RU2794767C1 - Method for producing frozen ready second courses - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: method for production of a moulded product from a dough shell with a filling intended for instant preparation, including the following steps: preparation of a filling with a component based on natural plant extracts, where the filling is made from potato and/or meat and/or chicken filling with or without adding cracklings, fried onions, smoked meats, or curd filling, and/or filling with apple, pear, raisin, dried apricot, apricot, custard, and the component based on natural plant extracts contains an extract selected from the group including pomegranate extract, pineapple extract, blueberry extract, or a combination thereof; preparation of a test casing from flour of the highest grades of grain crops; formation of the product from the dough shell and filling; applying a uniform layer of vegetable oil to the surface of the product; steaming the product until cooked; tempura coating with addition of sugar in an amount of 1-1.5%; deep frying; freezing and packaging of the finished product in containers. A moulded product is also proposed made from a dough shell with a filling, intended for instant preparation, obtained by the specified method and including a filling with a component based on natural plant extracts and a dough shell made from flour of the highest grades of cereals, with tempura coating with addition of sugar in an amount of 1-1.5%, while the filling is made from potato, and/or meat, and/or chicken filling with or without the addition of cracklings, fried onions, smoked meats, or curd filling, and/or filling with the addition of apple, pear, raisins, dried apricots, apricot, custard, and the component based on natural plant extracts contains an extract selected from the group including pomegranate extract, pineapple extract, blueberry extract, or a combination thereof.

EFFECT: reduced oxidative stability of the product, increased shelf life of the product, as well as improved appearance and organoleptic properties after cooking and heating.

10 cl, 3 dwg, 1 tbl, 3 ex

Description

Field of invention

The invention relates to the food industry, in particular to a method for the production of ready-made second courses in dough, frozen, and ready for reheating.

Prior Art

Currently, there are quite a lot of ways to prepare frozen second courses, ready to eat after heating. From this category of dishes can be called dumplings, dumplings, manti, pancakes with various fillings. The shelf life of the product, its attractive appearance after reheating depends on the method of production and storage, on the components that make up the product.

As a rule, such products, despite being stored at low temperatures, have a limited shelf life - no more than 6 months, and after the expiration of the shelf life, it is not recommended to eat such products due to the formation of oxidation products that lead to spoilage of the filling, dough, growth of microorganisms in the product.

Methods for the production of frozen ready meals are known from the prior art. Patent RU 2693254 describes a method for the production of ready-made second courses frozen with a coating, which includes the following steps:

a) preparation of a filling consisting of minced meat and/or chicken and/or vegetable;

b) preparing a shell consisting of minced meat and/or chicken and/or vegetable;

c) forming a product from a shell and filling of a spherical shape by a co-extrusion method;

d) applying a uniform coating to the product from the shell and filling of a spherical shape by drageeing - sequential application of layers of lezon, breading, tempura;

e) deep-frying at a temperature of 150-200°C for 2-4 minutes until cooked;

f) freezing in a quick-freezing tunnel at a temperature of -30...-25°C for 30-60 minutes; And

g) packaging of the product in a container.

This invention is directed to reducing the moisture content of the product by coating the surface of the food product with a uniform reliable edible multilayer moisture barrier.

From patent RU 2747865, a method for the production of steamed dumplings is also known, which includes the steps:

- preparation of a filling consisting of minced meat and/or chicken and/or vegetable;

- preparation of a test casing from flour of the highest grades of grain crops;

- formation of the product from the shell and filling;

- applying to the surface of the product frying oil selected from the group including sunflower, corn, rapeseed;

- steaming the product until cooked;

- freezing;

- packaging of the product in a container.

This method of production allows for a longer storage of the product when frozen and a higher quality of the product during cooking.

