WO2022192415A1

WO2022192415A1 - Process for preparing breaded and battered food

Info

Publication number: WO2022192415A1
Application number: PCT/US2022/019574
Authority: WO
Inventors: Donald R. MAXEDON
Original assignee: R&D Coating Solutions LLC
Priority date: 2021-03-11
Filing date: 2022-03-09
Publication date: 2022-09-15

Abstract

A breading process for providing a breaded food product and a battered food product including the steps of coating a food product with a predust, a batter, and sauteed breader to form an edible coating on the food product. Misting the edible coating on the food product with water before thermally processing the food product in a cooking step, and coating a food product with a first predust, a first batter, a second predust, and a second batter to form an edible coating on the food product. Setting the edible coating on the food product in an oven before thermally processing the food product, misting the edible coating on the food product with water, and freezing and packing the food product to be reheated, respectively.

Description

PROCESS FOR PREPARING BREADED AND BATTERED FOOD

CROSS-REFERENCE TO RELATED APPLICATIONS [0001 ] The present patent application incorporates by reference the entire provisional patent application identified by U.S. Serial No. 63/159,700, filed on March 11, 2021, and claims priority thereto under 35 U.S.C. § 119(e). The present patent application also incorporates by reference the entire provisional patent application identified by U.S. Serial No. 63/159,713, filed on March 11, 2021, and claims priority thereto under 35 U.S.C. § 119(e).

BACKGROUND

[0002] Breaded foods and batter fried foods have enjoyed sustained popularity across many food cultures around the world. Consumers of breaded foods and battered foods are likely drawn to their unique texture and golden-brown appearance. However, achieving this desired texture and appearance requires labor intensive processes that employ different types of animal fats and/or vegetable oils.

[0003] Typically, fried breaded and/or battered foods are prepared, for example, by coating food products with a Hour-based mixture, followed by a Hour-based mixture or batter, before submerging the coated food products in heated animal fats and/or vegetable oils to achieve the desired texture and golden-brown appearance sought after by consumers.

[0004] Increasingly, however, more health-conscious consumers are turning away from fried, breaded and battered foods because fried, breaded and battered foods are highly caloric and contain high levels of fats. This is largely due to the methods of preparing fried, breaded and battered foods. In recognition of the changing dietary preferences of consumers, manufacturers and other commercial preparers of food products have sought to obtain similar texture, flavor, and appearance of fried, breaded and/or battered foods without the typical oil- frying process. This includes the use of different coatings for food products that, when prepared, attempt to imitate the characteristics of traditionally fried, breaded food products. However, these attempts have been met with varying degrees of success. Often, these new processes do not produce food products having the appearance, texture, or taste of fried products.

[0005] A need exists for a coating for food products and process of producing food products having the taste, texture, and appearance of fried, breaded food and fried, battered food without relying on traditional oil-frying method. It is to such a coating and process of preparing food products employing the coating that the inventive concepts disclosed and claimed herein are directed. SUMMARY OF THE INVENTIVE CONCEPTS [0006] The inventive concepts disclosed and claimed herein generally relate to a breading process for producing breaded food products and battered food products.

[0007] The process of producing breaded food products includes coating a food product with a predust comprising cracker meal, and one or more natural coating ingredients in a first coating step, wherein the cracker meal is sauteed with oil. Following the first coating step, coating the food product with a batter in a second coating step, the batter comprising dry ingredients and water. Next, coating the food product from the second coating step with a sauteed breader comprising bread crumbs, cracker meal, and one or more natural coating ingredients in a third coating step to form an edible coating on the food product, wherein the bread crumbs are sauteed with the oil. Then, misting the edible coating on the food product from the third coating step with water in misting step. Following the misting step, thermally processing the food product in a cooking step.

[0008] The process for producing battered food products includes coating a food product with a first predust comprising cracker meal, flour, starch and one or more other flavoring ingredients in a first predust step. Following the first predust step, coating the food product with a first batter in a first coating step, the first batter comprising dry ingredients, water, and oil. Next, coating the food product from the first coating step with a second predust comprising cracker meal, and one or more natural coating ingredients in a second predust step. Then, coating the food product from the second predust step with a second hater in a second coating step to form an edible coating on the food product, the second batter comprising dry ingredients, water, and oil. Following the second coating step, setting the edible coating on the food product in an oven in a setting step. Next, thermally processing the food product from the setting step in a cooking step before misting the edible coating on the food product from the cooking step with water in a misting step, and freezing the food product from the misting step for packaging.

BRIEF DESCRIPTION OF THE DRAWINGS [0009] To assist those of ordinary skill in the art in making and using the inventive concepts disclosed herein, reference is made to the appended drawings.

