U.S. patent application number 09/772422 was filed with the patent office on 2001-07-12 for method and apparatus for making an helical food product.
Invention is credited to Barker, John Harry, Joll, David John, Matthews, Bernard Trevor, Roberts, Peter Elwyn, Wilson, David Norman.
Application Number | 20010007691 09/772422 |
Document ID | / |
Family ID | 10812076 |
Filed Date | 2001-07-12 |
United States Patent
Application |
20010007691 |
Kind Code |
A1 |
Matthews, Bernard Trevor ;
et al. |
July 12, 2001 |
Method and apparatus for making an helical food product
Abstract
The present invention provides a food product comprising one or
more plastic food substrates formed into a helical configuration
and coated with a fluid barrier agent to prevent reannealing of
adjacent turns of the product. The fluid barrier agent may be an
edible vegetable oil such, for example, as hydrogenated vegetable
oil, Soya oil, rape oil, sunflower oil, safflower oil, peanut oil
or a mixture of such oils. The product may define a single helix or
a multiple helix, e.g. a double or triple helix. The invention also
provides a method and apparatus for making such a helical food
product.
Inventors: |
Matthews, Bernard Trevor;
(Norwich, GB) ; Joll, David John; (Corpusty,
GB) ; Roberts, Peter Elwyn; (Norwich, GB) ;
Wilson, David Norman; (Norwich, GB) ; Barker, John
Harry; (Sheringham, GB) |
Correspondence
Address: |
Ratner & Prestia
One Westlakes, Berwyn, Suite 301
P.O. Box 980
Valley Forge
PA
19482-0980
US
|
Family ID: |
10812076 |
Appl. No.: |
09/772422 |
Filed: |
January 30, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09772422 |
Jan 30, 2001 |
|
|
|
09075284 |
May 8, 1998 |
|
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Current U.S.
Class: |
426/516 ;
426/249 |
Current CPC
Class: |
A21C 11/163 20130101;
A21C 3/08 20130101 |
Class at
Publication: |
426/516 ;
426/249 |
International
Class: |
A23L 001/31 |
Foreign Application Data
Date |
Code |
Application Number |
May 9, 1997 |
GB |
9709460.1 |
Claims
What is claimed is:
1. A food product comprising one or more plastic food substrates
formed into an helical configuration and coated with a fluid
barrier agent to prevent reannealing of adjacent turns of the
product.
2. A food product as claimed in claim 1 wherein said product has
the form of a single helix or a multiple helix.
3. A food product as claimed in claim 1 wherein said fluid barrier
agent comprises an edible liquid vegetable oil.
4. A food product as claimed in claim 1 wherein the or each of the
plastic food substrate is selected from meat, cheese and pastry
based doughs.
5. A food product as claimed in claim 1 wherein at least one of the
substrates is a meat-based substrate.
6. A food product as claimed in claim 1 wherein the or each meat
based substrate further comprises a water retaining agent, which
serves to retain water within the product on cooking.
7. A food product as claimed in claim 6 wherein said meat substrate
comprises 5 to 20% weight of said water retaining agent.
8. A food product as claimed in claim 6 wherein said water
retaining agent comprises a hydratable, dried or partially dried
food stuff that hydrates under product cooking by absorbing water
released from the meat.
9. A food product as claimed in claim 6 wherein said water
retaining agent comprises one or more carbohydrates or
starches.
10. A food product as claimed in claim 6 wherein said water
retaining agent is rusk.
11. A food product as claimed in claim 6 wherein said water
retaining agent comprises a fat emulsion comprising protein as a
stabilizer.
12. A method for making a helical food product in accordance with
the present invention, which method comprises extruding one or more
plastic food substrates through a nozzle into a hollow shaping part
whilst causing or allowing relative rotation of the nozzle and
shaping part, thereby to form a product of helical configuration,
and applying a fluid barrier agent to the outer surface of the
product as it is dispensed from the nozzle into the shaping part,
which barrier agent is adapted to prevent reannealing of adjacent
turns of the helical product.
13. A method as claimed in claim 12 wherein two or more food
substrates are coextruded, said substrates being extruded through
juxtaposed dispensed passageways in said nozzle.
