GB2551050A

GB2551050A - Improvements in or relating to the coating of food with batter

Info

Publication number: GB2551050A
Application number: GB1708629.9A
Authority: GB
Inventors: Moorcroft Peter
Original assignee: ICELANDIC GROUP UK Ltd
Current assignee: ICELANDIC GROUP UK Ltd
Priority date: 2016-06-02
Filing date: 2017-05-31
Publication date: 2017-12-06
Anticipated expiration: 2037-05-31
Also published as: GB2551050B; WO2017207954A1; GB201708629D0; GB201609650D0

Abstract

A portion of food 16 such as fish, seafood or meat is coated with a composite batter coating and part-cooked to at least partially cook the coating. The coating comprises a powder or crumb coating 20, 22 and a primary batter 24. The primary batter comprises batter 30 including at least flour, water and an emulsifier, aerated in a mixer 28 with food-safe gas 34 such as air, C02 or N2. Excess batter is recirculated and degassed via secondary mixer 44. The food portion 16 may undergo de-glazing 15, pre-dusting 17 and/or batter wash-coating 18 prior to application of the composite batter. The powder or crumb coating 20, 22 may be applied after the primary batter 24 (see figure 4). The emulsifier is preferably palm oil and forms 7-8% by weight of the primary batter coat. The level of aeration in the primary batter coat may be controlled within a predetermined range. The primary batter is preferably applied by conveying the food portion through a batter bath 41 using a belt 92 located above the bath, and subsequently passing through a batter curtain 24. The battered food portion is part-cooked by conveying through an oil bath (see fig. 8).

Description

Imnimvcmeiits in or Relating to flie Coating of Food with Batter Technical Field

Hie invention relates to improvements in or relating to the coating of food widi batto*, and in particular a method of ^plying a batter coating, and an apparatus for the coating of food ^th batter.

Background

It is known to provide a way of battering food such as fish comprising three steps. In a first stage a pre-wash of batter is applied to fish, which may be fiozen or fiesh, on a belt using a curtain enrober. In a second stage a crumb is applied using a mechanical breader with a crumb curtain and base bed of crumb. In a third stage a finther coat of batter is applied to the fish using a subm^ge system whereby the fish passes through and is submerged in a trough of batter. In this prior art system, batter is mixed in a vessel with a high speed whisk or shear blade in the base and an outer jacket to keep the l^itter cool. Batter viscosity is measured at each stage using a flow cup (i.e. a cup with a hole in its base is filled with a known amoimt of batter, and the time taken for the batter to flow out of the hole is recorded). Importantly, in the third stage the batter is mixed using chilled water at 5 °C, and is maintained within a target viscosity and kept at a chilled temperature of around 10 °C +/- 2 °C. The amount of interinediate crumb pick up is measured by weighing. The batter contains various raising agents which react under the correct cooking conditions to deliver a level of crispness. Once the seafood product (i.e. fish) has passed through the three stages it enters a flyer for 50-60 seconds with rapeseed oil at 195-205 °C. The product is not fully cooked (i.e. seafood remains fi:ozen but the outer coating is cooked). The final stage before packing is to re-£reeze the product so the product can be stored before sale. The product may be sold to the consumer in the frozen state, or it may be defrosted at the point of sale for purchase by the consumer.

Whereas the known way of coating food may keep fresh, for example up to seven days once thawed, a problem may be encountered towards the end of this shelf life because water and juices may be lost from the food resulting in soggy batter. The water may contribute to reducing the shelf life and appearance of the food, or at least contribute to a reduction in the colour, flavouror integrity ofthe food after two or three days. In addition, the soggy batter looks unsightly and may break away prior to cooking vMch is unappealing to the consumer. A further problem is that an optimal (i.e. Organoleptic) process result for the correct texture afrer cooking (i.e. crispness, light eating, and no thick under layer) is difficult to achieve. Chilled (i.e. non-frozen) batter products have a seven day sl^lf life, and ofren after two or three days the texture attributes reduce creating a much softer and heavier tasting product. Frozen batter products are cooked by the consumer from frozen, so entail fewer problems over the life of the product. A further problem is that, although die product is part fried within the process, the final cooking by the consumer is by baking in an oven. This oven baking does not replicate the traditional cooking method of deep frying, so creating the correct texture which replicates deep fiying is a further challenge.

It is broadly an object of Ihe present invention to address one or more of the above mentioned disadvantages of the previously known ways of battering food.

In particular, it is an object of tiie present invention to provide a method and apparatus that afford one, some or all of the following product attributes: • Texture with crispness, light eating and no thick under layer; • Uniformity of eating experience regardless of the point within the chilled life of up to seven days at which home cooking is performed; • Correct/intended texture achieved after consumer oven baking; • Consistent product quality for every production run; and • A robust and measurable process.

Summary

What is required is a way of battering food which may reduce or minimise at least some of the above-mentioned problems.

According to a first aspect of the invention, there is provided a method of applying a composite batter coating to a portion of food, the method including: applying the composite batter coating to the portion of food, the composite batter coating comprising at least a primary batter coat, and a crumb coat or a powder coat; and part-cooking the portion of food to at least partially cook the composite batter coating; \>riierein applying the composite batter coating comprises providing the primary batter coat comprising at least fiour, water and an emulsifier; and aerating the primary batter coat with a food-safe gas prior to applying the primary batter coat.

Such a method has the advantage that the portion of battered food may be fresher for a longer period of time, which may increase the shelf life, or at least contributes to an improved colour, flavour or integrity of the food over a given period of time. It will be appreciated that the emulsifier is a food safe emulsifier.

In addition, an advantage is that there are no intermediate layers of batter after ovencooking and there is only one homogenous layer. In other words the base batter coat, crumb coat, and primary batter coat appear as one after oven cooking. The batter also makes the fish look bigger i.e. has a volumising effect, which is appealing to the consumer because it is light and crispy.

Also, the batter process provides the advantage of an improved quality of the batter (e.g. a better quality colour of batter and a less mushy batter) at or near to the end of the shelf life of the product. The problem of a “soggy bottom” for the finished product is avoided.

In one embodiment, applying the composite batter coating comprises: applying a base batter coat to the portion of food; applying the crumb coat to the base batter coat; and applying the primary batter coat to the crumb coat.

The method may ftuther include de-glazing the portion of food prior to applying the base batter coat or the powder coat.

In one embodiment, applying the composite batter coating comprises: ^yplying the primary batter coat to the portion of food; and applying the crumb coat to the primary batter coat.

The mediod may further include de-glazing the portion of food prior to ^plying the primary batter coat, or applying a base batter coat to the portion of food prior to applying the primary batter coat.

The method may further include applying a powder coat to the portion of food prior to applying the primary batter coat.

Preferably, the method further includes implying the primary batter coat using a fantail nozzle. Using a nozzle in this form can reduce wastage of batter. In addition, using a nozzle in this form can reduce handling of the batter and reduce “knock out” of the CO2 from the mixture, i.e. as the use of a fiill “curtain” of batter is avoided.

Preferably, aerating the primary batter coat comprises controlling the amount of the food-safe gas in die primary batter coat so as to maintain the level of aeration thereof within a predetermined range. Advantageously, the level of £teation is not fixed and may be readily controlled to the ^propriate value, depending on the type of batter.

