IES80940B2

IES80940B2 - A method for preparing a poultry product

Info

Publication number: IES80940B2
Authority: IE
Inventors: David Cahill
Original assignee: David Cahill
Priority date: 1998-04-20
Filing date: 1998-12-22
Publication date: 1999-06-30
Also published as: IE981087A1; GB9828818D0; IES981088A2; GB2336517A; GB2336517B

Abstract

A method of preparing a poultry food product comprises the sequential steps of mixing raw poultry fillets or pieces with a solution containing at least 10%, preferably 15%, by weight of sodium chloride; holding the mixture at a temperature of less than 3‹C, preferably between 1 and 3‹C, for a period of at least 30 minutes, preferably 1 to 2 hours; arranging the pieces in a desired orientation, preferably by dividing the pieces into separate lanes along a vibrating conveyor to space the pieces apart; applying a pre-dust; applying a batter, then preferably applying a crumb; at least partially cooking the pieces and freezing the cooked pieces. Prior to the pre-dusting and/or after the step of application of the batter, the pieces may be settled for at least 10 seconds, preferably between 15 to 20 seconds and at least 20 seconds respectively for each step. The first settling step may be achieved by leading the pieces along a conveyer to the pre-dusting station. The battered pieces may be settled by leading the pieces along a conveyer to a bath of hot cooking oil, preferably without the conveyor contacting the oil.

Description

The invention relates to a method for preparing a poultry meat, especially chicken, food product. More particularly the invention relates to a method for preparing at least partially cooked and frozen chicken pieces, especially chicken fillets and gujons.

Statements of Invention According to the invention there is provided a method for preparing a poultry food product comprising the steps of:15 mixing raw poultry fillets or pieces with a solution containing at least 10% by weight of sodium chloride; holding the mixture at a temperature of less than 3°C for a period of at least 0.5 hours; arranging the poultry fillets or pieces in a desired orientation; applying a pre-dust to the orientated poultry pieces; applying a batter to the pre-dusted orientated poultry pieces; at least partially cooking the pre-dusted battered poultry pieces; and freezing the cooked poultry pieces.

S 8 09 4 0 In one embodiment of the invention the mixture is held for a period of from 1 to 2 hours, preferably at a temperature of from 1°C to 3°C.

In one embodiment the method includes the step of settling the pieces prior to predusting. Preferably, the pieces are settled for a period of at least 10 seconds prior to pre-dusting. Ideally, the pieces are settled for a period of from 15 to 20 seconds prior to application of a pre-dust. Preferably the pieces along a conveyor to a predusting station.

In one embodiment of the invention the method includes the step, after application of batter, of settling the battered pieces for a period of at least 10 seconds prior to cooking. Preferably, the battered pieces are settled for a period of at least 20 seconds prior to cooking. Ideally, the battered pieces are settled by leading the battered pieces along a conveyor to a bath of hot cooking oil.

In one arrangement the battered pieces are led into the oil from the conveyor without the conveyor itself contacting the oil.

Preferably the solution with which the poultry pieces are mixed contains approximately 15% by weight of sodium chloride.

In a preferred embodiment of the invention the poultry pieces are arranged in a desired orientation by dividing a plurality of poultry pieces into separate lanes along a conveyor and vibrating the conveyor to space the pieces apart along each lane.

In one embodiment of the invention the method includes the step, after application of a batter, of applying a crumb to the battered poultry pieces. •3 Brief Description of the Drawings The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings, in which:Fig. 1 is a block diagram of a method for preparing poultry food products according to the invention; Fig. 2 is a perspective view of apparatus used in a tempering step in the method; Fig. 3 is a side view of equipment used in various steps in the method of Fig· l; Fig. 4 is a perspective view of portion of the apparatus of Fig. 3; Fig. 5 is a side view of a cooker and associated equipment used in a cooking step of Fig. 1.

Fig. 6 is a side view of an alternative arrangement used in a cooking step of Fig. 1; and Fig. 7 is a perspective view of part of a conveyor used in the arrangement f Fig. 6.

Detailed Description Referring to the drawings and initially to Fig. 1, there is illustrated a method for preparing a poultry food product according to the invention.

Frozen blocks 1 of poultry meat, meat pieces or gujons, typically of white chicken meat, are arranged on shelves 2 of a tempering rack 3 as illustrated in Fig. 2 to allow for air circulation. The blocks 1 are tempered on the racks 3 for a minimum period of 48 hours to bring the temperature of the blocks up from -20°C to between -10° and -12°C. The racks 3 used and the processing conditions for tempering ensure that an even tempering of the poultry meat is achieved in a highly efficient manner.

Raw poultry fillets or pieces 100 which may be fresh or tempered from frozen are io mixed 101 in a tumbler mixer with a salt solution containing at least 10%, and preferably approximately 15% by weight of sodium chloride. The tumble mixing has the effect of making the poultry pieces succulent without adversely affecting the physical structure of the pieces. The mixture is then transferred to a tote bin and held 102 for a period of at least 0.5 hours at a temperature of less ±an 3°C.