14. Apparatus for making a helical food product in accordance with
the present invention, which apparatus comprises a nozzle for
extruding one or more plastic food substrates; a hollow shaping
part that is arranged to receive the substrate(s) from the nozzle,
said shaping part having an open end downstream of the nozzle;
rotating means for causing or allowing relative rotation of the
nozzle and shaping part so as to form the substrate(s) into a
product of helical configuration; and dispensing means for
dispensing a fluid barrier agent onto the outer surface of the
helical product as it debouches the nozzle, which fluid barrier
agent is adapted to prevent reannealing of adjacent turns of the
helical product; the arrangement being such that in use said
helical product is formed within the shaping part, is coated with
said fluid barrier agent and is dispensed continuously from the
apparatus by the open end of the shaping part.
15. Apparatus as claimed in claim 14 wherein said nozzle is
journalled for rotation within the hollow shaping part.
16. Apparatus as claimed in claim 14 wherein the nozzle and shaping
part define an annular space therebetween, which annular space is
open at its downstream end, and said fluid dispensing means is
arranged to introduce the fluid barrier agent into said annular
space, such that in use the barrier agent is delivered from the
annular space via the open downstream end thereof onto the helical
product as the product debouches the nozzle.
17. Apparatus as claimed in claim 14 wherein the nozzle comprises a
single dispensing passageway for dispensing a plastic meat-based
substrate into the shaping part, said dispense passageway being
configured such that the substrate is directed outwardly at an
angle to the axis of rotation as it debouches into the shaping
part, so as to assist in forming the substrate into a helical
configuration.
18. Apparatus as claimed in claim 14 wherein said nozzle is
equipped with two or more dispense passageways that are arranged
juxtaposed one another, each dispensed passageway having an inlet
for connection to a respective pumped supply of the plastic food
substrate and an outlet for debauching the food substrate into the
shaping part.
19. Apparatus as claimed in claim 18 comprising a first base block
component, one or more second intermediate components, a third
outlet component and a plurality of nozzle components; wherein said
first and third components can be assembled, optionally with one or
more of the second components interposed therebetween, to define a
continuous, substantially cylindrical cavity, which cavity is
adapted to receive one of said nozzle components for rotation
therein; wherein each of said nozzle components has an upstream
end, a downstream end and a plurality of longitudinally extending
open bores, each of which bores has an outlet at the downstream end
of the nozzle component and an inlet, the respective inlets of the
bores being longitudinally spaced from one another; wherein each of
said second intermediate components and said nozzle components are
shaped to define an annular recess around a respective inlet on a
nozzle component when fitted, and each second component comprises a
supply means adapted to supply a respective food substrate to said
annular recess; wherein said third component and said nozzle
components are shaped to define an annular space therebetween when
a nozzle component is fitted, which space is open at its downstream
end, and means are provided for supplying a fluid barrier agent to
the space; wherein the third component extends downstream of a
nozzle component when fitted to form a shaping part; and wherein
the first base block component is adapted to receive an output of a
rotating means which can be coupled to the upstream end of a nozzle
component when fitted for causing rotation of the nozzle component
within the cavity; the arrangement being such that the first and
third components can be assembled with one or more the second
intermediate components, and a nozzle component with a
corresponding number of bores received within the cavity thus
formed, for extruding the corresponding number of plastic food
substrates to form a helical product having the corresponding
number of helices.
20. Apparatus as claimed in claim 19 wherein one or both of the
first or third components is also equipped with a supply means for
supplying a respective plastic food substrate to a respective one
of the bores within a nozzle component when fitted.
21. Apparatus as claimed in claim 19 wherein the nozzle components
have different numbers of bores.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an helical food product,
particularly an helical skinless sausage-like product. The present
invention also provides a method and apparatus for extruding
plastic food substrates, particularly meat substrates, to form food
products of helical configuration.
BACKGROUND TO THE INVENTION
[0002] GB-A-2156727 (Pemberton Sintermatic SA) discloses a method
for the production of helical protein products in which a
proteinaceous product, such as meat or a meat-like product is
injected into a cylindrical mould through a nozzle. As extrusion
proceeds, the nozzle is withdrawn from the mould to form said
helical product. Optionally the mould and nozzle may be rotated
relative to one another, but according to GB-A-2156727 this is not
necessary provided the rates of extrusion and nozzle withdrawal are
correctly adjusted. The wall of the mould is porous and as the
product is formed in the nozzle, an acid is applied through the
wall onto the outer surfaces of the product, which acid causes
coagulation of the proteinaceous product at the surface so as to
render the surface cohesive, by which is meant that the product
becomes self-supporting, so that thereafter it can retain its
shape.