Preferably, aerating the primary batter coat comprises using an aeration device eomiected to a source of the food-safe gas. Preferably, aerating the primary batter coat comprises periodically or continuously: measuring the level of aeration of the primary batter eoat. and if level of aeration is not within a predetermined range, adjusting the input pressure of the food-safe gas into the aeration device so as to maintain the level of aeration within the predetermined range. Preferably, measuring the level of aeration of the primary batter coat comprises measuring the ratio of the weight of a fixed volume of (i) batter for the primary batter coat to (ii) non-aerated batter that has not entered the aeration device.

Preferably, the predetermined range corresponds to a ratio of the weight of a fixed volume of (i) aerated batter for the primary batter coat to (ii) non-aerated batter having the range 43.75% to 50%. The combination of the correct ingredients, accurate levels of aeration and accurate depositing/enrobing produces a product with the desired attributes. In particular, when finally cooked, the batter exhibits crispiness with blade/like or spike-like projections or other so-called “flares” and “highlights” of batter, thereby giving the finished (cooked) product a hand-made look.

In one embodiment, the aeration device is configured to receive a first input of non-aerated batter at 6 bar and a second input of food-safe gas at 8 bar.

In embodiments, the emulsifier forms 2-10%, more preferably 5-10%, and more preferably 7-8% by weight of the primary batter coat.

Preferably, the emulsifier is a fat or oil. Preferably, the emulsifier is palm oil fat. Such a fat or oil is a food-safe fat or oil. It is understood by the inventors that the fat or oil releases or “sweats out” of the batter when the food product is oven-cooked by the consumer, thereby creating the crispy flares. It is believed that the gas bubbles remain in the batter due to the fat/onulsifier (e.g. palm oil fat) and in effect the gaslocks onto the fat, creating a better aeration of the batter when mixed.

The method preferably furth»- comprises, prior to the step of aerrding the primary batter coat, controlling the tonperature of the batter for the primary batter coat so as to be within a predetermined temperature rmige. Preferably, die predetermined temperature rmge is 8-12 °C, more preferably 8-11 °C, and more preferably 10 °C.

The aeration device preferably comprises a rotor and stator, die rotor and stator having intermeshing pins.

The method may further comprise: collecting a portion of the primary batter coat that does not adhere to the portion of food during the ^plying the composite batter coating; remixing the portion of die primary batter coat in a secondary mixer so as produce a remixed portion of batter from which the food-safe gas has been substantially removed; and incorporating the remixed portion of batter into tfae primary batter coat prior to aerating the primary batter coat with the food-safe gas. Thus, excess batter is collected in a secondary mixer vdiich re-mixes the batter, thereby reduciug the levels of gas before it is returned to the aeration device. Re-mixing the batter ensures an accurate and continuous level of aeration.

Preferably said applying the composite batter coating to the portion of food comprises applying the primary batter coating to the portion of food from above. Such a way of applying the aerated batter from above helps to retain the bubbles within the aerated batter

Miien ^plying it to the portion of food so that the gas is less likely to be knocked out of the batter during the ^)plication stage.

Preferably the method further comprises collecting a portion of the jnimary batter coat in a batter bath, and coating an underside and sides of the portion of food in the batter bath using the portion of primary batter coat. Preferably the method forther comprises coating the imderside and sides of the portion of food in the batter bath before applying the primary batter coating to tiie portion of food from above. Such a way of coating tiie portion of food means that the next step of part-cooking the portion of food is performed immediately after the top of the portion of food has been coated with the primary batter.

Preferably the method further comprises using a belt above the batter bath to draw the portion of food through the batter bath.

Preferably, part-cooking the portion of food comprises frying the composite batter coating. Preferably said frying comprises submerging the portion of food in an oil bath.

Preferably the method frirther includes using one or more belts at least partially or vriiolly within the oil bath to draw the portion of food through the oil bath. Preferably the method further includes using the one or more belt to submerge tiie portion of food in the oil bath.

Preferably the method further includes adjusting a horizontal position of the one or more belts to set a position at which the portion of food is engaged in order to set a point at which the portion of food is submerged in the oil bath. Such an arrangement providies tiie advantage of a degree of control when a belt contacts the portion of food in order to reduce or minimise marking of the portion of food by the belt.

Preferably the method further including fiying the portion of food within 1 to 5 seconds after application of the primary batter coat Preferably the method further including fiying the portion of food within 2 to 4 seconds after application of the primary batter coat.

Preferably, the food-safe gas is one or more of carbon dioxide, nitrogen, air, and nitrous gas.

According to a second aspect of the invention there is provided a portion of food coated with batter using the method according to any of the method claims 1 - 32.

According to a third aspect of the invention there is provided an app>aratus for applying a composite batter coating to a portion of food, the composite batter coating comprising at least a primary batter coat, and a crumb coat or a powder coat, the apparatus including: a source of a primary batter coat, the primary batter coat comprising at least flour, water and an emulsifier; an aeration device, coupled to the source of the primary batter coat, for aerating the primary batter coat with a food-safe gas prior to applying the primary batter coat; a plurality of coating plication st^es for ^plying the composite batter coating to the portion of food, the plurality of coating application stages including at least a primary batter coat application stage and a crumb coat application stage; and a cooking device for part-cooking the portion of food to at least partially cook the composite batter coating.

In one embodiment, die plurality of coating {^plication stages comprise: a base batter coat implication stage, for applying a base batter coat to the portion of food; the crumb coat implication stage, for ^plying the crumb coat to the base batter coat; and the {nimary batter coat application stage, for applying the primary batter coat to the crumb coat

The apparatus may further include a de-glazing device, for de-glazing the portion of food prior to applying the base batter coat or the powder coat

In another embodiment, the plurality of coating application stages comprise: the {nimaiy batter coat application stage, for flying the primary batter coat to the portion of food; and the crumb coat application stage, for qtplying the crumb coat to the primary batter coat.

The apparatus may hirther including; a de-glazing device, for de-glazing the portion of food prior to ^plying the primary batter coat; or a base batter coat application stage, for ^plying a base batter coat to the portion of food prior to ^plying the primary batter coat

The apparatus may further include a powder application stage, for apfdying a powdor coat to the portion of food prior to applying the primary batter coat.

PreferaMy, the primary batter coat implication stage includes a fantail nozzle for applying the primary batter coat.

The apparatus prefqiably fiirther comprises a controller for controlling the amount of the food-safe gas in the primary batter coat so as to maintain the level of aeration thereof within a predetermined range.

Preferably, the aeration device is coimected to a source of the food-safe gas. The ^rparatus preferably further comprises a controller configured for periodically or continuously: measuring the level of aeration of the primary batter coat, and if the level of aeration is not within a predetermined range, adjusting the input pressure of the food-safe gas into the aeration device so as to maintain the level of aeration within the predetermined range. Preferably, measuring the level of aeration of the primary batter coat comprises measuring the ratio of the weight of a fixed volume of (i) batter for the primary batter coat to (ii) non-aerated batter that has not entered die aeration device.

Preferably, the predetermined range corresponds to a ratio of the weight of a fixed volume of (i) aerated batter for the primary batter coat to (ii) non-aerated batter having the range 43.75% to 50%.

Preferably, the aeration device is configured to receive a first input on non-aerated batter at 6 bar and a second input of food-safe gas at 8 bar.