Also, patent RU 2573317 discloses a molded meat product in a dough shell, sprinkled with breading, in the form of small balls, golden in color, ready to eat after heating, consisting of a middle in the form of a meat component and a dough shell coated with breading, after heating, retaining juiciness and nutritious properties of the meat component, characterized in that it has a coating of the meat component in the following order: a layer of tempura dough, a layer of lezon, a layer of breading, a layer of lezon, a layer of breading, while the meat component includes minced beef and / or chicken, and / or pork, chopped bacon, salt, onion, ice, protein texturate, tempura dough includes flour, melange, vegetable oil, water, salt, dough improver, lezon includes water, flour, salt, and a method for its production . The production method consists in the fact that the meat component is made, molded, dough is made, the molded meat component is coated with dough, breaded, cooked and frozen, characterized in that the body of the molded meat component is covered with cooked tempura dough, lezonized with cooked lezion, breaded, again lezonized with cooked lezion, breaded, then deep-fried once in deep fat for 3-5 minutes until a golden crust is formed and put on a sieve to remove excess oil, the fried finished product is frozen, the meat component is also different, which is made by loading the following ingredients into the meat mixer in stages: ice , prepared and crushed protein texturate, beef and / or pork, and / or chicken mince, chopped bacon, salt, hydrated spice mixture, and / or wheat fiber, and / or semolina and mix for about 5-7 minutes, lay shredded onion, and / or garlic, and / or black pepper, and / or red pepper and mix in both directions until smooth, stand, shape, tempura dough is made by loading the following ingredients into the mixer in stages: premium flour, melange, oil vegetable, water, salt, dough improver, mixed, the lezon is made as follows: water is poured into the lezon mixer, it is turned on, flour and salt are added, mixed until completely dissolved.

With this method of production, the creation of ready-made frozen meat products in dough, intended for storage, and when heated, does not lose taste, while the product does not contain starch.

These methods do not offer to reduce the oxidative stability of the product, and thereby increase the shelf life of the product itself, and improve its appearance and organoleptic properties after cooking and reheating.

Description of figures

On FIG. 1 shows a process flow diagram for the production of a product according to the invention.

On FIG. 2 shows the product with an indication of the layers deposited on it.

On FIG. 3 presents data on the oxidative stability of the obtained product.

Description of the invention

The present invention provides a method for producing a molded stuffed dough product, comprising the steps of:

- preparation of filling, including various types of filling, with a component based on natural plant extracts;

- preparation of a test casing from flour of the highest grades of grain crops;

- formation of the product from the shell and filling;

- applying a uniform layer of vegetable oil to the surface of the product;

- steaming the product until cooked;

- application of tempura;

- deep frying;

- freezing;

- packaging of the product in a container.

The filling can be minced meat, chicken or vegetable mince obtained by grinding the respective raw material. Minced meat can be cooked on the appropriate equipment: meat grinders, mechanical deboners, choppers, blenders. Minced meat, regardless of the main type of raw material, may include additives: onions, garlic, spices, seasonings, vegetables, crackers, gluing and thickening additives, dough improvers. Gluing and thickening additives help to increase the density of minced meat. For example, commonly used food additives may include milk powder, egg powder, phosphate, carrageenan, pectins, gelling food auxiliaries (eg, food waste) and gelling agents, crackers and breadcrumbs, emulsifiers, preservatives. Minced meat may include various types of raw materials, for example, a mixture of minced chicken and vegetables with spices, or a mixture of minced meat and vegetables. Also, the filling can be made from potato and/or meat and/or chicken filling with or without the addition of cracklings, fried onions, smoked meats, or be a curd filling and/or filling with the addition of apples, pears, raisins, dried apricots, apricots, custard.

Also, a component based on plant extracts is added to the filling and contains an extract selected from the group including grape seed extract, pomegranate extract, pineapple extract, green tea extract, blueberry extract, or a combination thereof.

Various types of flour can be used to prepare the dough shell, in particular, flour of the highest grades of grain crops. The flour for preparing the dough shell may be wheat flour, buckwheat flour, corn flour and other types of flour. The most preferred wheat flour of the highest grades for the preparation of the dough shell. Also, the shell may include additives, in particular, salt, emulsifiers, pectins, spices, seasonings and dyes. The process of preparing the dough shell itself includes kneading the dough from flour, water and, if necessary, additives. Mixing can be carried out in a special apparatus (dough mixer) or a blender with appropriate equipment, until a dough with the necessary properties is obtained: the dough sheet is plastic, not dry, not flowing. The kneading process also includes obtaining a dough sheet by rolling out the required thickness. An important difference is that the flour for the dough casing has a gluten content of more than 28% and an extensibility of more than 20 cm.

Next comes the stage of forming the product from the test shell and filling. The resulting product is a unit that includes a filling, surrounded by a test shell on all sides, isolating the access of the external environment to the filling. Preferably, the shape of the product may be different: spherical, ellipsoidal, elongated, figured, in the form of dumplings with tucks, "ears", or in the form of ravioli. The preferred shape is spherical or ellipsoidal.

After receiving the product, including the filling and the test shell, vegetable oil is applied to its surface. Vegetable oil is, as a rule, oil of vegetable origin: sunflower, corn, rapeseed, olive. Oil can be applied by dipping or immersing the item in a container filled with cooking oil, or by sprinkling or smearing.