[0003] A problem with the method of GB-A-2156727 is that by forming
in situ a cohesive skin on the surface of the product by the
application of acid or heat, the adjacent turns of the product tend
to stick together where they touch to form a generally cylindrical
product having a ribbed appearance. Areas of the surface that are
inadvertently missed with the acid or heat treatment during
manufacture tend to re-anneal during subsequent cooking of the
product.
[0004] Another disadvantage of the method of GB-A-2156727 is that
it does not permit the continuous manufacture of product. Each
helical unit has to be made individually within the mould, and
removed from the mould before the next unit can be formed.
Furthermore, it is difficult to adjust the extrusion and nozzle
withdrawal rates suitably to obtain an helical product.
OBJECTS OF THE INVENTION
[0005] Accordingly it is an object of the present invention to
provide a skinless, helical food product in which the adjacent
turns are substantially prevented from re-annealing during
manufacture or subsequent cooking.
[0006] Another object of the invention is to provide an improved
method of manufacturing an helical food product.
[0007] A particular, ancillary object of the present invention is
to provide a continuous process for manufacturing an helical food
product, which process should ideally be easy to set-up and operate
with minimum wastage.
[0008] Yet another object is to provide an improved apparatus for
implementing the method of the invention.
SUMMARY OF THE INVENTION
[0009] According one aspect of the present invention therefore
there is provided a food product comprising one or more plastic
food substrates formed into an helical configuration and coated
with a fluid barrier agent to prevent re-annealing of adjacent
turns of the product.
[0010] By `helical` is meant a single helix or a multiple helix,
e.g. a double or triple helix. Said food product may be formed from
a single plastic food substrate as a single or multiple helix.
Alternatively a multiple helix food product may be made from a
plurality of different food substrates, typically two, three or
four such substrates.
[0011] The fluid barrier agent acts to prevent bonding of the food
substrate(s) in adjacent turns of the helical product during
subsequent processing steps, including cooking. Said fluid barrier
agent may be a liquid vegetable oil such, for example, as
hydrogenated vegetable oil, Soya oil, rape oil, sunflower oil,
safflower oil, peanut oil or a mixture of such oils. Alternatively,
said fluid barrier agent may comprise an oil and water emulsion.
Such an emulsion may comprise approximately equal amounts of oil
and water, together with a suitable emulsifying and/or stabilising
agent. Said emulsion may be formed by ambient or chilled
temperature high shear mixing using Soya protein isolate; milk
protein (caesinates) lactose/milk minerals; milk protein with
stabilizers, Xanthan gum, Guar gum and/or deheated mustard power;
or blood plasma. At higher energies and temperatures, sodium
stearoyl lactoylate can be used. Alternatively the emulsion could
be prepared using polyglycol alginates. Higher energy systems of
emulsification, by application involve the dispersion of an
emulsifying agent into a fraction of the liquid oil phase heated
above the melting point of the emulsifying agent. The dispersed
emulsifier, in oil, is then introduced into the bulk oil and mixed,
and finally introduced by high shear into the water phase, neat or
with the water optionally pre-stabilised with gums such as Xanthan,
Guar or other hydrocolloids such as hydroxypropylmethyl cellulose
or modified celluloses, carrageenans, starches, alginates or
gelatin.
[0012] Said emulsifying agent may be selected from lipophilic mono
and di glycerides of fatty acid, or acetic acid, lactic acid,
citric acid, tartaric acid esters of glyceride or a blend thereof,
e.g. E471, E472 (a), (b), (c), (d), (e), (f). Alternatives include
the lecithins.
[0013] Said fluid barrier agent may optionally carry one or more
additives selected from water or oil soluble seasonings and
flavouring components.
[0014] The or each plastic food substrate may, for example, be
selected from meat, cheese and pastry based doughs. Preferably at
least one of the substrates will be meat based. Said meat may be
fresh or frozen, finely comminuted or mechanically separated
(recovered) meat. Said meat may be animal or poultry meat, and may
be lean meat or, preferably, a mixture of lean meat and fat. Such
meat-based substrates may comprise 25-100 wt % meat, preferably
50-75 wt %, including fat. For example a meat-based substrate may
typically comprise about 70% meat. The meat component itself may
comprise 60-80 wt % mechanically separated meat, typically about 70
wt %. Said meat based substrate may further comprise 5-15 wt % ice,
typically about 12 wt %, and optionally one or more seasonings and
flavourings. By "meat" here is meant physical meat. Said physical
meat may have an analytic meat content of 60-80 %, typically about
70 % wt, with the remainder usually being largely water.