Preferably, the emulsifier forms 2-10%, more preferably 5-10%, and more preferably 7-8% by weight of the primary batter coat.

Preferably, the emulsifier is a fat or oil. Preferably, the «nulsifier is palm oil fat.

The ^>paratus preferably further comprises a controller for, prior to the step of aerating the primary batter coat, controlling the temperature of the batter for the primary batter coat so as to be within a predetermined temperature range.

Preferably, the predetermined temperature range is 8-12 °C, more preferably 8-11 °C, and more preferably 10 ®C.

Preferably, the aeration device comprises a rotor and stator, the rotor and stator having intermeshing pins.

The apparatus may further comprise: a collection device for collecting a portion of the primary batter coat that does not adhere to the portion of food during the applying the composite batter coating; a secondary mixer for remixing the portion of the primary batter coat so as produce a remixed portion of batter from i^ch the food-safe gas has been substantially removed; and at least one conduit for incorporating die remixed portion of batter into the primary batter coat prior to aerating the primary batter coat ivith a food-safe gas.

Preferably the primary batter coating stage comprises an oudet to apply the primary batter coating to the portion of food from above. Such a way of applying the aerated batter from above helps to retain the bubbles within the aerated batter when ^plying it to the portion of food so that the gas is less likely to be knocked out of the batter diuing the application stage.

Preferably the apparatus comprises a batter bath to collect a portion of the primary batter coat, wherein the primary batter coating stage comprises coating an underside and sides of the portion of food with the portion of primary batter coat in the batter bath. Preferably the apparatus comprises coating the underside and sides of the portion of food in the batter bath before ^plying the primary batter coating to the portion of food finm above. Such a way of coating the portion of food means that the next step Of part-cOoking the portion of food is performed immediately after the top of the portion has been coated with the primary batter.

Preferably the qjparatus comprises a belt above the batter bath to draw the portion of food through the batter bath.

Preferably, the cooking device comprises a flyer conflgured for flying composite batter coating. Preferably said flyer comprises an oil bath for submerging the portion of food.

Preferably one or more belt are provided at least partially within the oU bath to draw the portion of food through the oil bath. Preferably the one or more belts are operable to submerge the portion of food in the oil bath.

Preferably the apparatus comprising an adjustment device for adjusting a horizontal position of die one or more belts to set a position at which the portion of food is engaged in order to set a point at which the portion of food is submerged in the oil bath. Such an arrangement provides the advantage of a degree of eontrol when a belt contacts the portion of food in order to reduee or minimise marking of the portion of food by the belt.

Preferably one or more belts have a non-stiek eoating to reduce sticking of fhe portion of food thereto.

According to a fourth aspect of the invention there is provided an apparatus for performing the method according to the first aspect of the invention.

According to an alternative characterisation of the invention there is {novided a method of applying a batter coat to a portion of food, the method including: inoviding the batter coat comprising at least flour, water and an emulsifier; aerating the batter coat witii a food-safe gas; transporting the portion of food on a conveyor device past a batter ^tplication sh^; applying the batter coat to the portion of food at the batter ^φplication stage; and part-cooking the portion of food to at least partially cook the batter coat.

According to a fiirther alternative characterisation of the invention there is provided an ^paratus for applying a batter coat to a portion of food, the apparatus including: a source of a batter coat, the batter coat comprising at least flour, water and an emulsifier; an aeration device, coupled to the source of the batter coat, for aerating the batter coat with a food-safe gas; a batter plication stage; a conveyor device for transporting thereon die portion of food past the batter application stage; a cooking device for part-cooking the portion of food to at least partially code the composite batter coating; wherein, in use, the batter coat is applied to the portion of food as the portion of food passes the batter application stage.

According to a further alternative characterisation of the invention there is provided a method of ^plying a batter coat to a portion of food, the method including; providing a first batter coat comprising at least flour and water; ^plying the first batter coat to the portion of food; applying a crumb coat or a powder coat to the first batter coat; providing a second batter coat comprising at least flour, water and an emulsifier; aerating the second batter coat with a food-safe gas; applying the second batter coat to the portion of food over the first coat and the crumb coat; and part-fiying the portion of food to at least partially cook die first coat, the crumb coat, and second batter coats.

According to a further alternative characterisation of the invention there is provided an sqipaiatus for ^iplying a batter coat to a portion of food, the apparatus including; a source of a first batter coat, the first batter coat comprising at least flour and water; a source of a second batter coat, the second batter coat comprising at least flour, water and an emulsifier; an aeration device, coτφled to the soinve of die second batter coat, for aerating the second batter coat with a food-safe gas; a source of crumb or a powder; a first batter ^plication stage to ^ly the first batter coat to the portion of food; a crumb application stage to apply a crumb coat to the first batter coat, or a powder application stage to apply a powder coat to the first batter coat; a second batter application stage to apply the second batter coat to the portion of food over the first batter coat and the crumb coat or the powder coat; and a cooking device for part-cooking the portion of food to at least partially cook the first batter coat, the crumb coat or the powder coat, and second batter coat

According to a further alternative characterisation of the invention there is provided a method of applying a batter coat to a portion of food, the method including; providing a batter coat comprising at least flour, water and an emulsifies aerating the batter coat with a food-safe gas; applying the batter coat to the portion of food; ^plying a crumb coat or a powder coat to the batter coat; part-fiying the portion of food to at least partially cook the batter coat and the crumb coat.

According to a further alternative characterisation of the invention there is provided an apparatus for applying a batter coat to a portion of food, the ^paiatus including; a source of a batter coat, the batter coat comprising at least flour, water and an emulsifier; an aeration device, coupled to the source of the batter coat, for aerating the batter coat with a food-safe gas; a source of crumb or powder; a batter application stage to tφply the batter coat to the portion of food; a crumb application stage to £^ly a crumb coat to the batter coat, or a powder application stage to £^ly a powder coat to the batter coat; and a cooking device for part-cooking the portion of food to at least partially cook the batter coat and the crumb coat or powdo* coat.

Particular embodimrats of tire alternative characterisations of the invention may be as set forth above with respect to the first to fourth aspects of the invention.

Any jneferred or optional features of one aspect or characterisation of tiie invention may be a preferred or optional feature of other aspects or characterisations of the invention.

Brief Description of the Drawings

Other features of the invention will be ^parent fiOm the following description of preferred embodiments shown by way of example only with reference to the accompanying drawings, in which;

Figure 1 shows a schematic side view of an apparatus for applying a composite batter coating to a portion of food according to an embodiment of die invention; Figure 2 shows a cross section of a portion of food with a batter coating, produced by the apparatus of Fig. 1;

Figure 3 shows steps of a method according to an embodiment of the invention; Figure 4 shows a schematic side view of an apparatus for applying a composite batter coating to a portion of food according to another embodiment of the invention; F^ure 5 shows a cross section of a portion of food with a batter and bread coating, produced by the tqiparatus of Fig. 4;

Figure 6 shows steps of a method according to anodier embodiment of the invention; F^ure 7 shows a schematic side view of an apparatus for applying a composite batter coating to a portion of food according to anodier embodiment of the invention; and

Fi^re 8 shows a schematic side view of a flash frying ^paratus for use with the ^paiatus of Figures 1,4 and 7 according to another embodiment of the invention.

