere for approximately 4 hours.10)The process of any previous claim, further comprising freezing the flexible pork crackling precursor.11) The process of claim 10, wherein the freezing is to a temperature of approximately -18°C.12)The process of any previous claim, further comprising chilling the flexible pork crackling precursor.13)The process of claim 10 or claim 11, wherein chilling the flexible pork crackling precursor is carried out prior to freezing the flexible pork crackling precursor.14)The process of claim 12 or claim 13, wherein the chilling is to a temperature of approximately 4°C or less.15) The process of any of claims 12 to 14, wherein after exposing the container to the steam atmosphere the flexible pork crackling precursor is chilled to a temperature of approximately 4°C or less within a period of approximately 90 minutes.16) The process of any of claims 10 to 15, wherein the flexible pork crackling precursor is sealed within the container during freezing and/or chilling.17) The process of any previous claim, wherein the one or more pork rinds have length and/or width dimensions between approximately 50mm and 400 mm.18) The process of any previous claim, wherein the one or more pork rinds have length and width dimensions between approximately 200 mm and 250 mm.19)The process of any previous claim, wherein the one or more pork rinds are approximately 5 mm in thickness.20) The process of any previous claim, wherein the pork rind is comprised of a skin layer which is substantially free from fat.21)The process of any previous claim, wherein there is a plurality of pork rinds and the pork rinds are arranged in the container in one or more layers.22) A pre-packaged pork crackling precursor produced by the process of any of claims 1 to 21.23)A pre-packaged pork crackling precursor comprising: a sealed container having an interior surface and an exterior surface and at least one pork crackling precursor therein, the or each pork crackling precursor being a flexible steam-cooked pork rind, and wherein at least one pork crackling precursor is in thermal contact with the interior surface of the container.24) The pre-packaged pork crackling precursor of claim 23, wherein the sealed container encloses a vacuum.25) The pre-packaged pork crackling precursor of claim 23 or claim 24, wherein the pork crackling precursor is frozen.26) The pre-packaged pork crackling precursor of claim 23 or claim 24, wherein the pork crackling precursor is chilled to a temperature of approximately 4°C or less.27) The pre-packaged pork crackling precursor of any of claims 23 to 26, wherein the pork crackling precursor has length and/or width dimensions between approximately mm and 400 mm.28) The pre-packaged pork crackling precursor of any of claims 23 to 27, wherein the sealed container has at least one flexible wall.29) The pre-packaged pork crackling precursor of any of claims 23 to 28, wherein the sealed container is a bag capable of being subjected to a vacuum.30) The pre-packaged pork crackling precursor of any of claims 23 to 29, wherein the sealed container has a water vapour permeability of less than approximately 5 g/m224h.31)The pre-packaged pork crackling precursor of any of claims 23 to 30, wherein the pork crackling precursor is between approximately 3 mm and 7 mm in thickness and comprises a skin layer.32) A process for preparing a pork crackling product, the process comprising: providing the pre-packaged pork crackling precursor of any of claims 23 to 31; removing the pork crackling precursor from the container; optionally thawing the pork crackling precursor to obtain a flexible pork crackling precursor; and cooking the pork crackling precursor to obtain the pork crackling product.33) The process of claim 32, wherein the cooking is at a temperature of between approximately 175°C and 225°C.34) The process of claim 32 or claim 33. wherein the cooking is at a temperature of approximately 200°C.35)The process of any of claims 32 to 34, wherein the cooking is for a period of approximately 20 minutes.36) The process of any of claims 32 to claim 35, further comprising thawing the flexible pork crackling precursor prior to cooking.37) The process of any of claims 32 to 36, further comprising shaping the flexible pork crackling precursor prior to cooking.38)A process of producing a pork crackling, the process comprising the process for preparing a pre-packaged pork crackling precursor of any of claims 1 to 22, in combination with the process for preparing a pork crackling from a pre-packaged pork crackling precursor of any of claims 32 to 37.39) A process for preparing a pre-packaged pork crackling precursor substantially as hereinbefore described.40) A pre-packaged pork crackling precursor substantially as hereinbefore described.
41)A process for preparing a pork crackling product substantially as hereinbefore described.