[0015] In especially preferred embodiments of the present
invention, the or each meat-based substrate further comprises one
or more water-retaining agents, which serve to retain water within
the product on cooking. It will be appreciated by those skilled in
the art that, on cooking, meat loses water, which gives rise to
shrinkage and weight loss of the product. By including a
water-retaining agent within the meat substrate(s), such water loss
is reduced. Moreover, those skilled in the art will further
recognise that a helix represents a fairly `high energy`
configuration, and on cooking the product will tend to unwind. Such
partial unwinding will result in elongation of the product along
the longitudinal axis of the helix. Of course, the extent of such
elongation would be offset by shrinkage of the product overall as a
result of water loss. However, by controlling water loss in
accordance with the present invention, an helical product in
accordance with the present invention can be produced which, on
cooking, exhibits a net expansion. This is a particularly
interesting effect, which appeals especially to children.
[0016] In some embodiments, said meat substrate may comprise 5-20
wt % of such a water-retaining agent, preferably 8-15 wt %. Said
water-retaining agent may comprise a hydratable, dried or partially
dried foodstuff that hydrates under product cooking by absorbing
water released from the meat. Especially preferred are granular
water-swellable agents, which expand on cooking to assist in
overall expansion of the helical product.
[0017] Said water-retaining agent will preferably comprise one or
more carbohydrates. Carbohydrates are preferred as they may also
assist in disrupting the meat protein matrix during cooking.
Suitable carbohydrates are rusk and starches, e.g. native starch
(tapioca). About 13-14 wt % rusk is especially preferred, although
the rusk content can be reduced to around 7-8 wt % provided another
water-retaining or swelling agent is employed in addition. As
water-retaining agents may also be employed fat emulsions
stabilized by protein. Said protein may comprise any globular or
linear proteins that are known in the art for stabilizing a fat
emulsion, such for example as Soya or milk proteins, e.g. Soya
protein isolate or caesinates. The meat substrate may comprise up
to one part fat emulsion to four parts meat, typically one to six
parts. Said fat emulsion will also provide an alternative fat
source to the meat itself.
[0018] In some embodiments, said meat substrate may comprise
collagen fibre; typically 1-3 % wt, e.g. 2 % wt. It has been found
that at ambient temperature up to about 58.degree. C. collagen
fibre holds water and thus may act as a water retaining agent. On
cooking, collagen fibre forms a weak gel or liquid form of gelatin.
This relaxing of the structure of the collagen fibre has been found
to promote extension of the product as described above. Collagen
fibre also assists in preparing a meat substrate that is suitable
for extrusion. In some embodiments of the invention collagen fibre
may be used in conjunction with carbohydrate (e.g. rusk) as a
water-retaining agent.
[0019] According to another aspect of the present invention, there
is provided a method for making an helical food product in
accordance with the present invention, which method comprises
extruding one or more plastic food substrates through a nozzle into
a hollow shaping part whilst causing or allowing relative rotation
of the nozzle and shaping part, thereby to form a product of
helical configuration, and applying a fluid barrier agent to the
outer surface of the product as it is dispensed from the nozzle
into the shaping part, which barrier agent is adapted to prevent
re-annealing of adjacent turns of the helical product.
[0020] Where two or more food substrates are co-extruded, such
substrates may be extruded through juxtaposed dispense passageways
in said nozzle.
[0021] According to the method of the present invention, the
helical product may be collected from the shaping part, treated to
make the surface of the product sufficiently rigid for cutting, and
then cut to convenient lengths. The crust hardening may be achieved
by heat-setting, e.g. by flash-frying, or crust freezing.
Conveniently, crust freezing may be effected by passing the product
through a cryogenic tunnel to achieve an internal product
temperature in the range -3 to -5.degree. C., typically about
-4.degree. C. The product may be dusted with seasoning and/or
seasoning elements and frozen. The product will usually be sold and
cooked by the consumer from frozen.
[0022] According to another aspect of the present invention there
is provided an apparatus for making an helical food product in
accordance with the present invention, which apparatus comprises a
nozzle for extruding one or more plastic food substrates; a hollow
shaping part that is arranged to receive the substrate(s) from the
nozzle, said shaping part having an open end downstream of the
nozzle; rotating means for causing or allowing relative rotation of
the nozzle and shaping part so as to form the substrate(s) into a
product of helical configuration; and dispensing means for
dispensing a fluid barrier agent onto the outer surface of the
helical product as it debouches the nozzle, which fluid barrier
agent is adapted to prevent re-annealing of adjacent turns of the
helical product; the arrangement being such that in use said
helical product is formed within the shaping part, is coated with
said fluid barrier agent and is dispensed continuously from the
apparatus via the open end of the shaping part.