DetaOed Description

Figure 1 shows a schematic side view of an apparatus for ^>plying a composite batter coating to a portion of food according to an embodiment of the invention, generdly designated 10. The apparatus 10 has a wire belt 12 vdiich moves in a direction indicated at arrow 14 so that aportion of food 16 passes tiie various coating stages of the apparatus. The portion of food 16 is frozen. The first stage is to ^>ply a wash-coat of batter shown at 18, for example using a known curtain enrober apparatus. The wash-coat may be termed an adhesive coat or a base coat The second stage is to ^ply a crumb coating finm above and below as shown at 20, 22. The crumb is ^^lied using a mechanical breader with a crumb curtain and base bed of crumb. The crumb coating 20,22 may include, or may be, flour and/or rice particles. The crumb coating 20, 22 may be termed a breaded coating, or an intermediate coating, and is a dry granular coating or a powder coating. One effect of the wash-coat 18 is to remove or sofien a glaze that is present on the surface of the fiozen food 16. The glaze is the frozen surface (i.e. frozen water) of the food 16 that might otherwise prevent or reduce the crumb coating 20, 22 from adhering to the portion of food 16. Alternatively, a steam device (not shown) may be used to remove the glaze on the frozen food as shown at IS. The third stage is to apply a second batter coat 24 to the portion of food from above as shown at 24. The second batter coat 24 may be termed a primary batter coat. The crumb coating 20,22 and the second batter coating 24 may be termed a composite batter coating. A mixing head 28 mixes a batter mixture 30 fiOm a hopper 32 with carbon dioxide gas 34 to aerate the batter. The batter 30 is mixed in the hopper 32 with a high speed whisk or shear blade in the base and an outer jacket to keep the batter cool. Batter viscosity is measured at each stage using a flow cup (i.e. a οφ with a hole in its base is filled with a known amount of batter, and the time t^en for the batter to flow out of the hole is recorded). Importantly, die batter 30 is mixed in the hopper 32 using chilled water at 5 and is maintained within a target viscosity and kept at a chilled temperature of around 10 °C +/- 2 °C. A fantail nozzle 36 then implies the second batter coat 24 from above. Any drips of batter from the food shown by arrow 38 are collected in a tray 40 and form a bath 41 to coat die underside of the food as shown at 42. Excess batter is then passed to a secondary mixer 44 which re-inixes the batter to reduce the levels of carbon dioxide before it is returned to the hopper 32. Re-mixing of the batter ensures an accurate and continuous level of aeration. The second batter coat 24 comprises batter made from ingredients 25 that are put into the hopper 32. The ingredients 25 are shown in the following table (the 2 -10 % Palm fat is a key ^ulsifier ingredient so that the batter and gas mix form an emulsion):

The portion of food shown at 46 is then flash fried (not shown) using a known process whereby it enters a flyer for 50-60 seconds with r^)eseed oil at 195-205 °C. The product is not fully cooked (i.e. the food may remain frozen but the outer coating is cooked). The final stage before packing is to le-fl^ze the product so that it can be stored before sale. The product may be de-flOsted at the point of sale to the consumer or may be sold in a frozen condition to the consumer.

In one arrangement a pre-dust step 17 is paformed on die portion of food 16 prior to applying the wash-coat of batter shown at 18 in Figure 1. The pre-dust step 17 comprises coating the portion of food 16 with flour or a powdered flavoured coating. Such a predust step 17 may be termed coating the portion of food with a powder coat. One effect of this is to create an adhesion coat between the portion of food 16 and the wash-coat of batter 18. The steam device (not shown) inay be used to remove the glaze On the frozen food as shown at 15 prior to the pre-dust step 17.

In one arrangement the wash-coat of batter 18 and the crumb coat 20 are omitted, and the de-glazing step 15 and the pre-dust step 17 are performed prior to £5>plying the batter coat 24 to the portion of food. With such an arrangement the steam device may be used to remove the glaze on the flnzen food as shown at 15 prior to the pre-dust step 17.

Figure 2 shows a cross section of a portion of food with a batter coating, generally designated 50. In Figure 2 like features to the arrangements of Figure 1 are shown with like reference numerals. In Figure 2 the portion of food 50 is shown after the flash fried step described above, and prior to the final oven-baking step by the consumer. At this stage the batter coating is relatively malleable which means that it is less likely to crack away from the fish (e.g. due to handling and stacking at the supermarket) prior to the consumer oven-cooking the food. The food is shown at 52, the first batter coating is shown at 54, the crumb coating is shown at 56, and the second batter coating is shown at 58. Air bubbles 60 are shown in the second batter coating. The powder coat 53 may be between the food 52 and the batter coating 54.

Figure 3 shows steps of a method according to an embodiment of the invention, generally designated 70, for coating a portion of food, e.g. a portion of fish. Initially (step 72) the batter mixtme is provided (such as batter mixture 30 in a hopper 32 in Fig. 1, and optionally also in a separate container/supply). In addition the crumb or powder for applying a crumb coat or powder coat is provided (step 74). Thereafter, a first, non-aerated batter coat (e.g. from hopper 32 in Fig. 1, or from a separate supply) is applied to the fish (step 75), i.e. as a wash coat, as shown at 18 in Fig. 1, for example using a known curtain eniober apparatus. A powder coat may be applied to the portion of food 16 prior to applying the wash coat 18, as shown at 17 in Fig. 1. The powder coat may be ^plied to the portion of food 16 instead of the wash coat 18 and tiie crumb coat 20.

Next, at step 76, the crumb or powder is applied to tiie first batter coat on the fish, i.e. such as by applying a crumb coating or powder coating from above and below as shown at 20,22 in Fig. 1. The crumb may be applied using a mechanical breader with a crumb curtain and base bed of crumb. At least a portion of the batter mixture (30 in a hopper 32 in Fig. 1) is aerated (step 78), e.g. a mixing head 28 mixes a batter mixture 30 from a hopper 32 with carbon dioxide gas 34 to aerate the batter, as shown in Fig. 1. Then, at step 80, a second batter coat 24 is applied to die (crumb/powder coating on the) fish, i.e. such as by a fantail nozzle 36, as shown in Fig. 1.

Thereafter, die steps of fl^^fiying (82) the battered fish ptHtion and fieezing (84) the battered fish pordon are performed, i.e. to finally prepare the fish for packing and trmispmt to a point of sale.

Whereas the above embodiments relate to {flying batter to a portion of food to i»ovide a battered product, the apparatus 10 may also be used to provide a breaded product (e.g. fish fingers). When using the apparatus 10 for breading a portion of food, the stages are switched round as mentioned below.

