WO2018090287A1 - Air fry vended fried chicken process and product - Google Patents

Air fry vended fried chicken process and product Download PDF

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Publication number
WO2018090287A1
WO2018090287A1 PCT/CN2016/106236 CN2016106236W WO2018090287A1 WO 2018090287 A1 WO2018090287 A1 WO 2018090287A1 CN 2016106236 W CN2016106236 W CN 2016106236W WO 2018090287 A1 WO2018090287 A1 WO 2018090287A1
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WO
WIPO (PCT)
Prior art keywords
muscle meat
meat portions
portions
whole chicken
chicken muscle
Prior art date
Application number
PCT/CN2016/106236
Other languages
French (fr)
Inventor
Huike DUAN
Original Assignee
Cargill Animal Protein Further Processing (Chuzhou) Co. Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cargill Animal Protein Further Processing (Chuzhou) Co. Ltd filed Critical Cargill Animal Protein Further Processing (Chuzhou) Co. Ltd
Priority to PCT/CN2016/106236 priority Critical patent/WO2018090287A1/en
Publication of WO2018090287A1 publication Critical patent/WO2018090287A1/en

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Classifications

    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L13/00Meat products; Meat meal; Preparation or treatment thereof
    • A23L13/50Poultry products, e.g. poultry sausages
    • A23L13/55Treatment of original pieces or parts
    • A23L13/57Coating with a layer or stuffing
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L13/00Meat products; Meat meal; Preparation or treatment thereof
    • A23L13/50Poultry products, e.g. poultry sausages
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L13/00Meat products; Meat meal; Preparation or treatment thereof
    • A23L13/70Tenderised or flavoured meat pieces; Macerating or marinating solutions specially adapted therefor
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23PSHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P20/00Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
    • A23P20/10Coating with edible coatings, e.g. with oils or fats

Definitions

  • the present invention relates to method for preparing precooked, coated chicken portions ready for vending in an air-frying vending machine, products and uses.
  • Deep fat fryers are traditionally used to cook French fries, chicken, onion rings and numerous other food products. Air frying techniques have been developed to reduce the amount of oils and fat absorption into the food product.
  • US Patent No. 9,351,495 to McFadden describes, for example, an accelerated cooking air fryer. McFadden notes that such an air fryer is capable of cooking high quality food product within metal food baskets and other metal cooking devices commonly found in residential, commercial, industrial and vending venues.
  • Coated chicken portions ready for vending in an air-frying vending machine are provided by a method comprising:
  • each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm;
  • marinating the treated whole chicken muscle meat portions in a marinade to form marinated whole chicken muscle meat portions, the marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
  • the dusting composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade and the dusting composition combined have a protein content of from 8 to 14%;
  • the batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having a Stein Cup viscosity of from 12 seconds to 20 seconds;
  • the crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh;
  • precooking the battered whole chicken muscle meat portions to form precooked, coated whole chicken muscle meat portions precooking the battered whole chicken muscle meat portions to form precooked, coated whole chicken muscle meat portions.
  • precooked, coated chicken portions prepared by any of the processes described herein are also provided.
  • precooked, coated chicken portions ready for vending in an air-frying vending machine comprise whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm, the whole chicken muscle meat portions having been:
  • marinated with a marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
  • a dusting composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade the dusting composition combined have a protein content of from 8 to 14%.
  • battered with a batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having a Stein Cup viscosity of from 15 seconds to 18 seconds;
  • a crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh
  • Methods of using the precooked, coated chicken portions as described herein comprise storing the precooked, coated chicken portions in the frozen state in an air-fry vending machine for vending to a consumer.
  • Whole chicken muscle meat portions are provided in portions having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm. It has been found chicken portions prepared using ground chicken provide unsatisfactory mouth feel, and additionally does not provide adequate structural integrity. In an aspect, the whole chicken muscle meat portions do not contain skin and/or bone components. In an aspect, the whole chicken muscle meat portions are formed from breast portions. In an aspect, the whole chicken muscle meat portions are formed from leg and thigh meat portions. It has been found that chicken portions prepared using chicken muscle meat portions that are formed from leg and thigh meat portions provide excellent flavor properties, and additionally excellent value in terms of cost.
  • chicken portions having a length that is smaller than 6 cm are of a size that is unsatisfactory both from an organoleptic perspective and from a processing perspective. When the portion is too small, the product does not present a satisfying portion and provides an undesirable mouth feel. Additionally, chicken portions that are too small present processing challenges because they are more prone to getting jammed in the equipment, potentially blocking transfer of pieces. It additionally has been found that chicken portions having a length that is larger than 9 cm tends to break easily, particularly during the air-fry step. This leads to the problems identified above with respect to portion sizes that are too small.
  • each portion of the whole chicken muscle meat portions has a length of from 7 to 8 cm.