[0023] Conveniently, said nozzle may be journalled for rotation
within the hollow shaping part. Said shaping part may define a
generally cylindrical conduit that accommodates the outlet end of
the nozzle, which conduit extends downstream of the nozzle. Said
shaping part may comprise a ring that encircles the outlet end of
the rotary nozzle.
[0024] Preferably, the nozzle and shaping part define an annular
space therebetween, which annular space is open at its downstream
end, and said fluid dispensing means is arranged to introduce the
fluid barrier agent into said annular space, such that in use the
barrier agent is delivered from the annular space via the open
downstream end thereof onto the helical product as the product
debouches the nozzle. Said fluid dispensing means may comprise a
port formed in the shaping part, which port is adapted for
connection to a pumped supply of said fluid agent.
[0025] Typically said nozzle may comprise an elongate, generally
cylindrical component that is adapted for rotation about its
longitudinal axis, having a chuck at one end for connection to a
rotating means such, for example, as the output of a motor.
[0026] In some embodiments, the nozzle may comprise a single
dispensing passageway for dispensing a plastic meat-based substrate
into the shaping part. Said dispense passageway may be configured
such that the substrate is directed outwardly at an angle to the
axis of rotation as it debouches into the shaping part, so as to
assist in forming the substrate into an helical configuration. The
cylindrical component may thus be provided with a longitudinal
axial bore, which bore has an inlet at one end for connection to a
pumped supply of said food substrate, and an outlet at the other
for debouching the substrate interiorly of the shaping part. The
axial bore may be deflected away from the longitudinal axis towards
the outlet end, so as to direct the debouching meat substrate
towards the inner surface of the shaping part. The end face of the
component, in which end face the outlet is formed, may be skewed
with respect to said longitudinal axis. Said end face may subtend
an angle of 15 to 75.degree., preferably 30 to 60.degree., with the
plane of an orthogonal section through said axis. Said end face may
be substantially planar, so as to assist in propelling the
dispensed meat-based substrate downstream within the shaping
part.
[0027] Alternatively, in some embodiments, said nozzle may be
equipped with two or more dispense passageways that are arranged
juxtaposed one another. Each dispense passageway may have an inlet
for connection to a respective pumped supply of a plastic food
substrate and an outlet for debauching the food substrate into the
shaping part. Each of said outlets may be offset from the axis of
rotation of the nozzle to assist in forming the substrates into a
multiple helix. Said outlets may be of the same diameter as each
other or they may have different diameters depending on the desired
characteristics of the product. The cylindrical component may thus
be provided with a plurality of substantially parallel,
longitudinal, non-axial bores to provide the dispense passageways,
which bores are open at each end to provide the respective inlets
and outlets.
[0028] In a particularly preferred aspect of the present invention,
the apparatus in accordance with the invention may have a modular
construction comprising a plurality of components which can be
assembled in different ways to allow co-extrusion of different
numbers of plastic food substrates as required. Said apparatus may
thus comprise a first base-block component, one or more second
intermediate components, a third outlet component and a plurality
of nozzle components; wherein said first and third components can
be assembled, optionally with one or more of the second components
interposed therebetween, to define a continuous, substantially
cylindrical cavity, which cavity is adapted to receive one of said
nozzle components for rotation therein; wherein each of said nozzle
components has an upstream end, a downstream end and a plurality of
longitudinally extending open bores, each of which bores has an
outlet at the downstream end of the nozzle component and an inlet,
the inlets of the bores being longitudinally spaced from one
another; wherein each of said second intermediate components and
said nozzle component are shaped to define an annular recess around
a respective inlet on the nozzle component when fitted, and each
second component comprises a supply means adapted to supply a
respective food substrate to said annular recess; wherein said
third component and said nozzle component are shaped to define an
annular space therebetween, which space is open at its downstream
end, and means are provided for supplying a fluid barrier agent to
the space; wherein the third component extends downstream of the
nozzle component when fitted to form a shaping part; and wherein
the first base-block component is adapted to receive an output of a
rotating means which can be coupled to the upstream end of a nozzle
component when fitted for causing rotation of the nozzle component
within the cavity; the arrangement being such that the first and
third components can be assembled with one or more of the second
intermediate components, and a nozzle component with a
corresponding number of bores received within the cavity thus
formed, for extruding the corresponding number of plastic food
substrates to form an helical product having the corresponding
number of helices.