After applying vegetable oil to the surface of the product in a uniform layer, the resulting product is heated until half cooked or ready. The product can be heated in an IR camera, in water or steam. Steam heating is preferred. Until half cooked, it is necessary to heat for 3-5 minutes at a temperature of 94-98 ° C, until cooked - at a temperature of 94-98 ° C for 5-12 minutes.

After heating, the product is subjected to applying tempura, deep-fried and frozen. Tempura is prepared from chicken eggs and/or melange and/or egg powder, premium wheat flour, salt, a mixture of spices and water, by pouring flour, salt, egg products, spices and spices into a mixer, and stirring until the components are completely dissolved. A prerequisite for the preparation of tempura is the addition of sugar in the amount of 1-1.5%, which will further influence the formation of color (caramelization) when the product is deep-fried. Deep frying is carried out at a temperature of 150-200°C for 2-4 minutes until cooked.

Freezing can be shock, or, for example, when using a quick freezer tunnel. Preferably, the freezing temperature is -30 to -25°C, the freezing process is carried out for 30-60 minutes. The temperature of the product at the outlet after freezing should not exceed minus 18°C.

After freezing, the ready-made instant product is packed in an appropriate container. The resulting finished product can be stored at a temperature of -3 to -18°C for at least 180 days without deterioration in appearance (cracking of the dough shell) and loss of taste, as well as with a reduced amount of oxidation products. When prepared by the end user, this product may be heated by boiling in water, steaming, or reheating in a microwave oven (MW) or in a container with or without oil (frying).

The process for the production of instant foods according to the invention will be disclosed in the examples below. These examples are not intended to limit the scope of the invention in any way, and are merely illustrative of the preparation method described.

Examples

Example preparation of a product according to the invention

a) Preparation of a blank (filling) consisting of:

option number 1 meat and/or chicken fillings and/or by-products with or without the addition of cracklings, smoked meats, vegetables, mushrooms, various cereals;

option number 2 curd filling and/or other sweet fillings and/or custard with or without: various fruits, berries, candied fruits, dried fruits, chocolate products;

option number 3 fillings from cereal products with or without additions: meat, chicken, cracklings, smoked meats, vegetables, mushrooms, dried fruits;

option number 4 stuffings from mushrooms and / or vegetables with or without additions: meat, chicken, cracklings, smoked meats;

option number 5 fruit and/or berry fillings with or without additions of: nuts, chocolate, candied fruits

option number 6 cheese filling with or without: cracklings, smoked meats, vegetables, mushrooms, nuts;

option number 7 fillings from fish and / or seafood with or without vegetables, mushrooms, various cereals;

with the introduction of a component based on plant extracts (grape seeds, pomegranate, pineapple, green tea, blueberries).

The product was prepared according to the flow chart shown in Fig. 1.

The preparation of the filling for ready-made frozen second courses was carried out by preparing all the components, weighing the raw materials and ingredients, grinding the raw meat on a top with a lattice diameter
5-8 mm. Mixing of raw materials was carried out in a mixer in both directions until all components were evenly distributed within 5-10 minutes. The blanks (fillings) were cooled to a temperature of -4 - -2˚C. The blank (filling) was evenly mixed, consisting of raw materials and components in accordance with the recipe), with the addition of a component based on plant extracts (grape seeds, pomegranate, pineapple, green tea, blueberries) to stabilize the color, prevent rancidity, and extend the shelf life , preserving the freshness of the product for at least 180 days.

Next, a test piece (shells) was prepared from flour of the highest grades of grain crops, which can be replaced with durum wheat flour partially or completely, glassy wheat flour partially or completely. A mandatory requirement for the quality of flour was a gluten content of more than 28% and an extensibility of more than 20 cm. , 2-4% - egg melange (0.1-1% - potato flakes or cottage cheese, depending on the recipe), 1.0-1.5% salt, vegetable oil.

The moisture content of the finished dough piece (shell) is 35-37%. The amount of prescription water may differ depending on the grade, quality and physico-chemical parameters of the flour used. It is possible to prepare a dough piece (shell) without the use of table salt, but this should be taken into account when compiling minced meat.

The dough piece (shell) was kneaded in continuous or automatic dough mixers for 8-20 minutes, depending on the modification of the dough mixer.