  • chicken portions having a diameter that is smaller than 1.5 cm are of a size that is unsatisfactory both from an organoleptic perspective and from a processing perspective. When the portion is too small, the product does not present a satisfying portion and provides an undesirable mouth feel. Additionally, chicken portions having too small a diameter break easily, and then present processing challenges because they are more prone to getting jammed in the equipment, potentially blocking transfer of pieces. It additionally has been found that chicken portions having a diameter that is larger than 1.8 may not cook properly and may be too large to pass through the portion transfer equipment of the air-fry machine.
  • the whole chicken muscle meat portions are treated with a phosphate composition to form treated whole chicken muscle meat portions. It has been found that treatment of the whole chicken muscle meat portions modifies the pH of the meat, which in turn enhances the juiciness of the final air-fried chicken product. Treatment of the whole chicken muscle meat portions with a phosphate composition improves the mouth feel of the final air-fried chicken product. Additionally, of the whole chicken muscle meat portions with a phosphate composition improves water retention of the meat, thereby improving juiciness of the final air-fried chicken product.
  • the phosphate composition is applied in an amount to very lightly coat the whole chicken muscle meat portions. In an aspect, the phosphate composition is applied at a rate of about 0.1 to 0.5%by weight to lightly coat the whole chicken muscle meat portions. In an aspect, the phosphate composition is applied at a rate of about 0.2 to 0.4%by weight to lightly coat the whole chicken muscle meat portions.
  • the phosphate composition comprises sodium tripolyphosphate, sodium pyrophosphate, and disodium dihydrogen pyrophosphate.
  • the phosphate composition comprises from about 60 to 97%by weight of sodium tripolyphosphate, from about 5 to 30%by weight of sodium pyrophosphate, and from about 2 to 15%by weight of disodium dihydrogen pyrophosphate.
  • the phosphate composition comprises from about 70 to 84%by weight of sodium tripolyphosphate, from about 12 to 25%by weight of sodium pyrophosphate, and from about 4 to 10%by weight of disodium dihydrogen pyrophosphate.
  • the phosphate composition comprises about 75%by weight of sodium tripolyphosphate, about 18%by weight of sodium pyrophosphate, and about 7%by weight of disodium dihydrogen pyrophosphate.
  • the whole chicken muscle meat portions are treated with the phosphate composition by mixing the whole chicken muscle meat portions with the phosphate composition and tumbling the mixture in a tumbler.
  • the whole chicken muscle meat portions are tumbled under vacuum.
  • the vacuum is from about - 0.03MP to about -0.13MP.
  • the vacuum is from about -0.05MP to about -0.1MP.
  • the vacuum is about -0.0MP.
  • the whole chicken muscle meat portions are tumbled at a temperature of from about 32°F to about 39°F.
  • the treated whole chicken muscle meat portions are marinated in a marinade to form marinated whole chicken muscle meat portions. It has been found that use of the marinade can provide superior texture and structural integrity of the meat portion and reduce breakage of the meat portion during subsequent processing steps. Further, use of the marinade can provide better mouth feel and special flavor components in the final air-fried chicken products. In an aspect, all components of the marinade are water soluble. In an aspect, the marinade comprises sugar, salt, malt dextrin, sodium glutamate, and yeast extract.
  • the marinated whole chicken muscle meat portions are dusted with a dusting composition to form dusted whole chicken muscle meat portions.
  • the dusting composition comprises wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice.
  • the dusting composition is applied in an amount to lightly coat the marinated whole chicken muscle meat portions.
  • the dusting composition is applied at a rate of about 0.5%to about 5%by weight to lightly coat the marinated whole chicken muscle meat portions.
  • the dusting composition is applied at a rate of about 1%to about 3%by weight to lightly coat the marinated whole chicken muscle meat portions.
  • the composition of the marinade and the dusting composition combined have a protein content of from 8 to 14%. In an aspect, the composition of the marinade and the dusting composition combined have a protein content of from 10 to 12%. It has been found that the use of the indicated protein content in the marinade and the dusting composition combined improves structural integrity of the chicken portion and adhesion of the batter and crumb components to the chicken portion in the final air-fried chicken product.
  • a batter is applied to the dusted whole chicken muscle meat portions to form battered whole chicken muscle meat portions.
  • the batter comprises wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate.
  • the batter has a Stein Cup viscosity of from 12 seconds to 20 seconds.
  • the batter has a Stein Cup viscosity of from 15 seconds to 18 seconds.
  • Stein Cup viscosity is measured by placing the composition at 10°C to be measured in a sample cup having a volume of 230ccs and having an orifice at the bottom of the cup with a diameter of 8mm, and allowing composition to drain from the cup.
  • the Stein Cup viscosity is reported as the time at which no more of the composition drains from the cup (i.e., all of the composition has drained except for droplets that may remain in the cup due to surface tension, as will be understood by the artisan in this field) .
  • a crumb coating composition is applied to the battered whole chicken muscle meat portions to form coated whole chicken muscle meat portions. It has been found that application of a crumb coating advantageously provides the final air-fried chicken products a crisp mouth feel and golden color.
  • the crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh. In other words, crumbs are used that will pass through a size 5 standard US mesh, but that will not pass through a size 14 standard US mesh.