[0029] In some embodiments one or both of the first and third
components may also be equipped with a supply means for supplying a
respective plastic food substrate to a respective one of the bores
within the nozzle component.
[0030] The nozzle components will normally have different numbers
of bores, typically two, three, four, five, etc, When it is desired
to extrude a product having a given number of helices within a
multiple helix, e.g. a double or triple helix, then the apparatus
is assembled using the appropriate number of second intermediate
components and a nozzle component having said given number of bores
is used.
[0031] The present invention thus provides a novel helical meat
product that substantially retains its helical configuration
through manufacture, sale and cooking, by the application of a
fluid barrier agent to the outer surface of the product during its
manufacture. Said fluid is usually an oil or an oil/water emulsion
and may act by weakening protein bonds formed during solubilisation
or mixing of the meat comminutes, thus avoiding weak bonding during
subsequent cooking or protein denaturation steps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] In the drawings:
[0033] FIG. 1 is a side view of an helical food product in
accordance with the present invention.
[0034] FIG. 2 is a side view of another helical food product in
accordance with the present invention.
[0035] FIG. 3 is a side elevation of an apparatus in accordance
with the present invention for making an helical food product.
[0036] FIG. 4 is a plan view of the apparatus of FIG. 3, partly in
cross-section on the line IV-IV as shown in FIG. 3.
[0037] FIG. 5 is a side view, partly in cross-section, of another
apparatus in accordance with the present invention.
[0038] FIG. 5A is an end view of the nozzle component of the
apparatus of FIG. 5.
[0039] FIG. 6 is a cross-sectional view of various components of
the apparatus of FIG. 5, shown disassembled.
[0040] FIGS. 7A-7E show the configurations of various different
nozzle components for use in the apparatus of FIGS. 5 and 6.
DETAILED DESCRIPTION OF THE INVENTION
Examples 1 to 4
[0041] Four product mixes were prepared to the following
recipes:
1 Example 1 Example 2 Example 3 Example 4 Recipe % % % % 25.75
Frozen Fresh MST.sup.1 51.5 -- 51.5 Fresh 25.75 Port Fat 16.5 --
16.5 10.00 Rusk 13.5 -- 8.0 8.00 Ice 12.5 9.24 16.0 12.70 Pork
Belly 3.5 -- 3.5 3.50 Seasoning 2.5 -- 2.5 2.50 Collagen Fibre --
-- 2.0 -- Whey Protein -- -- -- 1.00 Concentrate Soya Protein -- --
-- 0.80 Isolate Water -- -- -- 4.00 Palm Oil -- 5.80 -- 4.00
Calcium Carbonate -- -- -- 2.00 Rehydrated TVP.sup.2 -- 19.81 -- --
2:1 dry Tapioca Starch -- 4.00 -- -- Chicken Flavouring -- 0.96 --
-- Salt -- 0.97 -- -- Herb Extract -- 0.02 -- -- GW Pepper -- 0.05
-- -- Sodium Caseinate -- 1.63 -- -- Skimmed Milk -- 2.00 -- --
Powder Skin -- 10.00 -- -- Red Trims -- 10.00 -- -- Oyster Meat --
20.52 -- -- Baardered White -- 15.00 -- -- Trims 100.00% 100.00%
100.00% 100.00% Post Mix Temperature +4.degree. +4.degree.
+7.degree. C. +5.6.degree. C. .sup.1MST = Mechanically separated
turkey .sup.2TVP = Textured vegetable protein
[0042] Each of the above product mixes was formed into skinless,
helical products as shown in FIG. 1 having an extruded diameter of
about 10 mm and an outer coil diameter of about 25 mm and coated
with a fluid barrier agent using apparatus of the kind that is
described below. As fluid barrier agents were used liquid vegetable
oil, water and a 50/50 oil/water (Soya) emulsion. By way of
comparison, a helical food product was made from the Example 1
product mix which was coated with a 5% lactic acid solution. The
helical products were crust frozen, dusted with a standard barbecue
glaze and cut into approximately 50 g sections having a target
length of 11.1 cm. The products were then cooked by grilling,
baking or shallow frying. The length of each product was measured
before and after cooking. The results were as set out in following
Table 1.
2TABLE 1 on g length Final length % Increase Addn Cook Method cm cm
Cook loss in length Product Wt(g) Final Wt(g) Recipe Example 1
Lubricant: Oil (n = 3) Grill 11.3 .+-. 0.6 14.8 .+-. 0.3 23.6 .+-.