[00010] FIG. 1 is a flowchart illustrating steps to coat a food product for preparing a breaded food product according to an exemplary embodiment of the inventive concepts disclosed herein. [00011] FIG. 2 is a flowchart illustrating steps to coat a food product for preparing a battered food product according to an exemplary embodiment of the inventive concepts disclosed herein.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS [00012] Before explaining at least one embodiment of the inventive concept(s) in detail by way of exemplary drawings, experimentation, results, and laboratory procedures, it is to be understood that the inventive concept(s) is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings, experimentation and/or results. The inventive concept(s) is capable of other embodiments or of being practiced or carried out in various ways. The language used herein is intended to be given the broadest possible scope and meaning; and the embodiments are meant to be exemplary -not exhaustive. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

[00013] Unless otherwise defined, scientific and technical terms used in connection with the presently disclosed and claimed inventive concept(s) shall have the meanings commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. The foregoing techniques and procedures are generally performed according to conventional methods well known in the art and as described in various general and more specific references cited and discussed throughout the present specification. The nomenclatures utilized in connection with, and the laboratory procedures and techniques of, analytical chemistry, synthetic organic chemistry, and medicinal and pharmaceutical chemistry described herein are those well-known and commonly used in the art. Standard techniques are used for chemical syntheses and chemical analyses.

[00014] All the articles, compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation, given the present disclosure. While the articles, compositions and methods of the inventive concept(s) have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the articles, compositions and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit and scope of the inventive concept(s). All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the inventive concept(s) as defined by the appended claims. [00015] As utilized under the present disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:

[00016] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”

[00017] The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.”

[00018] Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

[00019] The use of the term “at least one” will be understood to include one as well as any quantity more than one, including but not limited to, 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 100, etc. The term “at least one” may extend up to 100 or 1000 or more, depending on the term to which it is attached; in addition, the quantities of 100/1000 are not to be considered limiting, as higher limits may also produce satisfactory results. In addition, the use of the term “at least one of X, Y, and Z” will be understood to include X alone, Y alone, and Z alone, as well as any combination of X, Y, and Z.

[00020] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. [00021] The term “or combinations thereof’ as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof’ is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, MB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context. [00022] As used herein, the term “meat” refers to fish, shell-fish, poultry, beef, veal, pork, various game meats, and any other type of animal product commonly referred to as meat or fish. A meat may be available in various cuts, including with or without bones. [00023] As used herein, the term “coating” may be one or more layers of a substance, for example a batter, breader, or predust applied to a food product. The “coating” may comprise several layers applied individually.

[00024] As used herein, the term “predust” may be a dry component of a coating. A “predust” may be applied to a food product prior to a bater or breader layer of a coating. Predust may be available in a variety of sizes, including very fine to very coarse, and may include additional ingredients such as flavorings and seasonings.

[00025] As used herein, the term “bater” may be a liquid or liquid based coating. A bater may be a suspension, emulsion, or solution of a liquid that contains a second liquid and/or a solid, such as, for example, gums, starches, or flour.

[00026] As used herein, the term “breader” may be a dry component of a coating. A “breader” may include, for example, cracker meal, bread crumbs, extruded crumbs, or flour. Bread crumbs may be American bread crumb or Japanese bread crumbs. Breader may be available in a variety of sizes, including from very fine to very coarse, and can include additional ingredients such as flavorings and seasonings.

[00027] In the following detailed description of embodiments of the inventive concept, numerous specific details are set forth in order to provide a more thorough understanding of the inventive concept. However, it will be apparent to one of ordinary skill in the art that the inventive concept within the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the instant disclosure.

[00028] Finally, as used herein any reference to "one embodiment" or "an embodiment" means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment.

[00029] Referring now to FIG. 1, shown therein is a flowchart illustrating steps to coat a food product to prepare a breaded food product according to an exemplary embodiment of the inventive concepts disclosed herein.

[00030] In a step 110a, a marinade is applied to a food product. The food product may be a meat, vegetable, fruit, appetizer, cheese, pasta-based food product, or a combination thereof. Generally, the size of the food product is not critical. The food products may vary from bite-sized to whole food products. The food product may also be a formed food product which is manufactured from particles of one or more food products and reformulated into particular shapes. The food product may be uniform in size or of varying sizes. The food product may also be portioned to a particular size. The food product may be fresh, frozen, or semi-frozen. The food product may be raw, cooked, or partially cooked. The food product may be boneless or bone-in. In one embodiment, frozen food products are thawed to, for example, refrigerated temperature before the marination step 110a.

[00031 ] The marinade applied to the food product in step 110a may impart flavor to the food product, tenderize the food product, and may introduce moisture into the food product to prevent the food product from becoming too dry once cooked. The marinade may also allow for uniformity of flavor of the food products. The marinade may be a liquid marinade, the composition of the liquid marinade may include liquid ingredients, dry ingredients, or both. [00032] The liquid marinade may include a flavored stock, an alkali metal phosphate, and salt. The liquid marinade may contain a flavored stock, such as chicken stock, beef stock, turkey stock, vegetable stock, fish and seafood stock, bone broth, or a combination thereof. Flavored stock may impart flavor to the food product and provide moisture. The flavored stock for the liquid marinade may be salted or unsalted. The liquid marinade may comprise about 0% to 100% by weight of flavored stock. In one embodiment, the liquid marinade may comprise about 96% by weight of unsalted chicken stock.