  • the bread crumb composition comprising bread crumbs having a size of from 7 standard US mesh to 10 standard US mesh. It has been found that larger crumb particles within the above noted standard US mesh ranges advantageously increase the amount of oil taken up in the product when par-fried. This increase in oil take-up can provide superior mouth feel in the final air-fried chicken products. Additionally, it has been found that larger crumb particles within the above noted standard US mesh ranges advantageously improve appearance of the final air-fried chicken products.
  • the crumb coating composition is prepared from a composition comprising wheat powder, oil, salt, sugar, and dry yeast.
  • the battered whole chicken muscle meat portions are cooked to form precooked, coated whole chicken muscle meat portions.
  • the battered whole chicken muscle meat portions are par-fried in oil.
  • the oil is at a temperature of from about 170°C to about 190°C.
  • the battered whole chicken muscle meat portions are par-fried for from about 20 seconds to 40 seconds, or from about 25 seconds to 35 seconds.
  • the battered whole chicken muscle meat portions are baked.
  • the battered whole chicken muscle meat portions are first par-fried in oil and then baked.
  • the battered whole chicken muscle meat portions are cooked to a center temperature of from 73°C to 85°C.
  • the battered whole chicken muscle meat portions are cooked to a center temperature of from 78°C to 82°C.
  • the precooked whole chicken muscle meat portions are frozen to a center temperature of from -1°C to -18°C to form frozen coated whole chicken muscle meat portions. In an aspect, the precooked whole chicken muscle meat portions are frozen in a time of less than 40 minutes. In an aspect, the precooked whole chicken muscle meat portions are frozen in a time of from 15 to 40 minutes, or from 25 to 35 minutes.
  • water is applied to the frozen precooked whole chicken muscle meat portions in an amount effective to increase the crispness of final coated chicken portions when cooked in an air-frying vending machine as compared to like frozen coated whole chicken muscle meat portions that have not had water applied thereto. It has been found that application of water to the frozen product increases the crispness of the final air-fried chicken products.
  • the water that is applied to the frozen precooked whole chicken muscle meat portions is purified water.
  • the water is treated by reverses osmosis treatment.
  • An aspect of the present invention is the precooked, coated chicken portions prepared by the process as described herein.
  • precooked, coated chicken portions are provided that are ready for vending in an air-frying vending machine comprising whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm, the whole chicken muscle meat portions having been:
  • marinated with a marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
  • a dusting composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade the dusting composition combined have a protein content of from 8 to 14%;
  • battered with a batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having the batter has a Stein Cup viscosity of from 12 seconds to 20 seconds; coated with a crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh, and
  • a method of using the precooked, coated chicken portions as described herein comprising storing the precooked, coated chicken portions in the frozen state in an air-fry vending machine for vending to a consumer.
  • the precooked, coated chicken portions are cooked in an air-frying vending machine comprising commercial off the shelf components.
  • the air-frying vending machine comprises components that are configured specifically to manipulate whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm.
  • the air-frying vending machine is programmed to vend and cook precooked, coated whole chicken muscle meat portions having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm.
  • Coated chicken portions are prepared using the overall formula of components as set forth in the Precooked, Coated Chicken Formula of Table 1.
  • the precooked, coated chicken portions may be prepared by applying the above components in an overall weight content as indicated in Table 1 above, using the following process:
  • Whole chicken muscle meat portions are provided, each portion having a length of about 7 cm and a diameter of from 1.5 to 1.8 cm.
  • a phosphate composition comprising sodium tripolyphosphate, sodium pyrophosphate, and disodium dihydrogen pyrophosphate is mixed with the whole chicken muscle meat portions in water, and the mixture is tumbled under vacuum, at a rate of 4r/min for 20 minutes.
  • the tumbled product is marinated with a marinade comprising Sugar, salt, malt dextrin, sodium glutamate, yeast extract, onion powder, and garlic powder at 0-4°C for 20 minutes.
  • a marinade comprising Sugar, salt, malt dextrin, sodium glutamate, yeast extract, onion powder, and garlic powder at 0-4°C for 20 minutes.
  • the marinated product is predusted with a dry powder composition
  • a dry powder composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice.
  • the batter composition comprises wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate; and has a Stein Cup viscosity of from 15 seconds to 18 seconds.
  • the crumb composition comprises wheat powder, oil, salt, sugar, and dry yeast.
  • the crumb coated product is par-fried in 180°C oil for 30 seconds.
  • the par-fried product is heated in an oven at a temperature of 135°C and a humidity of 85%for a time sufficient to obtain a product center temperature of 80°C. After this product center temperature is achieved, the product is held in the oven for one additional minute.
  • the product is frozen to a product center temperature of from -1 to -18°C in a time of no longer than 30 minutes.
  • Reverse osmosis water is applied to both sides of the product.
  • the product is packaged in a container suitable for shipping and storage.
  • Example 1 The above process is carried out as in Example 1 above using the Precooked, Coated Chicken Formula of Table 1, except that the amount of water in the formula as set forth in Table 1 was increased to 10%. Increase in water to this amount increased the juiciness of the final air-fried chicken product.