Figure 4 shows a schematic side view of an apparatus for qiplying a composite b^ter coating to a portion of food according to another embodiment of the invention, generally design^ed 80. In Figure 4 like features to tiie arrangements of Figure 1 are shown with like reference numerals. In Figure 4 the portion of food 16 is frozen. The first stage is to apply the aerated batter vdiich is an adhesive coat as shown at 24. The adhesive coat may be termed a primary batter coat. The crumb coating 20,22 and the batter coating 24 may be termed a composite batter coating. The crumb coating 20,22 may include, or may be, flour and/or rice particles. The crumb coating 20,22 may be termed a breaded coating, or an intmnediate coating, and is a dry granular coating or a powder coating. As previously described the mixing head 28 mixes the batter mixture 30 from the hopper 32 with carbon dioxide gas 34 to aerate the batter. The batter 30 is mixed in the hopper 32 as described above with the high speed whisk or shear blade in the base and the outer jacket to keep the batter cool. Batter viscosity is measured at each stage using the flow cup. Importantly, the batter 30 is mixed in the hopper 32 using chilled water at 5 °C, and is maintained within the target viscosity and kept at a chilled temperature of around 10 °C +/- 2 °C. Tfre fantail nozzle 36 then applies the batter coat 24 from above. Any drips of batter from the food shown by arrow 38 are collected in the tray 40 and form the bath 41 to coat the underside of the product as shown at 42. Excess batter is then passed to the secondary mixer 44 which re-mixes the batter to reduce the levels of carbon dioxide before it is returned to the hopper 32. Re-mixing of the batter ensures an accurate and continuous level of aeration. The second batter coat 24 comprises batter made from ingredients 25 that are put into the hopper 32. The second stage is to apply a crumb coating from above and below as shown at 20,22. The crumb is ^lied tising a mechanical breader with a crumb curtain and base bed of crumb. The crumb coating may alternatively be a breaded coating. The portion of food shown at 46 is frien flash fried (not shown) using a known process described above vdiereby it enters a fryer for 50-60 seconds with rqteseed oil at 195-205 °C. The product is not frilly cooked (i.e. the food may remain frnzen but the outer coating is cooked). The final stage before packing is to re-freeze the product so friat it can be stored before sale. The product may be de-fiosted at the point of sale to the consumer or may be sold in a frozen condition to the consumer.

In another arrangement the de-glazing step 15 is performed on the portion of food 16prior to applying the aerated batter coat 24 to the portion of food 16 shown in Figure 4. The de-glazing step IS may comprises coating the portion of food 16 with a mixture of flour and water. The de-glazing step may comprise the wash-coat of batter shown at 18 above (i.e. a first coat of batter). Alternatively, a steam device (not shown) may be used to remove the glaze on the firozen food. One effect of the de-glazing step is to remove or soften a glaze that is present on the surface of the fix)zen food 16. The glaze is the frozen surface of the food 16 that might otherwise prevent or reduce the aerated batter coat 24 from adhering to the portion of food 16.

In another arrangement a pre-dust step 17 is performed on the portion of food 16 prior to applying the aerated batter coat 24 to the portion of food 16 shown in Figure 4. Hie predust step 17 may be performed just after the de-glazing step 15 (i.e. applying the wash coat 18 instead of steam). The pre-dust step comprises coating tiie portion of food 16 with flour or a powdered flavoured coating. Such a pre-dust step 17 may be termed coating the portion of food with a powder coat One effect of this is to create an adhesion coat between the portion of food 16 and the aerated batter coat 24. In this arrangement the aerated batter 24 and the pre-dust layer become homogenous such that the pre-dust layer is not visible to the consumer after oven cooking of the portion of food.

Figure 5 shows a cross section of a portion of food with a batter and bread coating, generally designated 90. In Figure 5 like features to the arrangements of Figure 2 are shown with tike reference munerals. In Figure 5 the portion of food 90 is shown after the flash filed step described above, and prior to the final oven-baking step by the consumer.

At this stage the batter coating is relatively malleable means that it is less likely to crack away from tiie fish (e.g. due to handling and stacking at the su|)ennaiket) prior to the consumer oven-cooking the food. The food is shown at 52, the batter coating is shown at 54, and the crumb coating is shown at 56. Air bubbles 60 are shown in the batter coating. The powder coat 53 may be between the food 52 and the batter coating 54.

Figure 6 shows steps of a method according to another embodiment of the invention, generally designated 70, for coating a portion of food, e.g. a portion of fish. Initially (step 72) the batter mixture is provided (such as batter mixture 30 in a hopper 32 in Fig. 4, and optionally also in a separate containeΓ/sιφply). In addition the crumb or powder for applying a crumb coat or powder coat is provided (step 74).

At least a portion of the batt^ mixture (30 in a hopper 32 in Fig. 1) is aerated (step 78), e.g. a mixing head 28 mixes a batter mixture 30 from a hopper 32 with carbon dioxide gas 34 to aerate the batter, as shown in Fig. 1. Then, at step 80, an aerated batter coat 24 is applied to the fish from above, i.e. such as by a fantail nozzle 36, as shown in Fig. 4. A base batter coat (i.e. a wash-coat) or a de-glazing step may be ^plied to the portion of food prior to applying the aerated batter coat 24, as shown at 15 in Fig. 4. A powder coat may be applied to the portion of food prior to ^jplying the aerated batter coat 24, as shown at 17 in Fig. 4.

Next, at step 76, the crumb or powder is applied to the aerated batter coat on the fish, i.e. such as by applying a crumb coating or powder coating from above and below as shown at 20,22 in Fig. 4. The crumb may be applied using a mechanical breader with a crumb curtain and base bed of crumb.

Thereafter, the steps of flash-fiying (82) the battered fish portion and fijeezing (84) the battered fish portion are performed, i.e. to finally prepare the fish for packing and transport to a point of sale.

Figure 7 shows a schematic side view of an apparatus for applying a composite batter coating to a portion of food according to another embodiment of the invention, generally designated 90. In Figure 7 like features to the arrangements of Figure 1 and 4 are shown with like reference numerals. Figure 7 shows that the stages of ^plying the second batter coat 58 to the portion of food fiem above as shown at 24, and coating the underside of die food as shown at 42 in the bath 41 are switched round vdien compared to Figure 1. The arrangements of Figure 7 provide the advantage that the air bubbles 60 wiftiin the batter coat 58 are more likely to remain therein prior to fiash fiying the portion of ftx)d shown at 46 as described above. It will be appreciated that the effect of coating the underside of the portion of food first in die bath 41 followed by appljdng die second batter coat 58 to the portion of food fixim above as shown at 24 means that flash fiying of the top coat occurs more quickly after the top coat has been ^^lied. The resulting fiied batter coat has a greatly improved appearance and crispiness. The tray 40 may be termed a trough.

Figure 7 also sdiows a wire belt 92 above the bath 41 of batter. The wire belt 92 moves in a direction indicated by die arrows so that the portion of food passes through the bath 41 of batter to coat the underside of the food as shown at 42. The batter in the bath 41 is a relatively high viscosity and the wire belt 92 provides the advantage of helping to move (i.e. draw) the portion of food through the batter. Whereas the bath 41 is primarily intended to coat the underside of the food it will be appreciated that the sides of the portion of food may also be coated. Optionally the top of the portion of may be partially coated in the bath 41.

It will be appreciated that the various aspects described above in relation to Figure 1 also apply to Figure 7. These aspects may include using a deglazing step on the fix>zen food as shown at 15, applying the wash-coat of batter ^own at 18, optionally using the pre-dust step 17 on the portion of food 16 prior to ^plying the wash-coat of batter shown at 18, apply a crumb coating fiom above and below as shown at 20, 22, and aerating the batter coat 24 using tiie £φparatus, ingrethents and steps 25,28,30,32,34,36,38,40,41, 44.

The various aspects of Figure 7, in particular the switching round of the stages of £φplying the second batter coat 58 to the portion of food from above as shown at 24, and coating the underside of the food as shown at 42 in the bath 41, may also be used with the embodiment of Figure 4.