[00033] The liquid marinade may contain alkali metal phosphates such as, for example, sodium tripolyphosphate, sodium hexametaphosphate, sodium pyrophosphate, dipotassium phosphate, or a combination thereof. The liquid marinade may comprise up to about 0.5% by food product weight of alkali metal phosphates. The liquid marinade may comprise about 0% to about 2% by weight of alkali metal phosphates. In one embodiment, the liquid marinade may comprise about 2% by weight of sodium tripolyphosphate. Sodium tripolyphosphate is commonly used in marinades to increase meat yield and water-holding capacity, as well as improve color and texture. The liquid marinade may also contain salt, such as sodium chloride. In some embodiments, the salt may be an encapsulated salt to better maintain the cellular integrity of meat proteins. The liquid marinade may comprise an amount of salt based on consumer preference. In one embodiment, the liquid marinade may comprise about 2% by weight of salt. Salt, similarly, is another common ingredient in marinades, and may enhance food product flavor, increase moisture retention, and, when used with sodium tripolyphosphate, may act as a synergist with sodium tripolyphosphate to extract salt-soluble proteins. The liquid marinade may be suitable for injection into food products. The marinade may be applied to the food product by conventional procedures known in the art, including the use of a vacuum tumbler, and marinade injectors. The alkali metal phosphates and salt may be uniformly dispersed in the flavored stock to form the liquid marinade.

[00034] In one embodiment, marinating step 110a is performed in a vacuum tumbler. Vacuum tumbling is a method of marination in which food products are placed in a rotating tumbler in the presence of a marinade under reduced pressured. Applying a vacuum mechanically distorts the food product, expanding it, and allows for effective absorption of the marinade. Further, the mechanical distortion of the food product, such as meats, may break down meat fibers to enhance tenderization. Once the food products are placed into the vacuum tumbler, an amount of liquid marinade may be metered into the vacuum tumbler. An amount of liquid marinade of approximately 10% to 25% by weight of the food product may be placed into the vacuum tumbler with the food product. In one embodiment, an amount of liquid marinade, such as, about 13% by weight of the food product, may be metered into the vacuum tumbler. The food product may be tumbled in the vacuum tumbler for approximately 15-25 minutes. The food product may be marinated in the vacuum tumbler for a predetermined amount of time, or until substantially all the liquid marinade is absorbed by the food product. [00035] In some embodiments, after marinating step 110a, the food product may be tumbled in the vacuum tumbler with a liquid batter. In that embodiment, an amount of liquid batter, such as, about 10 % by weight of the food product, comprising approximately 35% to 40% batter solids, may be metered into the vacuum tumbler. The food product may be tumbled in the vacuum tumbler without vacuum for approximately 5 minutes.

[00036] In another embodiment, marinating step 110a may be optional.

[00037] In an alternative embodiment, marinating step 110a may be performed by injecting the liquid marinade directly into the food product using, for example, a single needle injector or multi -needle injector. In that embodiment, the food product may be a bone-in meat product. The food product may be injected at one or more injection locations, and a desired volume of liquid marinade may be deposited at each of the one or more injection locations. [00038] In another embodiment, after marinating step 110a, the food product may be placed on a vibratory conveyor belt, which produces a vibration, or otherwise agitates the food products as the food products are being conveyed along the vibratory conveyor belt, causing the liquid marinade to be uniformly dispersed throughout the food product.

[00039] After the marination step 110a, a predust may be applied to the food product in a step 120a.

[00040] In step 120a, a predust may be added to the vacuum tumbler to coat the food product after the marination step 110a. Application of a predust to the food product may improve the adhesion of a coating, improve yield, impart flavor, and improve crispiness of a food product. The predust may contain one or more of cracker meal, food starch, fiber, flour, spices, natural colors and flavors. The cracker meal may contribute to the food product’s ultimate texture, flavor, and appearance. The cracker meal may be sauteed to impart a refined saute fried flavor and golden-brown appearance to the food product. In one embodiment, bread crumbs may be sauteed with oil using a heated plate with a surface temperature of about 400° F. The oil may be a vegetable oil, an animal fat or oil, or a combination thereof. The oil may be a soy bean oil, cotton seed oil, palm kernel oil, safflower oil, com oil, beef tallow, pork lard, goose or duck fat, or a combination thereof. Commercially available mixers, such as, PlowBlend™ blenders may perform step 120a. The predust may also contain wheat flour, tapioca flour, rice flour, yellow com flour or a combination thereof. Food starch, such as natural starches, may be included in the predust for added crispiness and for improve oil-barrier properties. Similarly, natural colors may be added to the predust composition to create a uniform golden color around the food product. The predust may be formed by combining the bread crumbs, cracker meal, food starch, fibers, flour, natural flavors and colors, and spices. In some embodiments, the predust may further comprise artificial flavors and colors, and antioxidants to control rancidity. The combined predust may be processed to obtain varying particle sizes. In one embodiment, the predust is typically a fine powder.

[00041] An amount of predust may be metered into the vacuum tumbler to coat the marinated food product. In one embodiment, an amount of predust, such as, about 0% to about 2% by weight of the food product, may be metered into the vacuum tumbler. The food product may be tumbled in the vacuum tumbler with the predust for about 3 minutes to about 5 minutes. The food product may be coated with the predust in the vacuum tumbler for a predetermined amount of time, or until substantially all of the predust has adhered to the surface of the food product.