  • Example 1 The above process is carried out as in Example 1 above, except that the product is par-fried in 185°C oil for 28 seconds.
  • the resulting final air-fried chicken product exhibited more oil adsorption and a darker color than the like final air-fried chicken products that had been par-fried in 180°C oil for 30 seconds.
  • Example 1 The above process is carried out as in Example 1 above, except that the size of the crumb aperture was reduced to an aperture size of 4mm.
  • the product was found to take up less oil in the par-fry step, and the final air-fried chicken product exhibited mouth feel that was not as satisfying as like final air-fried chicken products prepared using a crumb aperture size of 5mm.
  • Example 1 The above process is carried out as in Example 1 above, except that the water spray after freezing step was omitted.
  • the resulting final air-fried chicken product exhibited less coating crispness and a lighter color than the like final air-fried chicken products that had been sprayed with water after the freezing step.
  • Example 1 The above process is carried out as in Example 1 above, except that formed ground chicken was used instead of whole chicken muscle meat portions.
  • the formed ground chicken meat was ground using a grinding machine fitted with a 13 mm eyelet.
  • the resulting final air-fried chicken product was found to fall apart to an unacceptable amount during preparation of the precooked, coated chicken portions, and additionally during the final air-frying process in the vending machine. Additionally, the final air-fried chicken products exhibited unacceptable mouth feel as compared to like final air-fried chicken products made from whole chicken muscle meat portions.
  • Example 1 The above process is carried out as in Example 1 above (including application of phosphate) , except that the tumbling step was omitted.
  • the omission of the tumbling step was found to decrease the protein binding, thereby providing a final air-fried chicken product having inferior structural integrity and “bite” as compared to like final air-fried chicken products that were tumbled.
  • Example 1 The above process is carried out as in Example 1 above, except that the size of the whole chicken muscle meat portions was increased to about 10mm.
  • the increase in the size of the whole chicken muscle meat portions was found to increase the amount of product breakage of the final air-fried chicken product as compared to like final air-fried chicken products having a portion length of about 7 cm.
  • the terms "about” or “approximately” mean within an acceptable range for the particular parameter specified as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, e.g., the limitations of the sample preparation and measurement system. Examples of such limitations include preparing the sample in a wet versus a dry environment, different instruments, variations in sample height, and differing requirements in signal-to-noise ratios. For example, “about” can mean greater or lesser than the value or range of values stated by 1/10 of the stated values, but is not intended to limit any value or range of values to only this broader definition. For instance, a concentration value of about 30%means a concentration between 27%and 33%.

Abstract

Precooked, coated chicken portions ready for vending in an air-frying vending machine comprise whole chicken muscle meat portions having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm. The whole chicken muscle meat portions have been treated with a phosphate composition, marinated and dusted with a dusting composition, wherein the composition of the marinade and the dusting composition combined have a protein content of from 8 to 14%. The whole chicken muscle meat portions additionally have been battered, coated with a crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh, and precooked. Methods for making and using the precooked, coated chicken portions are described.

Description

AIR FRY VENDED FRIED CHICKEN PROCESS AND PRODUCT FIELD
The present invention relates to method for preparing precooked, coated chicken portions ready for vending in an air-frying vending machine, products and uses.
BACKGROUND
Deep fat fryers are traditionally used to cook French fries, chicken, onion rings and numerous other food products. Air frying techniques have been developed to reduce the amount of oils and fat absorption into the food product. US Patent No. 9,351,495 to McFadden describes, for example, an accelerated cooking air fryer. McFadden notes that such an air fryer is capable of cooking high quality food product within metal food baskets and other metal cooking devices commonly found in residential, commercial, industrial and vending venues.
SUMMARY
It has been found that the preparation and delivery of chicken portions for use in air frying vending machines presents particular challenges in providing materials that will exhibit acceptable organoleptic properties in the final air-fried chicken products. Improvements in one or more properties such as structural integrity, mouth feel, crispness, appearance (including the color and apparent texture of the cooked product) , retention of coating, delivery of desired flavor profile based on oil content, and juiciness can be provided by the present invention.
Coated chicken portions ready for vending in an air-frying vending machine are provided by a method comprising:
providing whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm;
treating the whole chicken muscle meat portions with a phosphate composition to form treated whole chicken muscle meat portions;
marinating the treated whole chicken muscle meat portions in a marinade to form marinated whole chicken muscle meat portions, the marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
dusting the marinated whole chicken muscle meat portions with a dusting composition to form dusted whole chicken muscle meat portions, the dusting composition  comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade and the dusting composition combined have a protein content of from 8 to 14%;
applying a batter to the dusted whole chicken muscle meat portions to form battered whole chicken muscle meat portions, the batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having a Stein Cup viscosity of from 12 seconds to 20 seconds;
applying a crumb coating composition to the battered whole chicken muscle meat portions to form coated whole chicken muscle meat portions, the crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh; and
precooking the battered whole chicken muscle meat portions to form precooked, coated whole chicken muscle meat portions.