Ideally the pieces should be held at a temperature of from 0 to 3°C for a period of from 1 to 1.5 hours. I have found that this holding step 102 is particularly important in optimising subsequent process steps. The poultry pieces are more easily handled and have improved orgenoleptic properties.

The poultry pieces are then arranged 103 in a desired orientation for further processing. Preferably the poultry pieces are arranged in a desired operation by loading the mixture into a hopper and then dividing a plurality of the poultry pieces into separate lanes. The lanes are provided along a conveyor 25 which is vibrated to space the poultry pieces apart along each lane. This ensures that the pieces are readily orientated for optimum further processing.

The orientated poultry pieces are then settled in a settling step 104 for a period of at least 10 seconds, preferably for a period of from 15 to 20 seconds. In this case the poultry pieces are settled most effectively by leading them along an elongated conveyor 30. This settling step 104 is important in ensuring that the poultry pieces are in optimum condition for take up of pre-dust and subsequent battering.

A pre-dust is applied to the settled poultry pieces in a pre-dusting step 105 using a pre-dusting unit 31. After pre-dusting, batter is applied in one or more stages in a battering step 106 using a batter applicator 32. Subsequent to the battering step 106 the battered product is further settled in a settling step 107 for a period of at least 10 seconds and preferably approximately 20 seconds prior to cooking. The settling is most efficiently achieved by leading the battered formed pieces along a settling conveyor 36 prior to delivery into a fryer 39 in which the meat pieces are flash fried in a cooking step 108 at a temperature of at least 185°C for a period of not less than 20 seconds. This is a partial cook. After frying, the poultry meat pieces are frozen, for example, in a spiral freezer 38 in a freezing step 109 prior to packaging in step 110. The settling prior to frying is important in ensuring that the batter has been taken up by the poultry pieces to facilitate optimum frying with an even coating.

The battered poultry pieces may be delivered directly from the conveyor 36 to an in-feed conveyor 37 which is partially immersed in and delivers the battered pieces into cooking oil, which is shown at a level L in Fig. 5.

In an alternative arrangement illustrated in Figs. 8 and 9, the settling conveyor 36 includes a discharge section 40 which is pivotally mounted at 41 for angular adjustment with respect to the main body of the conveyor 36. In use, the discharge portion 40 of the conveyor is adjusted so that the discharge end of the conveyor section 40 is not immersed in, but lies just above, the level L of the cooking oil in the fryer 39. In this way, the cooking of the product is even more closely controlled as there is no precooking by the product encountering a hot section of conveyor prior to immersion in the cooking oil. This is particularly important for products with a light batter which can be easily damaged, destroying their physical and organoleptic properties.

The invention provides a highly optimised process for producing poultry pieces at optimum production rates and excellent product quality both in terms of physical appearance and taste.

Many variations on the specific embodiments of the invention will be readily apparent and accordingly the invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims

1. A method for preparing a poultry food product comprising the steps of:mixing raw poultry fillets or pieces with a solution containing at least 10% by weight of sodium chloride; holding the mixture at a temperature of less than 3°C for a period of at least 0.5 hours; arranging the poultry fillets or pieces in a desired orientation; applying a pre-dust to the orientated poultry pieces; applying a batter to the pre-dusted orientated poultry pieces; at least partially cooking the pre-dusted battered poultry pieces; and freezing the cooked poultry pieces.

2. A method as claimed in claim 1 wherein the mixture is held for a period of from 1 to 2 hours, preferably the mixture is held at a temperature of from 1°C to 3°C.

3. A method as claimed in any preceding claim including the step of settling the pieces prior to pre-dusting, preferably the pieces are settled for a period of at least 10 seconds prior to pre-dusting, preferably the pieces are settled for a period of from 15 to 20 seconds prior to application of a pre-dust, ideally the pieces are settled by leading the pieces along a conveyor to a pre-dusting station.

4. A method as claimed in any preceding claim including the step, after application of batter, of settling the battered pieces for a period of at least 10 seconds prior to cooking, preferably the battered pieces are settled for a period of at least 20 seconds prior to cooking, preferably the battered pieces are settled by leading the battered pieces along a conveyor to a bath of hot cooking oil, the battered pieces may be led into the oil from the conveyor without the conveyor itself contacting the oil, most preferably the solution with which the poultry pieces are mixed contains approximately 15% by weight of sodium chloride, ideally the poultry pieces are arranged in a desired orientation by dividing a plurality of poultry pieces into separate lanes along a conveyor and vibrating the conveyor to space the pieces apart along each lane, in one case the method includes the step, after application of a batter, of applying a crumb to the battered poultry pieces.

5. A poultry food product whenever prepared by a method as claimed in any preceding claim.