[00042] In an alternative embodiment, the liquid marinade and predust may be applied to the food product without a vacuum tumbler.

[00043] In another embodiment, predust step 120a may be optional.

[00044] After the predust step 120a, the food product may be removed from the vacuum tumbler for further processing. In a step 130a, a batter may be applied to the food product. The batter may combine a combination of water and dry ingredients. The batter may contain one or more of, food starches, flour, cracker meal, natural flavors and colors, spices, oil, water, and combinations thereof. The batter may also contain one or more varieties of flour, such as wheat flour, tapioca flour, rice flour, yellow com flour, or a combination thereof. The batter may also contain, for example, natural starches, citrus fibers, natural flavors and colors, spices, oil, or a combination thereof. In some embodiments, the bater may further comprise artificial flavors and colors, and antioxidants to control rancidity. In one embodiment, the bater may contain about 70% by weight water and 30% by weight dry ingredients. In on embodiment, the dry ingredients may be identical to or substantially similar to the predust formulation. The water content of the bater may be adjusted depending on desired viscosity and coating thickness. The bater may be applied to the food product by conventional procedures known in the art. [00045] In an alternative embodiment, the food product, after being batered in step 130a, may be removed to a refrigerator before being thermally processed in a step 160a, as discussed below.

[00046] In a step 140a, a sauteed breader may be applied to the batered food product. The sauteed breader may be prepared by sauteing bread crumbs in an oil. In one embodiment, Japanese or American bread crumbs may be sauteed in oil using a heated plate with a surface temperature of about 400°F. The oil may be a vegetable oil, animal fat or oil, or combination thereof. The oil may be a soy bean oil, coton seed oil, palm kernel oil, safflower oil, com oil, beef tallow, pork lard, goose or duck fat, or a combination thereof. The bread crumbs may be sauteed at a temperature lethal to microbial pathogens, to reduce microbial pathogen load of the coating of the food product. Additionally, the sauteed breader may impart fried flavor and golden-brown color to the food product. Along with sauteed bread crumbs, the sauteed breader may also include cracker meal, natural starches, citrus fibers, wheat flour, tapioca flour, rice flour, yellow com flour, natural flavors and colors, spices, oil, spray dried fats, flavored meat powders, or a combination thereof. In some embodiments, the bater may further comprise artificial flavors and colors, and antioxidants to control rancidity. In one embodiment, the breader may comprise ingredients substantially similar to the predust. Inclusion of natural starches to the sauteed breader may improve crumb texture and increase hold time under heat lamps. The sauteed breader may be coarser than the predust to impart a non-uniform texture to the food product.

[00047] After the food product has been batered and the sauteed breader has been applied to form an edible breaded coating, the breaded coating of the food product may be misted in a step 150a. The breaded coating of the food product may be misted with atop chilled water sprayer. In some embodiments, the food product is misted with a combination of vegetable oil, an emulsifier, and water.

[00048] After the misting step 150a, the food product may be thermally processed in a step 160a. The food product may be thermally processed by any heating method such as oven baking, frying, microwaving, grilling, steaming, infrared broiling, sous vide, etc. Commercially available contact cookers, such as, for example, JBT Progrill™ may perform step 160a. The food product may be heated for a sufficient amount of time to kill any harmful bacteria. In one embodiment, the food product may be heated in an oven with a combination of dry heat and steam until the internal temperature of the food product reaches 165 °F and 185 °F for bone-in food products. In another embodiment, the food product may be steamed for a sufficient amount of time to set the sauteed breader of the food product. In that embodiment, the food product may be steamed for approximately 60 to 90 seconds to set coating.

[00049] In one embodiment, the thermal processing step 160a includes placing the food product on conveyor belts, such as conveyor belts coated with Teflon, to convey the food product to an oven and/or grill heated plates to impart a pan-fried appearance to the food product.

[00050] Following the thermal processing step 160a, the food product may be frozen and packaged in a step 170a. The food product may be frozen after the thermal processing step 160a. The food product may be packaged in a polyethylene bag, vacuum packaged, or packaged in a modified atmosphere and hermetically sealed.

[00051] After the food product is frozen and packaged in step 170a, the food product may be reheated. The food product may be reheated in a convection oven, deep fat fryer, pan, microwave, convection oven, infrared broiler, wok, flat grill, air fryer, or a combination thereof. In one embodiment, the frozen food product may be removed from its packaging and placed on a cookie sheet with a wire rack before being placed in an oven at 400 °F for approximately 18 to 20 minutes. The food product may also be reheated until the food product reaches an internal temperate of about 160°F.

[00052] Referring now to FIG. 2, shown therein is a flowchart illustrating steps to coat a food product to prepare a battered food product according to an exemplary embodiment of the inventive concepts disclosed herein.