Figure 8 shows a schematic side view of a flash frying apparatus for use with the apparatus and methods of Figures 1, 3, 4, 6 and 7 according to anotiier embodiment of the invention, generally designated 100. In Figure 8 like features to the arrangements of previous embodiments are shown with like reference numerals. In Figure 8 the portion of food 46 is shown to be at the end of the wiie belt 12 as shown at the right side of Figtues 1,4 and 7. In Figure 8 the portion of food 46 then moves off the wire belt 12 as shown by arrow 102 so that it drops into a bath 106 containing hot oil so that it is submerged below a surface 108 of die hot oil, as shown at 110. The hot oil is within a tray or trou^ 104. A non-stick belt 111 is provided to guide the portion of food 110 through the hot oil. The non-stick belt has a non-stick coating such as TEFLON to reduce sticking of the portion of food 110 to the wire belt 111. As the portion of food 110 is flash filed it b^jns to float more readily and another wire belt 112 guides the portion of food through the hot oil as shown at 114. The wire belts 111,112 draw the portion of food through the bath 106, and move in a direction indicated by the arrows. The non-stick belt 111 is provided along approximately the first 25% of the bath 106, and the wire belt 112 is provided along approximately the remaining 75% of the bath 106. Also shown is anotho* wire belt 116 above the portion of food 114, which moves in a direction indicated by the arrows and operates to keep the portion of food 114 below the sur&ce 108 and to move the portion of food 114 through the bath 106 as shown at 118.

The wire belt 116 above the portion of food 114 is adjustable, as shown by a double headed arrow 120, so that a horizontally position of the wire belt 116 can be set Sirch adjustability may be provided by any convenient adjustment device or means, such as a screw device, or providing the wire belt 116 on a movable carriage. The Applicant has discovered that the horizontal position at \riiich the wire belt 116 is set has an important effect on the top coating (i.e. tiie aerated batter coating 58) of the portion of food 114. If the wire belt 116 engages the portion of food 114 too soon (i.e. if the wire belt 116 is too far to the left as shown in Figure 8) then the wire belt 116 may be imprint marks onto the top coating, ^iuch is undesirable. If the wire belt 116 engages the portion of food 114 too late (i.e. if the wire belt 116 is too &r to the right as shown in Figure 8) dien die portion of food 114 may start to drift in the bath 106 and not progress through the hot oil, \i«4iich is also undesirable. A balance has to be struck between these two fiictors, and the provision of horizontal adjustability to the wire belt 116, as shown by a double headed arrow 120, gready improves the operability of the apparatus 100 and the quality of die portion of food 118. It will be fqipreciated that the wire belt 116 having an adjustable position sets the point at which the portion of food 114 is submerged in the bath 106.

Figure 8 also shows a final wire belt 119 to lift the portion of food out of the hot oil as shown at 122. The finished portion of food is shown at 124 i^iiich can then be re-frozen before final packing and storage before sale. It will be appreciated that the frying apparatus 100 of Figure 8 may be used after any of the coating apparatus 10,80,90 shown in Figures 1,4 and 7, or described with reference to die methods of Figures 3 and 6. It will be appreciated that the wire belts 12,92,112,116,119 may be alternatively turned conveyor devices.

In the above embodiments the coating of fish is discussed, and it will be appreciated that other types of food or product may be coated using the apparatus or methods of Figure 1 - 8, such as other meat or products (goujons, nuggets, etc) or seafood (e.g. calamari, prawns, etc), or other products (e.g. chocolate bars).

In the above embodiments the batter 24 applied to the food has a level of food-safe fat or oil content to ensure a correct level of aeration using carbon dioxide gas and provides stability of the carbon dioxide bubbles within the batter 24. It is believed that the emulsifier agent within the batter (e.g. typically 5-10% palm oil fat) makes the aerated batter more stable. Whereas as the palm oil fat is disclosed above, it will be appreciated that any other food-safe oil or fat may be used with the proviso that the gas combines with the oil or fat to provide the required aeration to the batter 24. Whereas as the use of carbon dioxide gas is disclosed above, it will be appreciated that any other food-safe gas may be used such as nitrogen, air, nitrous gas etc, with the proviso that the gas combines with the fat to provide the reqiiired aeration to the batter 24.

In the above embodiments the use of the fantail nozzle 36 reduces wastage of the batter 24 because a full “curtain” of batter is avoided. Such a fantail nozzle 36 also reduces handling or processing of the batter. Such processing might otherwise reduce the amount of gas in the batter mixture. Alternatively a relatively large diameter pipe (e.g. with an internal bore of between 2 to 3cm) may be used in place of the fantail nozzle 36. Using a fentail nozzle 36, or a relatively large diameter pipe, may help to maintain the low pressure of the aerated batter to retain the bubbles therein when applying it to the portion of food. The pressure of the aerated batter exiting the fantail nozzle 36, or large diameter pipe is relatively low and may be around 5 to 6.5 bar. The fentail nozzle 36 or the large diameter pipe may be termed an outlet.

The mixing head 28 described above is an emulsifier ^paratus or an aeration apparatus. Such an appamtus may be a MONDOMIX apparatus available from Haas. Such an apparatus can provide a continuous flow of aerated batter 24. The mixing head 28 has a rotor and stator both fitted with intermeshing pins, which provide a constant shear to the battCT resulting in better temperature control and better control of the bubble size distribution in the batter 24. Within the mixing head 28 the liquid batter and the gas 34 merge and are homogenized widi accurate flow control under a controlled pressure to provide the batter 24 with a consistent quality. It is believed that the gas bubbles stay in the batter due to the fat/emulsifier (i.e. palm oil fat) and in effect tihe gas (e.g. carbon dioxide) locks onto the fat creating a better aeration of the batter when mixed. In effect the fat binds the batter mixture with the gas. When using the MONDOMDC apparatus with carbon dioxide, the first input to die mixing head 28 of non-aerated batter has a pressure of about 6 bar, and a second input of carbon dioxide has a pressure of about 8 bar, which provides a flow rate for the carbon dioxide of about 425 In/hr, where the unit “In” is a normal litre at standard conditions and 20°C. The first ϊΐφΐη of non-aerated batter may have a pressure in the range 4-8 bar, and a second input of carbon dioxide has a pressure of about 6-10 bar. Whereas the “normal litre” unit has been used it will be appreciated that die flow rate for the gas is measure in millimetres of mercury, which is converted to the “normal litre” unit with a conversion graph.

Using the above described calibrated flow cup, the batter 30 within the hopper 32 weighs 240g. After aerating the same volume of batter (i.e. the batter 24) weighs between 105 -120g. In other words a ratio of the weight of a fixed volume of (i) aerated batter 24 to (ii) non-aerated batter 30 has the range 43.75% to 50%.

Using the above embodiments, the combination of the ingredients, accurate levels of aeration and accurate depositing of the batter 24 produces a product with the desired attributes which has a hand-made look widi crispy “flares” and “highlights” of batter, as may be produced when battered fish is deep fiied in a fish and chip shop. It is believed that the pahn fat oil releases or “sweats out” of the batter when the food product is oven-cooked by the consumer which creates the crispy flares. After oven-cooking by the consumer the food product has no intermediate layers of batter so that there is only one homogeous layer (i.e. the first batter coat, the crumb coat, and second batter coat q>pear as one after oven cooking). A further advantage is that the oven cooked batter makes the food look bigger because the batter has a volumising effect, which is ^pealing to ftie consumer because it is light and crispy.