In an aspect of the present invention, precooked, coated chicken portions prepared by any of the processes described herein are also provided.
In an aspect of the present invention, precooked, coated chicken portions ready for vending in an air-frying vending machine comprise whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm, the whole chicken muscle meat portions having been:
treated with a phosphate composition,
marinated with a marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
dusted with a dusting composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade the dusting composition combined have a protein content of from 8 to 14%.
battered with a batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having a Stein Cup viscosity of from 15 seconds to 18 seconds;
coated with a crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh, and
precooked.
Methods of using the precooked, coated chicken portions as described herein comprise storing the precooked, coated chicken portions in the frozen state in an air-fry vending machine for vending to a consumer.
DETAILED DESCRIPTION
The aspects of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather a purpose of the aspects chosen and described is by way of illustration or example, so that the appreciation and understanding by others skilled in the art of the general principles and practices of the present invention can be facilitated.
Whole chicken muscle meat portions are provided in portions having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm. It has been found chicken portions prepared using ground chicken provide unsatisfactory mouth feel, and additionally does not provide adequate structural integrity. In an aspect, the whole chicken muscle meat portions do not contain skin and/or bone components. In an aspect, the whole chicken muscle meat portions are formed from breast portions. In an aspect, the whole chicken muscle meat portions are formed from leg and thigh meat portions. It has been found that chicken portions prepared using chicken muscle meat portions that are formed from leg and thigh meat portions provide excellent flavor properties, and additionally excellent value in terms of cost.
It has been found chicken portions having a length that is smaller than 6 cm are of a size that is unsatisfactory both from an organoleptic perspective and from a processing perspective. When the portion is too small, the product does not present a satisfying portion and provides an undesirable mouth feel. Additionally, chicken portions that are too small present processing challenges because they are more prone to getting jammed in the equipment, potentially blocking transfer of pieces. It additionally has been found that chicken portions having a length that is larger than 9 cm tends to break easily, particularly during the air-fry step. This leads to the problems identified above with respect to portion sizes that are too small.
In an aspect each portion of the whole chicken muscle meat portions has a length of from 7 to 8 cm.
It has been found chicken portions having a diameter that is smaller than 1.5 cm are of a size that is unsatisfactory both from an organoleptic perspective and from a processing  perspective. When the portion is too small, the product does not present a satisfying portion and provides an undesirable mouth feel. Additionally, chicken portions having too small a diameter break easily, and then present processing challenges because they are more prone to getting jammed in the equipment, potentially blocking transfer of pieces. It additionally has been found that chicken portions having a diameter that is larger than 1.8 may not cook properly and may be too large to pass through the portion transfer equipment of the air-fry machine.
The whole chicken muscle meat portions are treated with a phosphate composition to form treated whole chicken muscle meat portions. It has been found that treatment of the whole chicken muscle meat portions modifies the pH of the meat, which in turn enhances the juiciness of the final air-fried chicken product. Treatment of the whole chicken muscle meat portions with a phosphate composition improves the mouth feel of the final air-fried chicken product. Additionally, of the whole chicken muscle meat portions with a phosphate composition improves water retention of the meat, thereby improving juiciness of the final air-fried chicken product. In an aspect, the phosphate composition is applied in an amount to very lightly coat the whole chicken muscle meat portions. In an aspect, the phosphate composition is applied at a rate of about 0.1 to 0.5%by weight to lightly coat the whole chicken muscle meat portions. In an aspect, the phosphate composition is applied at a rate of about 0.2 to 0.4%by weight to lightly coat the whole chicken muscle meat portions.
In an aspect, the phosphate composition comprises sodium tripolyphosphate, sodium pyrophosphate, and disodium dihydrogen pyrophosphate. In an aspect, the phosphate composition comprises from about 60 to 97%by weight of sodium tripolyphosphate, from about 5 to 30%by weight of sodium pyrophosphate, and from about 2 to 15%by weight of disodium dihydrogen pyrophosphate. In an aspect, the phosphate composition comprises from about 70 to 84%by weight of sodium tripolyphosphate, from about 12 to 25%by weight of sodium pyrophosphate, and from about 4 to 10%by weight of disodium dihydrogen pyrophosphate. In an aspect, the phosphate composition comprises about 75%by weight of sodium tripolyphosphate, about 18%by weight of sodium pyrophosphate, and about 7%by weight of disodium dihydrogen pyrophosphate.
In an aspect, the whole chicken muscle meat portions are treated with the phosphate composition by mixing the whole chicken muscle meat portions with the phosphate composition and tumbling the mixture in a tumbler. In an aspect, the whole chicken muscle meat portions are tumbled under vacuum. In an aspect, the vacuum is from about - 0.03MP to about -0.13MP. In an aspect, the vacuum is from about -0.05MP to about -0.1MP. In an aspect, the vacuum is about -0.0MP. In an aspect, the whole chicken muscle meat portions are tumbled at a temperature of from about 32℉ to about 39℉.