[00053] In a step 110b, a marinade is applied to a food product. The food product may be a meat, vegetable, fruit, appetizer, cheese, pasta-based food product, or a combination thereof. Generally, the size of the food product is not critical. The food products may vary from bite-sized to whole food products. The food product may also be a formed food product which is manufactured from particles of one or more food products and reformulated into particular shapes. The food product may be uniform in size or of varying sizes. The food product may also be portioned to a particular size. The food product may be fresh, frozen, or semi-frozen. The food product may be raw, cooked, or partially cooked, and may include a breaded heat set coating. The food product may be boneless or bone-in. In one embodiment, frozen food products are thawed to, for example, refrigerated temperature before the marination step 110b. [00054] The marinade applied to the food product in step 110b may impart flavor to the food product, tenderize the food product, and may introduce moisture into the food product to prevent the food product from becoming too dry once cooked. The marinade may also allow for uniformity of flavor of the food products. The marinade may be a liquid marinade, the composition of the liquid marinade may include liquid ingredients, dry ingredients, or both. [00055] The liquid marinade may include a flavored stock, an alkali metal phosphate, and salt. The liquid marinade may contain a flavored stock, such as chicken stock, beef stock, turkey stock, vegetable stock, fish and seafood stock, bone broth, or a combination thereof. Flavored stock may impart flavor to the food product and provide moisture. The flavored stock for the liquid marinade may be salted or unsalted. The liquid marinade may comprise about 0% to 100% by weight of flavored stock. In one embodiment, the liquid marinade may comprise about 96% by weight of unsalted chicken stock.

[00056] The liquid marinade may contain alkali metal phosphates such as, for example, sodium tripolyphosphate, sodium hexametaphosphate, sodium pyrophosphate, dipotassium phosphate, or a combination thereof. The liquid marinade may comprise up to about 0.5% by food product weight of alkali metal phosphates. The liquid marinade may comprise about 0% to about 2% by weight of alkali metal phosphates. In one embodiment, the liquid marinade may comprise about 2% by weight of sodium tripolyphosphate. Sodium tripolyphosphate is commonly used in marinades to increase meat yield and water-holding capacity, as well as improve color and texture. The liquid marinade may also contain salt, such as sodium chloride. In some embodiments, the salt may be an encapsulated salt to better maintain the cellular integrity of meat proteins. The liquid marinade may comprise an amount of salt based on consumer preference. In one embodiment, the liquid marinade may comprise about 2% by weight of salt. Salt, similarly, is another common ingredient in marinades, and may enhance food product flavor, increase moisture retention, and, when used with sodium tripolyphosphate, may act as a synergist with sodium tripolyphosphate to extract salt-soluble proteins. The liquid marinade may be suitable for injection into food products. The marinade may be applied to the food product by conventional procedures known in the art, including the use of a vacuum tumbler, and needle injectors. The alkali metal phosphates and salt may be uniformly dispersed in the flavored stock to form the liquid marinade.

[00057] In one embodiment, marinating step 110b is performed in a vacuum tumbler. Vacuum tumbling is a method of marination in which food products are placed in a rotating tumbler in the presence of a marinade under reduced pressured. Applying a vacuum mechanically distorts the food product, expanding it, and allows for effective absorption of the marinade. Further, the mechanical distortion of the food product, such as meats, may break down meat fibers to enhance tenderization. Once the food products are placed into the vacuum tumbler, an amount of liquid marinade may be metered into the vacuum tumbler. An amount of liquid marinade of approximately 10% to 25% by weight of the food product may be placed into the vacuum tumbler with the food product. In one embodiment, an amount of liquid marinade, such as, about 13% by weight of the food product, may be metered into the vacuum tumbler. The food product may be tumbled in the vacuum tumbler for approximately 15-25 minutes. The food product may be marinated in the vacuum tumbler for a predetermined amount of time, or until substantially all the liquid marinade is absorbed by the food product. [00058] In some embodiments, after marinating step 110b, the food product may be tumbled in the vacuum tumbler with a liquid batter. In that embodiment, an amount of liquid batter, such as, about 10 % by weight of the food product, comprising approximately 35% to 40% batter solids, may be metered into the vacuum tumbler. The food product may be tumbled in the vacuum tumbler without vacuum for approximately 5 minutes.

[00059] In another embodiment, marinating step 110b may be optional.

[00060] In an alternative embodiment, marinating step 110b may be performed by injecting the liquid marinade directly into the food product using, for example, a single needle injector or multi -needle injector. In that embodiment, the food product may be a bone-in meat product. The food product may be injected at one or more injection locations, and a desired volume of liquid marinade may be deposited at each of the one or more injection locations. [00061] In another embodiment, after marinating step 110b, the food product may be placed on a vibratory conveyor belt, which produces a vibration, or otherwise agitates the food products as the food products are being conveyed along the vibratory conveyor belt, causing the liquid marinade to be uniformly dispersed throughout the food product.

[00062] After the marination step 110b, a predust may be applied to the food product in a step 120b.