8.6 30.9 29.7 .+-. 2.7 22.6 .+-. 2.3 Oven 11.7 .+-. 0.3 13.5 .+-. 0
22.5 .+-. 2.0 15.4 29.9 .+-. 2.2 23.4 .+-. 2.2 Stir fry 11.5 .+-.
0.6 15.5 .+-. 0.6 18.6 .+-. 3.3 34.5 29.8 .+-. 1.7 24.2 .+-. 2 Ave
26.7% Lubricant: Water (n = 5) Grill 11.5 .+-. 0.3 13.1 .+-. 0.2
16.5 .+-. 2 13.4 46.8 .+-. 2.3 39.1 .+-. 2 Oven 11.2 .+-. 0.3 12.2
.+-. 0.3 15.6 .+-. 2.0 8.9 47.7 .+-. 5.2 40.2 .+-. 4.5 Stir fry
11.3 .+-. 0.5 13.02 .+-. 0.4 15.5 .+-. 1.0 15.0 50.66 .+-. 3.5 43.4
Ave 12.7% Lubricant: Oil - Tight Coil Grill (n = 4) 11.5 .+-. 0.4
14.25 .+-. 0.3 18.6 .+-. 2.0 23.9 52.0 .+-. 2.6 42.2 .+-. 1.6 Oven
(n = 3) 12.1 .+-. 0.3 13.5 .+-. 0.5 16.6 .+-. 1.8 11.6 54.2 .+-.
2.3 45.1 .+-. 1.0 Stir fry (n = 3) 11.5 .+-. 0 14.2 .+-. 1.2 25.2
.+-. 8.4 23.5 51.4 .+-. 2.3 43.1 .+-. 3.3 Ave 19.5% Lubricant: Oil
(n.sup.1 = 5) Grill 11.6 .+-. 0.45 15.1 .+-. 0.7 22.7 .+-. 0.8 30.2
47.0 .+-. 1 36.4 .+-. 1 Oven 11.3 .+-. 0.6 13.3 .+-. 0.6 21.3 .+-.
2.5 17.7 46.5 .+-. 1.5 36.6 .+-. 1.4 Stir fry 11.4 .+-. 0.2 14.8
.+-. 0.9 21.5 .+-. 2.2 29.8 47.0 .+-. 1.5 36.9 .+-. 1 Ave 25.9
Lubricant: 1% Soya 50:50 Oil/Water (n = 5) Grill 11.8 .+-. 0.6 14.3
.+-. 0.9 20.2 .+-. 2.5 21.2 43.6 .+-. 3 34.7 .+-. 1.4 Oven 11.5
.+-. 0.9 13.8 .+-. 1.1 14.7 .+-. 3.0 20.0 45.3 .+-. 7 38.5 .+-. 5.8
Stir fry 11.3 .+-. 0.3 15.3 .+-. 1.2 19.3 .+-. 1.3 35.6 44.9 .+-.
7.5 36.1 .+-. 5.5 Ave 25.4% Comparative Example Lubricant: 5%
Lactic Acid Solution (n = 5) Grill 11.6 .+-. 0.22 12.4 .+-. 0.65
14.6 .+-. 1.3 6.9 45.1 .+-. 1.1 38.5 .+-. 1.4 Oven 11.3 .+-. 0.5
12.4 .+-. 0.6 12.8 .+-. 2.8 9.7 44 .+-. 3.0 38.7 .+-. 3 Stir fry
11.4 .+-. 0.2 13.4 .+-. 0.9 17.3 .+-. 1.3 17.54 46.6 .+-. 1.1 38.4
.+-. 1.0 Ave 11.4% Recipe Example 2 Lubricant: Oil (n = 5) Grill
11.6 .+-. 0.5 12.8 .+-. 1 17.5 .+-. 5.3 10.3% 48.9 .+-. 3 40.0 .+-.
3.7 g Oven 12.0 .+-. 0.3 12.9 .+-. 0.7 13.0 .+-. 3.0 7.5% 46.6 .+-.
3 41.8 .+-. 2.5 g Stir fry 21.4 .+-. 3.6 Ave 8.8% Lubricant: Water
(n = 5) Grill 10.9 .+-. 0.6 12.0 .+-. 0.3 11.64 .+-. 2.7 10.1% 49.2
.+-. 1.7 43.5 .+-. 2.2 Oven 11.3 .+-. 0.4 11.7 .+-. 0.4 16.7 .+-.