After the preparation process, the filling blanks and the dough shell were sent for molding. The blank (filling) was automatically fed into the storage hopper of the molding machine, the test blank (shell) was automatically fed into the test hopper. The blank (filling) was pumped into the molding zone through a nozzle. The dough piece (shell) pre-feeder formed two dough pieces in the form of a continuous belt, feeding them to the upper dough sheeter and then to the lower dough sheeter. The upper and lower dough sheeters produced two dough belts of a certain thickness. The dough sheet and the filling were fed into the molding zone, passed through the molding drums and the already molded semi-finished product was pushed out by the pushers of the drums, the finished semi-finished product fell out of the molding elements onto the discharge conveyor and was delivered to the installation for applying vegetable oil to the surface of the semi-finished product. The shaped semi-finished product was fed along the conveyor belt to the device for irrigation or dipping the product in vegetable oil, the amount of oil was
6-8% by weight of the molded product. Next, the semi-finished product was steamed at a temperature of 94-98°C for 5-12 minutes until cooked. Then, a uniform coating (tempura) was applied to the product from the shell and filling of an ellipsoid shape, a prerequisite for the preparation of tempura was the addition of sugar in an amount of 1-1.5%, which further influenced the formation of color (caramelization) when the product was deep-fried. After all, they were deep-fried at a temperature of 150-200°C for 2-4 minutes until cooked and frozen in a quick-freezing tunnel at a temperature of -30...-25°C for 30-60 minutes. The temperature of the product at the outlet after freezing should not exceed minus 18°C.

The finished product is stored at a temperature not exceeding minus 18°C for at least 180 days.

Example 2

Analysis of the oxidative stability of the product

The oxidative stability of the product was determined (with the addition of various components to the filling) during storage at six points for 7 months. at -18°C. To determine the accumulation of secondary non-volatile oxidation products (aldehydes and ketones), the increase of which leads to rancidity of the product, and thereby reduces the shelf life of the finished product, TBC indicators (thiobarbeturic number) were monitored during the experiment.

For various components, the following data were obtained:

Sample No. Component for stuffing Concentration,% Indicators TBCh, MDA mg/kg Day 100 110 130 135 170 205 2 Without adding a component 0 0.25 0.345 0.355 0.362 0.388 0.41 1 Ascorbic acid 0.2 0.175 0.26 0.265 0.267 0.27 0.29 6 Tocopherol + ascorbic acid 0.15 0.13 0.24 0.235 0.245 0.25 0.26 3 Tocopherol + ascorbic acid + rosemary 0.1 0.12 0.22 0.225 0.225 0.233 0.25 4 Tocopherol + ascorbic acid + rosemary + green tea 0.05 0.09 0.22 0.225 0.23 0.23 0.245 5 *Component 0.1 0.11 0.23 0.226 0.227 0.227 0.24

*Component based on natural plant extracts (grape seed, pomegranate, pineapple, green tea, blueberry).

According to the results of the laboratory, the preparation based on natural plant extracts (grape seeds, pomegranate, pineapple, green tea, blueberries) is the most effective in reducing oxidation processes in comparison with other components.

From the presented data, it can be seen that samples without components based on natural plant extracts have a high number of TBC, which indicates a significant oxidation of the stuffing. In the future, such products exhibit a sharp unpleasant odor and taste.

Example 3

Evaluation of the organoleptic properties of the product

The methodological guidelines have been developed on the basis of regulatory, technical and technological documentation, research in this area, as well as domestic and foreign experience in assessing the quality of food products.

Methodological instructions establish the procedure for organizing, conducting and processing the results of an organoleptic analysis of food products.

The method of carrying out the organoleptic analysis of products is mandatory and uniform for use; at food industry enterprises, including the quality control service that controls the quality of food products, as well as for other organizations, including territorial bodies of the State Standard, Gossannadzor and law enforcement agencies.

The methodology for conducting organoleptic analysis of products establishes the basic requirements for the premises, the instruments used, materials and specialists.

General provisions of the method.

Organoleptic analysis is a study of product quality using the senses - sight, smell, taste, touch.

Subject to scientifically based rules, the results of the organoleptic evaluation of product quality in terms of accuracy and reproducibility are equivalent to the results obtained using instrumental control methods.

Thanks to this method of analysis, you can quickly and easily assess the quality of raw materials, semi-finished products and culinary products, detect violations of the recipe, cooking technology. The accuracy, reproducibility and ability to compare the results of sensory analysis depends on the fulfillment of certain requirements, namely:

The procedure and conditions for the analysis;

Qualifications and skills of specialists;

Systems for evaluating the results of analysis.

The main indicators of this analysis are: appearance, color, smell, texture, taste.

Appearance - a complex indicator that characterizes the overall visual impression of the product, and includes a number of single indicators, such as shape, surface condition, uniformity in size, etc.