[00063] In step 120b, a predust may be added to the vacuum tumbler to coat the food product after the marination step 110b. Application of a predust to the food product may improve the adhesion of a coating, improve yield, impart flavor, and improve crispiness of a food product. The predust may contain one or more of bread crumbs, cracker meal, food starch, fiber, flour, spices, natural colors and flavors, and oil. The predust may include bread crumbs, such as American bread crumbs or Japanese bread crumbs. The bread crumbs and cracker meal may contribute to the food product’s ultimate texture, flavor, and appearance. The bread crumbs may be sauteed to impart a refined saute fried flavor and golden-brown appearance to the food product. In one embodiment, bread crumbs may be sauteed with oil using a heated plate with a surface temperature of about 400° F. The oil may be a vegetable oil, an animal fat or oil, or combination thereof. The oil may be a soy bean oil, cotton seed oil, palm kernel oil, safflower oil, com oil, beef tallow, pork lard, goose or duck fat, or a combination thereof. The predust may also contain wheat flour, tapioca flour, rice flour, yellow com flour or a combination thereof. Commercially available mixers, such as, for example, PlowBlend™ blenders may perform step 120b. Food starch, such as natural starches, may be included in the predust for added crispiness and for improve oil-barrier properties. Similarly, natural colors may be added to the predust composition to create a uniform golden color around the food product. The predust may be formed by combining the bread crumbs, cracker meal, food starch, fibers, flour natural flavors and colors, spray dried fats, flavored meat powders, and spices. In some embodiments, the first predust may further comprise artificial flavors and colors, and antioxidants to control rancidity. The combined predust may be processed to obtain varying particle sizes. In one embodiment, the predust is a fine powder with limited bread crumbs and cracker meal.

[00064] An amount of predust may be metered into the vacuum tumbler to coat the marinated food product. In one embodiment, an amount of predust, such as, about 0% to about 2% by weight of the food product, may be metered into the vacuum tumbler. The food product may be tumbled in the vacuum tumbler with the predust for up to about 5 minutes. The food product may be coated with the predust in the vacuum tumbler for a predetermined amount of time, or until substantially all of the predust has adhered to the surface of the food product. [00065] In an alternative embodiment, the liquid marinade and predust may be applied to the food product without a vacuum tumbler using conventional methods.

[00066] In another embodiment, the predust step 120b may be optional.

[00067] After the predust step 120b, the food product may be removed from the vacuum tumbler for further processing. In a step 130b, a first batter may be applied to the food product. The first batter may combine a combination of water, dry ingredients, and oil. The first batter may contain one or more of bread crumbs, food starch, flour, cracker meal, natural flavors and colors, spices, spray dried fats, flavored meat powders, oil, water, and combinations thereof. The first batter may contain bread crumbs, such as American or Japanese bread crumbs. The first batter may also contain one or more varieties of flour, such as wheat flour, tapioca flour, rice flour, yellow com flour, or a combination thereof. The first batter may also contain, for example, natural starches, citrus fibers, natural flavors and colors, spices, spray dried fats, flavored meat powders, oil, or a combination thereof. In some embodiments, the first batter may further comprise artificial flavors and colors, and antioxidants to control rancidity. In one embodiment, the first batter may contain about 2% to about 5% by weight oil. The addition of oil to the first batter may improve the finished batter coating appearance and improve batter coating release from Teflon™ slats, such as Cambridge™ belting or JBT ProGrill™/ProBake™ belting during further processing. In on embodiment, the dry ingredients may be identical to or substantially similar to the predust formulation. The water content of the first batter may be adjusted depending on desired viscosity and coating thickness. The first batter may be applied to the food product by conventional procedures known in the art. In an alternative embodiment, the first battering step 130b may be optional.

[00068] In a step 140b, a second predust may be applied to the food product after the first batter step 130b. Application of the second predust to the food product may improve the adhesion of a coating, improve yield, impart flavor, improve crispiness of a food product, and create a protective seal against product leakage. The second predust may contain one or more of bread crumbs, cracker meal, food starch, fiber, flour, spices, natural colors and flavors, and oil. The second predust may include bread crumbs, such as American bread crumbs or Japanese bread crumbs. The bread crumbs may contribute to the food product’s ultimate texture, flavor, and appearance. The cracker meal may be sauteed to impart a refined saute fried flavor and golden-brown appearance to the food product. In one embodiment, the cracker meal may be sauteed with oil using a heated plate with a surface temperature of about 400° F. The oil may be a vegetable oil, an animal fat or oil, or a combination thereof. The oil may be a soy bean oil, cotton seed oil, palm kernel oil, safflower oil, com oil, or a combination thereof. The second predust may also contain wheat flour, tapioca flour, rice flour, yellow com flour or a combination thereof. Food starch, such as natural starches, may be included in the predust for added crispiness and for improve oil-barrier properties. Similarly, natural colors may be added to the second predust composition to create a uniform golden color around the food product. The second predust may be formed by combining the bread crumbs, cracker meal, food starch, fibers, flour natural flavors and colors, spray dried fats, flavored meat powders, and spices. In some embodiments, the second predust may further comprise artificial flavors and colors, and antioxidants to control rancidity. The combined second predust may be processed to obtain varying particle sizes. In one embodiment, the second predust is a fine powder.