The Applicant has realised that an important aspect of die embodimrats described herein is to apply the aerated batter to the portion of food from above as shown at 24, and to flash fry the portion of food as soon as possible thereaft^. In effect 11» aerated batter is allowed to slowly fall onto the portion of food undo* the action of gravity. Such a way of applying the aerated batter ftom above helps to retain the bubbles within the aerated batter wiien applying it to the portion of food so that the gas is less likely to be knocked out of the batter during the application stage. The step of flash flying the portion of food as soon as possible after flying the aerated batter flxnn above also helps to produce batter with the above-described crispy ‘Tlares” and “highlights” of batter. This is because the bubbles within the aerated batter have less time to escape fiom tiie batter before being flying begins. In one embodiment tiie step of flash flying (i.e. the moment v4ien the portion of food enters the hot oil 106) begins within 1 to 5 seconds after ϊφρϋοηΑοη of the aerated batter, and more preferably within 2 to 4 seconds after application of the aerated batter.

Overall the batter process describe above also provides the advantage of an improved quality of the batter (e.g. a better quality colour of batter and a less soggy batter) at or near to the end of the shelf life of the product. The problem of a “soggy bottom” for the finished product is avoided.

In the above embodiments the use of a crumb coating 20, 22 (or a powder coating) is disclosed. Such a crumb coating 20,22 may comprise intermediate layers of flour and/or rice particles or bread particles. Furthermore the use of a wash-coat 18 is disclosed. Such a wash-coat 18 is a low viscosity batter coat used as an adhesive coat for the crumb coating 20,22 (or a powder coating). The wash-coat 18 may also be considered as a deglazing step.

The above embodiments mention re-fi:eezing the portion of food shown after 46 in Figures 1,3, and 7, or after 124 in Figure 8. Such re-fi*eezing may be performed using a nitrogen tunnel to re-jfreeze the surface (i.e. the crust) of the portion of food 46. Such a nitrogen tunnel is chamber of cold nitrogen gas that is be just above the boiling point of liquid nitrogen. The wire belt 12 passes through the chamber of nitrogen gas to flash fieeze the portion of food 46. Such an arrangement is intended to remove heat from the portion of food 46 fliat has been introduced by the flash fiying step.

In the above embodiments the portion of food 16 at the start of the process shown in Figures 1,4 and 7 is mentioned as being frozen. In another embodimrat the portion of food 16 may not be frozen, in \riiich case the de-glazing step 15 may not be required. With such an arrangement the step of fieezing the portion of food shown 46 at may not be required, but instead the portion of food 46 may be chilled to remove any imwanted heat from the portion of food 46 after the frying step.

While embodiments have been descrited by reference to emlx)diments having various components in their respective implementations, it will be appreciated that other embodiments make use of other combinations and permutations of these and other components.

Claims

1. A method of applying a composite batter coating to a portion of food, the method including; implying the composite batter coating to the portion of food, the composite batter coating comprising at least a primary batter coat, and a crumb coat or a powder coat; and part-cooking the portion of food to at least partially cook the composite batter coating; wherein applying the composite batter coating comprises: providing the primary batter coat comprising at least flour, water and an emulsifier; and aerating the primary batter coat with a food-safe gas prior to implying the primary batter coat.

2. A method according to claim 1, wherein applying the composite batter coating complies: ^plying a base batter coat to the portion of food; applying the crumb coat to the base batter coat; and ^>plying the primary batter coat to the crumb coat

3. A method according to claim 1 or 2, and further including de-glazing the portion of food prior to applying the base batter coat or the powder coat

4. A method according to claim 1, wherein applying the composite batter coating comprises: ^plying the primary batter coat to the portion of food; and ^>plying the crumb coat to the primary batter coat

5. A method according to claim 4, and further including de-glazing the portion of food prior to applying the primary batter coat or applying a base batter coat to the portion of food prior to applying the primary batter coat.

6. A method according to claim 4 or 5, and further including applying a powder coat to the portion of food prior to applying the primary batter coat.

7. A method according to any of the preceding claims, and hirther including ^plying the primary batter coat using a fantail nozzle.

8. A method according to any of the preceding claims, wherein aerating the primary batter coat comprises controlling the amount of the food-safe gas in the primary batter coat so as to maintain the level of aeration thereof within a predetermined range.

9. A metiiod according to any of the preceding claims, wherein aerating the primary batter coat comprises using an aeration device connected to a source of the food-safe gas.

10. A method according to claim 9, wherein aerating the primary batter coat comprises periodically or continuously: measuring the level of aeration of the primary batter coat, and if level of aeration is not vdthin a predetermined range, adjusting the input pressure of the food-safe gas into the aeration device so as to maintain the level of aeration within the predetermined range.

11. A method according to claim 10, vdierein measimng the level of aeration of llie primary batter coat comprises measuring the ratio of the wei^t of a fixed volume of (i) batter for the primary batter coat to (ii) non-aerated batter that has not entered the aeration device.

12. A method according to any of claims 8 to 11, \tdierein the predetermined range corresponds to a ratio of fire weight of a fixed volume of (i) aerated batter for the primary batter coat to (ii) non-aerated batter having the range 43.75% to 50%.

13. A method according to claim 9, or any claim dependent thereon, vriierein the aeration device is configured to receive a first input of non-aerated batter at 6 bar and a second input of food-safe gas at 8 bar.

14. A method according to any of the preceding claims, viierein the emulsifier forms 2-10%, more preferably 5-10%, and more preferably 7-8% by weight of the primary batter coat.

15. A method according to any of the preceding claims, vriierein the emulsifier is a fat or oil.

16. A metiiod according to claim 15, wherein the emulsifier is palm oil fat.

17. A method according to any of the pr»:eding claims, further comprising, prior to the step of aerating the primary batter coat, controlling the temperature of the batter for the primary batter coat so as to be within a predetermined temper^ure range.

18. A method according to claim 17, ^^oein the predetermined temperature range is 8-12 °C, more preferably 8-11 °C, and more preferably 10 °C.

19. A method according to claim 9, or any claim dependent thereon, wherein the aeration device comprises a rotor and stator, the rotor and stator having intermeshing pins.

20. A method according to any of the preceding claims, further comprising: collecting a portion of the primary batter coat that does not adhere to the portion of food during the ^plying the composite batter coating; remixing the portion of the primary batter coat in a second^ mixer so as to produce a remixed portion of batter fix>m which the food-safe gas has been substantially removed; and incorporating the remixed portion of batter into the primary batter coat prior to aerating the primary batter coat widi the food-safe gas.

21. A method according to any of the preceding claims, wherein said applying the composite batter coating to the portion of food comprises applying the primary batt^ coating to the portion of food fiom above.

22. A mediod according to claim 21, and fiirdier comprising: collecting a portion of the primary batter coat in a batter bath; and coating an underside and sides of the portion of food in the batt^ bath using the portion of primary batter coat.

23. A method according to claim 22, and fiulher comprising: coating the underside and sides of the portion of food in the batter bath before applying the primary batter coating to the portion of food from above.