Color (coloration) is an indicator of appearance that characterizes the impression caused by reflected light rays of visible color.

Smell is a quality indicator determined by the sense of smell. The intensity of the smell depends on the amount of volatile substances released from the products and their chemical nature.

Consistency is an indicator of the quality of food products, which characterizes the sum of the properties of the product, reproduced visually and tactilely.

When assessing consistency, determine:

Aggregate state (liquid, solid, etc.);

The degree of its homogeneity (homogeneous, flaky, cheesy, etc.);

Mechanical properties (brittleness, viscosity, elasticity, plasticity).

Taste is the most important indicator of product quality, which has a decisive influence on the assessment of its quality.
Taste is caused by substances that are soluble in water or saliva. Taste sensations are influenced by the texture and smell of dishes and products.
When evaluating taste, its qualitative characteristics (bitter, sour, sweet, salty taste) and intensity are characterized.

Analytical methods of organoleptic analysis are based on a quantitative assessment of quality indicators and allow you to establish a correlation between individual features. Analytical methods include paired comparison methods, triangular, duo-trio, ranking, scoring, etc.

Among the analytical methods, groups of qualitative and quantitative distinguishing tests can be distinguished.

Qualitative difference methods allow answering the question of whether there is a difference between the evaluated samples in one of the quality indicators (taste, smell, texture, appearance) or the overall impression of quality, but do not answer the question of what is the difference between the samples. This group includes comparison methods: paired, triangular, two out of three (duo-trio), two out of five. They are based on a comparison of two similar samples with slight differences. Samples can be presented as a pair (paired method), as samples of three samples (two of which are identical), or as samples of five samples (one sample is repeated twice in the sample, the other three times). Samples must be coded. Methods are used in cases where it is necessary to verify whether there are differences between two samples of the product. These tests are also used in the selection of tasters.

The product was evaluated according to the methods above.

Sample No. 5 according to example 2, containing a component based on natural plant extracts, had the best performance in organoleptic analysis after storage for 180 and 210 days. In particular, the absence of rancidity, changes in taste and color of both the dough shell and the filling were observed.

Claims (19)

1. A method for the production of a molded product from a dough shell with a filling intended for instant cooking, including the steps: - preparation of a filling with a component based on natural plant extracts, while the filling is made from potato and / or meat and / or chicken filling with or without the addition of cracklings, fried onions, smoked meats, or from curd filling, and / or filling with adding apple, pear, raisin, dried apricots, apricot, custard, and the component based on natural plant extracts contains an extract selected from the group including pomegranate extract, pineapple extract, blueberry extract or a combination thereof; - preparation of a test casing from flour of the highest grades of grain crops; - formation of the product from the dough shell and stuffing; - applying a uniform layer of vegetable oil to the surface of the product; - steaming the product until cooked; - coating tempura with the addition of sugar in the amount of 1-1.5%; - deep frying; - freezing; And - packaging of the finished product in a container. 2. The method according to claim 1, characterized in that the vegetable oil is applied to the surface by dipping, or spraying, or spraying, or spreading with a uniform layer. 3. The method according to claim 1, characterized in that the freezing is carried out at a temperature of -30 to -25°C for 30-60 minutes. 4. The method according to claim 1, characterized in that steaming is carried out at a temperature of 94-98°C for 5-12 minutes until cooked. 5. The method according to claim 1, characterized in that deep-frying is carried out at a temperature of 150-200°C for 2-4 minutes until cooked. 6. The method according to any one of claims 1, 2, characterized in that vegetable oil is used, which is sunflower oil, olive oil, rapeseed oil, corn oil. 7. The method according to claim 1, characterized in that flour is used for the dough shell, which has a gluten content of more than 28% and an extensibility of more than 20 cm. 8. A molded product from a dough shell with a filling intended for instant preparation, obtained by the method according to claim 1 and including a filling with a component based on natural plant extracts and a dough shell made from flour of the highest grades of grain crops, coated with tempura with the addition of sugar in in the amount of 1-1.5%, while the filling is made from potato and/or meat and/or chicken filling with or without the addition of cracklings, fried onions, smoked meats, or curd filling, and/or filling with the addition of an apple, pear, raisin, dried apricots, apricot, custard, and the component based on natural plant extracts contains an extract selected from the group including pomegranate extract, pineapple extract, blueberry extract, or a combination thereof. 9. Molded product according to claim 8, characterized in that it has a spherical or ellipsoidal shape. 10. A molded article according to claim 8, characterized in that it can be reheated for consumption.

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