[00069] In a step 150b, a second batter may be applied to the food product following the second predust step 140b. The second batter may combine a combination of water, dry ingredients, and oil. The second batter may contain one or more of bread crumbs, food starch, flour, cracker meal, gums, natural flavors and colors, spices, spray dried fats, flavored meat powders, oil, water, and combinations thereof. The second batter may contain bread crumbs, such as American or Japanese bread crumbs. The second batter may also contain one or more varieties of flour, such as wheat flour, tapioca flour, rice flour, yellow com flour, or a combination thereof. The second batter may also contain, for example, natural starches, citrus fibers, natural flavors and colors, spices, spray dried fats, flavored meat powders, oil, or a combination thereof. In some embodiments, the second batter may further comprise artificial flavors and colors, and antioxidants to control rancidity. The second batter may contain approximately 2% to 10% by weight oil. In one embodiment, the second batter may contain up to about 5% by weight oil. Adding oil to the second batter may improve the finished batter coating appearance and improve batter coating release from Teflon™ slats, such as Cambridge™ belting or JBT ProGrill™/ProBake™ belting during further processing. In on embodiment, the dry ingredients may be identical to or substantially similar to the first and second predust formulation. The water content of the second batter may be adjusted depending on desired viscosity and coating thickness. The second batter may be applied to the food product by conventional procedures known in the art.

[00070] After the second batter has been applied to the food product, the battered coating of the food product may be set in a step 160b. The food product from the second batter step 150b may then be removed and placed in a conveyor oven having a non-stick belt. The non stick belt may comprise Teflon™ slats. Commercially available conveyor ovens may be employed to set the battered coating of the food product in step 160b, such as, for example, the JBTPG Series ProGrill™/ProBake™ Contact Cooker. In one embodiment, the conveyor oven may be set at about 400 °F to about 450 °F and the food product may reside in the conveyor oven for approximately 2 minutes to set the batter coating with a combination of steam and dry heat. The batter coating may also be set in 100% steam.

[00071] After the setting step 160b, the food product may be thermally processed in a cooking step 170b. The food product may be thermally processed by any heating method such as baking, frying, microwaving, grilling, steaming, broiling, sous vide, etc. Commercially available contact cookers, such as, for example JBT ProGrill™/ProBake™ may perform step 170b. The food product may be heated for a sufficient amount of time to fully cook the food product and to kill any harmful bacteria. In one embodiment, the food product may be fried in a deep fryer set at 350 °F for approximately 4 to 4.5 minutes, or until the food product registers an internal temperature of 165 °F. [00072] After the cooking step 170b, the food product may be misted in a misting step 180b. The battered coating of the food product may be sprayed by a top and bottom chilled water sprayer. In some embodiments, the food product is misted with a combination of vegetable oil, an emulsifier, and water.

[00073] Following the misting 180b, the food product may be frozen and packaged in a step 190b. The food product may be frozen after the misting step 180b. The food product may be packaged in a polyethylene bag, vacuum packaged, or packaged in a modified atmosphere and hermetically sealed.

[00074] After the food product is frozen and packaged in step 190b, the food product may be reheated. The food product may be reheated in a convection oven, deep fat fryer, pan, microwave, convection oven, infrared broiler, wok, flat grill, air fryer, or a combination thereof. In one embodiment, the frozen food product may be removed from its packaging and placed on a cookie sheet with a wire rack before being placed in an oven at 400 °F for approximately 18 to 20 minutes.

[00075] From the above description, it is clear that the inventive concepts disclosed herein are adapted to carry out the objects and to attain the advantages mentioned herein as well as those inherent in the inventive concepts disclosed herein. While exemplary embodiments of the inventive concepts disclosed herein have been described for purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the scope of the inventive concepts disclosed herein and defined by the appended claims.

Claims

What is claimed is:

1. A process for preparing a breaded food product, comprising: coating a food product with a predust comprising cracker meal, and one or more natural coating ingredients in a first coating step; coating the food product from the first coating step with a batter in a second coating step, the batter comprising dry ingredients and water; coating the food product from the second coating step with a sauteed breader comprising bread crumbs, cracker meal, and one or more natural coating ingredients in a third coating step to form an edible coating on the food product, wherein the bread crumbs are sauteed with an oil; misting the edible coating on the food product from the third coating step with water in a misting step; thermally processing the food product from the misting step in a cooking step; and freezing the food product from the cooking step for packaging in a freezing step.

2. The process of claim 1, further comprising a step of coating the food product with a liquid marinade in an initial marinading step prior to the first coating step.

3. The process of claim 2, wherein the food product is coated with the liquid marinade in a vacuum tumbler.

4. The process of claim 2, wherein the liquid marinade includes one or more of a stock, an alkali metal phosphate, and salt.

5. The process of claim 4, wherein the stock is selected from a group consisting of chicken stock, beef stock, turkey stock, vegetable stock, fish and seafood stock, bone broth, water, and a combination thereof.

6. The process of claim 4, wherein the flavored stock is unsalted.

7. The process of claim 4, wherein the flavored stock is unsalted chicken stock.

8. The process of claim 4, wherein the alkali metal phosphate is selected from a group consisting of sodium tripolyphosphate, sodium hexametaphosphate, sodium pyrophosphate, dipotassium phosphate, and a combination thereof.