The treated whole chicken muscle meat portions are marinated in a marinade to form marinated whole chicken muscle meat portions. It has been found that use of the marinade can provide superior texture and structural integrity of the meat portion and reduce breakage of the meat portion during subsequent processing steps. Further, use of the marinade can provide better mouth feel and special flavor components in the final air-fried chicken products. In an aspect, all components of the marinade are water soluble. In an aspect, the marinade comprises sugar, salt, malt dextrin, sodium glutamate, and yeast extract.
The marinated whole chicken muscle meat portions are dusted with a dusting composition to form dusted whole chicken muscle meat portions. In an aspect, the dusting composition comprises wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice. In an aspect, the dusting composition is applied in an amount to lightly coat the marinated whole chicken muscle meat portions. In an aspect, the dusting composition is applied at a rate of about 0.5%to about 5%by weight to lightly coat the marinated whole chicken muscle meat portions. In an aspect, the dusting composition is applied at a rate of about 1%to about 3%by weight to lightly coat the marinated whole chicken muscle meat portions. In an aspect, the composition of the marinade and the dusting composition combined have a protein content of from 8 to 14%. In an aspect, the composition of the marinade and the dusting composition combined have a protein content of from 10 to 12%. It has been found that the use of the indicated protein content in the marinade and the dusting composition combined improves structural integrity of the chicken portion and adhesion of the batter and crumb components to the chicken portion in the final air-fried chicken product.
A batter is applied to the dusted whole chicken muscle meat portions to form battered whole chicken muscle meat portions. In an aspect, the batter comprises wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate. In an aspect, the batter has a Stein Cup viscosity of from 12 seconds to 20 seconds. In an aspect, the batter has a Stein Cup viscosity of from 15 seconds to 18 seconds. For purposes of the present disclosure, Stein Cup viscosity is measured by placing the composition at 10℃ to be measured in a sample cup having a volume of  230ccs and having an orifice at the bottom of the cup with a diameter of 8mm, and allowing composition to drain from the cup. The Stein Cup viscosity is reported as the time at which no more of the composition drains from the cup (i.e., all of the composition has drained except for droplets that may remain in the cup due to surface tension, as will be understood by the artisan in this field) .
A crumb coating composition is applied to the battered whole chicken muscle meat portions to form coated whole chicken muscle meat portions. It has been found that application of a crumb coating advantageously provides the final air-fried chicken products a crisp mouth feel and golden color. In an aspect, the crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh. In other words, crumbs are used that will pass through a size 5 standard US mesh, but that will not pass through a size 14 standard US mesh. In an aspect, the bread crumb composition comprising bread crumbs having a size of from 7 standard US mesh to 10 standard US mesh. It has been found that larger crumb particles within the above noted standard US mesh ranges advantageously increase the amount of oil taken up in the product when par-fried. This increase in oil take-up can provide superior mouth feel in the final air-fried chicken products. Additionally, it has been found that larger crumb particles within the above noted standard US mesh ranges advantageously improve appearance of the final air-fried chicken products.
In an aspect, the crumb coating composition is prepared from a composition comprising wheat powder, oil, salt, sugar, and dry yeast.
The battered whole chicken muscle meat portions are cooked to form precooked, coated whole chicken muscle meat portions. In an aspect, the battered whole chicken muscle meat portions are par-fried in oil. In an aspect, the oil is at a temperature of from about 170℃ to about 190℃. In an aspect, the battered whole chicken muscle meat portions are par-fried for from about 20 seconds to 40 seconds, or from about 25 seconds to 35 seconds. In an aspect, the battered whole chicken muscle meat portions are baked. In an aspect, the battered whole chicken muscle meat portions are first par-fried in oil and then baked. In an aspect, the battered whole chicken muscle meat portions are cooked to a center temperature of from 73℃ to 85℃. In an aspect, the battered whole chicken muscle meat portions are cooked to a center temperature of from 78℃ to 82℃.
In an aspect, the precooked whole chicken muscle meat portions are frozen to a center temperature of from -1℃ to -18℃ to form frozen coated whole chicken muscle meat portions. In an aspect, the precooked whole chicken muscle meat portions are frozen in a  time of less than 40 minutes. In an aspect, the precooked whole chicken muscle meat portions are frozen in a time of from 15 to 40 minutes, or from 25 to 35 minutes.
In an aspect, water is applied to the frozen precooked whole chicken muscle meat portions in an amount effective to increase the crispness of final coated chicken portions when cooked in an air-frying vending machine as compared to like frozen coated whole chicken muscle meat portions that have not had water applied thereto. It has been found that application of water to the frozen product increases the crispness of the final air-fried chicken products. In an aspect, the water that is applied to the frozen precooked whole chicken muscle meat portions is purified water. In an aspect, the water is treated by reverses osmosis treatment.
An aspect of the present invention is the precooked, coated chicken portions prepared by the process as described herein.
In an aspect of the present invention, precooked, coated chicken portions are provided that are ready for vending in an air-frying vending machine comprising whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm, the whole chicken muscle meat portions having been:
treated with a phosphate composition;
marinated with a marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
dusted with a dusting composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade the dusting composition combined have a protein content of from 8 to 14%;
battered with a batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having the batter has a Stein Cup viscosity of from 12 seconds to 20 seconds; coated with a crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh, and
precooked.