24. A method according to claim 22 or 23, and further comprising: using a belt above the batter bath to draw die portion of food through the batter bath.

25. A method according to any of the preceding claims, wherein part-cooking the portion of food comprises frying the composite batter coating.

26. A method according to claim 25, wherein said frying comprises submerging the portion of food in an oil bath.

27. A method according to claim 26, and finiher including: using one or more belts at least partially or >^olly witiiin the oil bath to draw the portion of food through the oil bath.

28. A mediod according to claim 27, and further including using the one or more belts to submerge the portion of food in the oil bath.

29. A method according to claim 27 or 28, and further including adjusting a horizontal position of the one or more belts to set a position at which the portion of food is engaged in order to set a point at which the portion of food is submerged in the oil bath.

30. A method according to any of claims 25 to 29, and hirther including hying the portion of food withiu 1 to 5 iseconds after ^plication of the primary batter coat.

31. A method according to clmm 30, and further including flying the portion of food within 2 to 4 seconds after application of tiie primary batter coat

32. A method according to any of tiie preceding claims, vdierein tiie food-safe gas is one or more of carbon dioxide, nitrogen, air, and nitrous gas.

33. A portion of food coated with batter using the method accmding to any of the method claims 1 - 32.

34. An ^paratus for ^plying a composite batter coating to a portion of food, the composite batter coating comprising at least a primary batter coat, and a crumb coat or a powder coat, the apparatus including: a source of a primary batter coat, the primary batter coat comprising at least flour, water and an emulsifier; an aeration device, coxipled to the somce of the primary batter coat, for aerating the primary batter coat with a food-safe gas prior to applying the primary batter coat; a plurality of coating application stages for applying the composite batter coating to the portion of food, the plurality of coating application stages including at least a primary batter coat application stage and a crumb coat application stage; and a cooking device for part-cooking the portion of food to at least partially cook the composite batter coating.

35. An ^paratus according to claim 34, wherein the plurality of coating application stages comprise: abase batter coat application stage, for ^plying a base batter coat to the portion of food; the crumb coat application stage, for applying the crumb coat to the base batter coat; and the primary batter coat application stage, for applying the primary batter coat to tile crumb coat

36. An apparatus according to claim 34 or 35, and fiirther including: a de-glazing device, for de-glazing die portion of food prior to applying the base batter coat or the powder coat.

37. An apparatus according to claim 34, wherein the plurality of coating application stages comprise: the primary batter coat application stage, for ^iplying die primary batter coat to the portion of food; and the crumb coat application stage, for applying the crumb coat to the primary batter coat.

38. An s^paratus according to claim 37, and fiirther including: a de-glazing device, for de-glazing the portion of food prior to applying die primary batter coat; or a base batter coat application stage, for ^plying a base batter coat to the portion of food prior to ^plying the primary batter coat.

39. An ^paratus according to claim 37 or 38, and further including a powder application stage, for applying a powder coat to the portion of food prior to applying the primary batter coat.

40. An apparatus according to any of claims 34 to 39, wherein the primary batter coat application stage includes a fantail nozzle for applying the primary batter coat.

41. An ^paiatus according to any of claims 34 to 40, further comprising a controller for controlling the amount of the food-safe gas in the primary batter coat so as to maintain the level of aeration thereof within a predetermined range.

42. An ^paratus according to any of claims 34 to 41, wherein the aeration device is connected to a source of the food-safe gas.

43. An apparatus according to claim 42, further comprising a controller configured for periodically or continuotjsly: measuring the level of aeration of the primary batter coat, and if the level of aeration is not within a predetermined range, adjusting the input pressure of the food-safe gas into the aeration device so as to maintain the level of aeration within the predetermined range.

44. An apparatus according to claim 43, wherein measuring the level of aeration of the primary batter coat comprises measuring the ratio of the weight of a fixed volume of (i) batter for the primary batter coat to (ii) non-aerated batter tiiat has not entered the aeration device.

45. An apparatus according to any of claims 41 to 44, wherein the predetermined range corresponds to a ratio of the weight of a fixed volume of (i) aerated batter for the primary batter coat to (ii) non-aerated batter having the range 43.75% to 50%.

46. An apparatus according to claim 42, or any claim dependent thereon, wherein the aeration device is configured to receive a first input of non-aerated batter at 6 bar and a primary input of food-safe gas at 8 bar.

47. An apparatus according to any of claims 34 to 46, wherein the emulsifier forms 2-10%, more preferably 5-10%, and more preferably 7-8% by weight of the primary batter coat

48. An apparatus according to any of claims 34 to 47, wherein the emulsifier is a fat or oil.

49. An apparatus according to claims 48, >\iierein the emulsifior is palm oil fiit

50. An ^paratus according to any of claims 34 to 49, fiirther comprising a controller for, prior to the step of aerating the primary batter coat, controlling the temperature of the batter for the primary batter coat so as to be within a predetermined temperature range.

51. An ^rparatus according to claim 50, vdierein the predetermined temperature range is 8-12 °C, more preferably 8-11 °C, and more preferably 10 °C.

52. An apparatus according to claim 42, or any claim dependent thereon, wherein the aeration device cominises a rotor and stator, die rotor and stator having intermeshing pins.

53. An apparatus according to any of claims 34 to 52, fiirther comprising: a collection device for collecting a portion of the primary batter coat that does not adhere to die portion of food during the applying the composite batter coating; a secondary mixer for remixing the portion of the primary batter coat so as to produce a remixed portion of batter horn which the food-safe gas has been substantially removed; and at least one conduit for incorporating the remixed portion of batter into the primary batter coat prior to aerating the primary batter coat with a food-safe gas.

54. An £φparatus according to any of claims 34 to 53, wherein the primary batter coating stage comprises an outlet to apply the primary batter coating to the portion of food from above.

55. An apparatus according to claim 54, comprising a batter bath to collect a portion of the primary batter coat, wherein the primary batter coating stage comprises coating an underside and sides of the portion of food with the portion of primary batter coat in the batter bath.

56. An ^paratus according to claim 55, cominisii^ coating die underside and sides of the portion of food in the batter bath before implying die primary batter coating to the portion of food from above.

57. An apparatus according to claim 55 or 56, comprising a belt above the batter bath to draw the portion of food through the batter bath.

58. An apparatus according to any of clmms 34 to 57, wherein the cooking device comprises a fiyer configured for flying the composite batter coating.

59. An apparatus according to claim 58, wherein said fiyer comprises an oil bath for submerging die portion of food.

60. An apparatus according to claim 59, wherein one or more belts are provided at least partially or vdiolly within the oil bath to draw the portion of food through the oil bath.

61. An apparatus according to claim 60, wherein the one or more belts are operable to submerge the portion of food in the oil bath.

62. An apparatus according to claim 60 or 61, comprising an adjustment device for adjusting a horizontal position of the one or more belts to set a position at Λ^ch the portion of food is engaged in order to set a point at \^ch the portion of food is submerged in the oil bath.

63. An ^paratus according to claim 60, 61 or 62, wherein one or more t^lts have a non-stick coating to reduce sticking of the portion of food thereto.

64. An apparatus according to any of claims 34 to 63, wherein the food-safe gas is one or more of carbon dioxide, nitrogen, air, and nitrous gas.