9. The process of claim 4, wherein the alkali metal phosphate is sodium tripolyphosphate.

10. The process of claim 4, wherein the weight ratio of the flavored stock, alkali metal phosphate, and salt is about 48:1:1.

11. The process of claim 1, wherein the food product is coated with the predust in the vacuum tumbler.

12. The process of claim 1, wherein the breadcrumbs are sauteed using a heated plate with a surface temperature of approximately 400°F.

13. The process of claim 1, wherein the one or more natural coating ingredients are selected from a group consisting of natural starches, citrus fibers, wheat flour, tapioca flour, rice flour, yellow com flour, natural flavors and colors, spices, oil, spray dried fats, flavored meat powders, and a combination thereof.

14. The process of claim 2, wherein the initial marinading step is optional.

15. The process of claim 1, wherein one or more of the predust, the batter, and the sauteed breader further comprise artificial flavors and colors.

16. The process of claim 1, wherein the weight ratio of the dry ingredients and water is about 3:7.

17. The process of claim 1, wherein thermally processing the food product includes at least one of baking, frying, microwaving, grilling, steaming, sous vide, or infrared broiling the food product.

18. The process of claim 1, wherein thermally processing the food product includes heating the food product in an oven so the internal temperature of the food product is in a range from about 165°F to at least about 185°F.

19. The process of claim 1, wherein thermally processing the food product includes steaming the food product for approximately 60 to 90 seconds.

20. The process of claim 1, further comprising a step of freezing the food product for packaging in a freezing step following the cooking step.

21. The process of claim 20, further comprising a step of reheating the food product following the freezing step.

22. The process of claim 21, wherein the step of reheating the food product following the freezing step includes heating the food product in at least one of a convection oven, a deep fat fryer, a pan, a microwave oven, a convection oven, an infrared broiler, a wok, a flat grill, and an air fryer.

23. A process for preparing a battered food product, comprising: coating a food product with a first predust comprising cracker meal, and one or more natural coating ingredients in a first predust step; coating the food product from the first predust step with a first batter in a first coating step, the first batter comprising dry ingredients, water, and oil; coating the food product from the first coating step with a second predust comprising cracker meal, and one or more natural coating ingredients in a second predust step, wherein the cracker meal is sauteed with an oil; coating the food product from the second predust step with a second batter in a second coating step to form an edible coating on the food product, the second batter comprising dry ingredients, water, and oil; setting the edible coating on the food product in an oven in a setting step; thermally processing the food product from the setting step in a cooking step; misting the edible coating on the food product from the cooking step with water in a misting step; and freezing the food product from the misting step for packaging.

24. The process of claim 23, further comprising a step of coating the food product with a liquid marinade in an initial marinading step prior to the first predust step.

25. The process of claim 24, wherein the food product is coated with the liquid marinade in a vacuum tumbler.

26. The process of claim 24, wherein the liquid marinade includes one or more of a stock, an alkali metal phosphate, and salt.

27. The process of claim 26, wherein the stock is selected from a group consisting of chicken stock, beef stock, turkey stock, vegetable stock, fish and seafood stock, bone broth, water, and a combination thereof.

28. The process of claim 26, wherein the flavored stock is unsalted.

29. The process of claim 26, wherein the flavored stock is unsalted chicken stock.

30. The process of claim 26, wherein the alkali metal phosphate is selected from a group consisting of sodium tripolyphosphate, sodium hexametaphosphate, sodium pyrophosphate, dipotassium phosphate, and a combination thereof.

31. The process of claim 26, wherein the alkali metal phosphate is sodium tripolyphosphate.

32. The process of claim 26, wherein the weight ratio of the flavored stock, alkali metal phosphate, and salt is about 48:1:1.

33. The process of claim 23, wherein the food product is coated with the first predust in the vacuum tumbler.

34. The process of claim 23, wherein the second predust step further includes sauteing the cracker meal with an oil.

35. The process of claim 34, wherein the cracker meal is sauteed using a heated plate with a surface temperature of approximately 400°F.

36. The process of claim 23, wherein the first coating step is optional.

37. The process of claim 23, wherein the one or more natural coating ingredients are selected from a group consisting of natural starches, citrus fibers, wheat flour, tapioca flour, rice flour, yellow com flour, natural flavors and colors, spices, spray dried fats, flavored meat powders, oil, and a combination thereof.

38. The process of claim 23, wherein one or more of the first predust, the second predust, the first batter, and the second batter further comprise artificial flavors and colors.

39. The process of claim 23, wherein the first batter, the second batter, or both include 5% by weight v oil.

40. The process of claim 23, wherein thermally processing the food product includes at least one of baking, frying, microwaving, grilling, steaming, sous vide, or broiling the food product.

41. The process of claim 23, wherein thermally processing the food product includes frying the food product in a fryer such that the internal temperature of the food product is at least about 165°F.

42. The process of claim 23, further comprising a step of reheating the food product following the freezing step.

43. The process of claim 42, wherein the step of reheating the food product following the freezing step includes at least one of heating the food product in a convection oven, a deep fat fryer, a pan, a microwave, a convection oven, an infrared broiler, a work, a flat grill, or an air fryer.