In as aspect of the present invention, a method of using the precooked, coated chicken portions as described herein is provided, comprising storing the precooked, coated chicken portions in the frozen state in an air-fry vending machine for vending to a consumer.
In as aspect, the precooked, coated chicken portions are cooked in an air-frying vending machine comprising commercial off the shelf components. In an aspect, the air-frying vending machine comprises components that are configured specifically to manipulate whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm. In an aspect, the air-frying vending machine is programmed to vend and cook precooked, coated whole chicken muscle meat portions having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm.
EXAMPLES
Representative embodiments of the present invention will now be described with reference to the following examples that illustrate the principles and practice of the present invention.
Example 1
Coated chicken portions are prepared using the overall formula of components as set forth in the Precooked, Coated Chicken Formula of Table 1.
Table 1
Figure PCTCN2016106236-appb-000001
In an aspect, the precooked, coated chicken portions may be prepared by applying the above components in an overall weight content as indicated in Table 1 above, using the following process:
1. Whole chicken muscle meat portions are provided, each portion having a length of about 7 cm and a diameter of from 1.5 to 1.8 cm.
2. A phosphate composition comprising sodium tripolyphosphate, sodium pyrophosphate, and disodium dihydrogen pyrophosphate is mixed with the whole chicken muscle meat portions in water, and the mixture is tumbled under vacuum, at a rate of 4r/min for 20 minutes.
3. The tumbled product is marinated with a marinade comprising Sugar, salt, malt dextrin, sodium glutamate, yeast extract, onion powder, and garlic powder at 0-4℃ for 20 minutes.
4. The marinated product is predusted with a dry powder composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice.
5. Batter is applied to the predusted product. The batter composition comprises wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate; and has a Stein Cup viscosity of from 15 seconds to 18 seconds.
6. Crumb is applied to the batter coated product. The crumb composition comprises wheat powder, oil, salt, sugar, and dry yeast.
7. The crumb coated product is par-fried in 180℃ oil for 30 seconds.
8. The par-fried product is heated in an oven at a temperature of 135℃ and a humidity of 85%for a time sufficient to obtain a product center temperature of 80℃. After this product center temperature is achieved, the product is held in the oven for one additional minute.
9. The product is frozen to a product center temperature of from -1 to -18℃ in a time of no longer than 30 minutes.
10. Reverse osmosis water is applied to both sides of the product.
11. The product is packaged in a container suitable for shipping and storage.
Example 2.
The above process is carried out as in Example 1 above using the Precooked, Coated Chicken Formula of Table 1, except that the amount of water in the formula as set forth in Table 1 was increased to 10%. Increase in water to this amount increased the juiciness of the final air-fried chicken product.
Example 3.
The above process is carried out as in Example 1 above, except that the product is par-fried in 185℃ oil for 28 seconds. The resulting final air-fried chicken product exhibited more oil adsorption and a darker color than the like final air-fried chicken products that had been par-fried in 180℃ oil for 30 seconds.
Example 4.
The above process is carried out as in Example 1 above, except that the size of the crumb aperture was reduced to an aperture size of 4mm. The product was found to take up less oil in the par-fry step, and the final air-fried chicken product exhibited mouth feel that was not as satisfying as like final air-fried chicken products prepared using a crumb aperture size of 5mm.
Example 5.
The above process is carried out as in Example 1 above, except that the water spray after freezing step was omitted. The resulting final air-fried chicken product exhibited less coating crispness and a lighter color than the like final air-fried chicken products that had been sprayed with water after the freezing step.
Comparative Example A.
The above process is carried out as in Example 1 above, except that formed ground chicken was used instead of whole chicken muscle meat portions. The formed ground chicken meat was ground using a grinding machine fitted with a 13 mm eyelet. The resulting final air-fried chicken product was found to fall apart to an unacceptable amount during preparation of the precooked, coated chicken portions, and additionally during the final air-frying process in the vending machine. Additionally, the final air-fried chicken products exhibited unacceptable mouth feel as compared to like final air-fried chicken products made from whole chicken muscle meat portions.
Comparative Example B.
The above process is carried out as in Example 1 above (including application of phosphate) , except that the tumbling step was omitted. The omission of the tumbling step was found to decrease the protein binding, thereby providing a final air-fried chicken product having inferior structural integrity and “bite” as compared to like final air-fried chicken products that were tumbled.
Comparative Example C.
The above process is carried out as in Example 1 above, except that the size of the whole chicken muscle meat portions was increased to about 10mm. The increase in the size of the whole chicken muscle meat portions was found to increase the amount of product breakage of the final air-fried chicken product as compared to like final air-fried chicken products having a portion length of about 7 cm.
As used herein, the terms "about" or "approximately" mean within an acceptable range for the particular parameter specified as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, e.g., the limitations of the sample preparation and measurement system. Examples of such limitations include preparing the sample in a wet versus a dry environment, different instruments, variations in sample height, and differing requirements in signal-to-noise ratios. For example, "about" can mean greater or lesser than the value or range of values stated by 1/10 of the stated values, but is not intended to limit any value or range of values to only this broader definition. For instance, a concentration value of about 30%means a concentration between 27%and 33%. Each value or range of values preceded by the term "about" is also intended to encompass the embodiment of the stated absolute value or range of values. Alternatively, particularly with respect to biological systems or processes, the term can mean within an order of magnitude, preferably within 5-fold, and more preferably within 2-fold, of a value.
Throughout this specification and claims, unless the context requires otherwise, the word “comprise” , and variations such as “comprises” and “comprising” , will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integer or step. When used herein “consisting of" excludes any element, step, or ingredient not specified in the claim element. When used herein, "consisting essentially of" does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. In the present disclosure of various embodiments, any of the terms "comprising" , "consisting essentially of" and "consisting of" used in the description of an embodiment may be replaced with either of the other two terms.
All patents, patent applications (including provisional applications) , and publications cited herein are incorporated by reference as if individually incorporated for all purposes. Unless otherwise indicated, all parts and percentages are by weight and all molecular weights are weight average molecular weights. The foregoing detailed description has been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom.  The invention is not limited to the exact details shown and described, for variations obvious to one skilled in the art will be included within the invention defined by the claims.

Claims (13)

  1. A method for preparing precooked, coated chicken portions ready for vending in an air-frying vending machine comprising:
    providing whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm;
    treating the whole chicken muscle meat portions with a phosphate composition to form treated whole chicken muscle meat portions;
    marinating the treated whole chicken muscle meat portions in a marinade to form marinated whole chicken muscle meat portions, the marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
    dusting the marinated whole chicken muscle meat portions with a dusting composition to form dusted whole chicken muscle meat portions, the dusting composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade and the dusting composition combined have a protein content of from 8 to 14%;
    applying a batter to the dusted whole chicken muscle meat portions to form battered whole chicken muscle meat portions, the batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having a Stein Cup viscosity of from 12 seconds to 20 seconds;
    applying a crumb coating composition to the battered whole chicken muscle meat portions to form coated whole chicken muscle meat portions, the crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh; and
    precooking the battered whole chicken muscle meat portions to form precooked, coated whole chicken muscle meat portions.
  2. The method of claim 1, wherein the whole chicken muscle meat portions are treated with the phosphate composition by mixing the whole chicken muscle meat portions with the phosphate composition and tumbling the mixture in a tumbler under vacuum.
  3. The method of claim 1, wherein the phosphate composition comprises sodium tripolyphosphate, sodium pyrophosphate, and disodium dihydrogen pyrophosphate.
  4. The method of claim 1, wherein the batter has a Stein Cup viscosity of from 15 seconds to 18 seconds.
  5. The method of claim 1, wherein the composition of the marinade and the dusting composition combined have a protein content of from 10 to 12%.
  6. The method of claim 1, wherein each portion of the whole chicken muscle meat portions has a length of from 7 to 8 cm.
  7. The method of claim 1, wherein the crumb coating composition is prepared from a composition comprising wheat powder, oil, salt, sugar, and dry yeast.
  8. The method of claim 1, wherein the bread crumbs have a size of from 7 standard US mesh to 10 standard US mesh.
  9. The method of claim 1, further comprising the step of freezing the precooked, coated whole chicken muscle meat portions to a center temperature of from -1℃ to -18℃ to form frozen precooked, coated whole chicken muscle meat portions.
  10. The method of claim 9, further comprising the step of applying water to the frozen precooked, coated whole chicken muscle meat portions in an amount effective to increase the crispness of final coated chicken portions when cooked in an air-frying vending machine as compared to like frozen precooked, coated whole chicken muscle meat portions that have not had water applied thereto.
  11. The precooked, coated chicken portions prepared by the process of claim 1.
  12. Precooked, coated chicken portions ready for vending in an air-frying vending machine comprising:
    whole chicken muscle meat portions, each portion having a length of from 6 to 9 cm and a diameter of from 1.5 to 1.8 cm, the whole chicken muscle meat portions having been:
    - treated with a phosphate composition,
    - marinated with a marinade comprising sugar, salt, malt dextrin, sodium glutamate, and yeast extract;
    - dusted with a dusting composition comprising wheat powder, starch, corn powder, disodium dihydrogen pyrophosphate, sodium bicarbonate, salt, protein powder, and spice, wherein the composition of the marinade the dusting composition combined have a protein content of from 8 to 14%.
    - battered with a batter comprising wheat powder, starch, rice powder, salt, oil, disodium dihydrogen pyrophosphate, and sodium bicarbonate and having a Stein Cup viscosity of from 12 seconds to 20 seconds;
    - coated with a crumb coating composition comprising bread crumbs having a size of from 5 standard US mesh to 14 standard US mesh, and
    - precooked.
  13. A method of using the precooked, coated whole chicken muscle meat portions of any of claims 11 or 12, comprising storing the precooked, coated chicken portions in the frozen state in an air-fry vending machine for vending to a consumer.
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