2.1 3.5% 50.4 .+-. 1.3 42 .+-. 1.7 Stir fry 15.9 .+-. 5.3 Ave 6.8%
Recipe Example 3 - Reduced Rusk Collagen Sausage Lubricant: Oil (n
= 5) Grill 11.10 .+-. 0.5 13 .+-. 0.8 14.7 .+-. 0.9 17.1 49.8 .+-.
2.3 42.4 .+-. 2.1 Oven 11.4 .+-. 0.5 13.4 .+-. 0.7 14.8 .+-. 1.1
17.5 49.9 .+-. 1.0 42.5 .+-. 0.6 Stir fry 11.0 .+-. 0 14.0 .+-. 0.8
14.0 .+-. 1.8 27.5 48.7 .+-. 0.8 45.7 .+-. 3.6 Ave 20.6% Recipe
Example 4 - Reduced Rusk/Starch/Palmoil Soya Emulsion/Carbonate
Lubricant: Oil (n = 5) Grill 11.1 .+-. 0.5 13.6 .+-. 0.6 20.1 .+-.
1.6 22.25 42.1 .+-. 3.2 33.6 Oven 11.1 .+-. 0.5 13.5 .+-. 0.8 16.4
.+-. 1.9 21.6 41.0 .+-. 3.9 34.5 .+-. 4.0 Stir fry 10.9 .+-. 0.2
13.9 .+-. 0.8 19.3 .+-. 1.8 27.5 38.7 .+-. 2.2 31.2 .+-. 2.3
[0043] As can be seen from the foregoing results, the product mixes
of Examples 1 and 4 gave the best results, with average percent
increases in product length cooking of 25.9% and 23.8% respectively
using vegetable oil as the lubricant. With a loose coil, the
average expansion of the mix of Example 1 increased to 26%, whilst
with a tight coil, the average expansion of the Example 1 mix
decreased to 19.5%. The mix of Example 2 performed the worst, and
it is thought that the highly "functional" protein ingredients of
that mix tended to result in cohesion of adjacent turns of the
helical coil. In Example 3, the rusk component was reduced to 8%
(as compared with 13.5% in Example 1), and this reduction in
carbohydrate content was compensated by including an additional
2.0% collagen fibre. As can be seen, the average expansion of the
product of Example 3 on cooking was 20.6%, although the reduction
in rusk impaired the organoleptic quality of the product in that
texturally it was too soft.
[0044] In Example 4, the rusk content was also reduced to 8%, and
this reduction in water binding material was compensated for by
incorporating a stable vegetable fat emulsion having a total
content in the mix of 11.8%. The results for Example 4 illustrate
that a protein-stabilized fat emulsion can be used to retain water
within the product on cooking by encapsulating the water in the
product matrix.
[0045] The best results were obtained by using the product mix of
Example 1 with a loose coil and vegetable oil as the fluid barrier
agent.
[0046] The helical products were made from the product mixes of
Examples 1 to 4 using apparatus illustrated in FIGS. 3 and 4. Of
course, the apparatus of the present invention is not limited to
the use of the particular product mixes of Examples 1 to 4, and the
apparatus may be used with any suitable extrudable food substrate
known to those skilled in the art.
[0047] The extrusion apparatus shown in accompanying FIGS. 3 and 4
comprises a first, fixed shaping tube (10) that defines a
substantially cylindrical bore (12) having an upstream end (14) and
a downstream end (16). Said bore has an internal diameter of about
25 mm. Towards the upstream end (14), said first tube (10)
comprises an exterior, ring-like flange portion (18) and an
externally threaded portion (20) that mates with an internal thread
in a bore of a fixing bracket (22). Said fixing bracket (22) is
mounted securely on a base plate (24), and the upstream end (14) of
the fixed shaping tube is screwed into the bore of the fixing
bracket, until the flange portion (18) of the fixed tube abuts on
the bracket at (26) to provide a firm attachment.
[0048] Said fixing bracket (22) further accommodates a first rotary
bearing (28) that carries a rotary inner tube (30).
[0049] Said inner tube (30) comprises a substantially cylindrical
portion (32) that is accommodated within the bore of the fixed tube
(10). At its upstream end (34), said inner tube (30) comprises an
integral disc portion (36) that is rebated, and accommodates a
second rotary bearing (38). Said second bearing (38) carries a
downstream end of a short connecting tube (40), the upstream end of
which can be connected to a pumped supply of a plastic food
substrate, such, for example, as one of the product mixes of
Examples 1 to 4 above.
[0050] The outer surface of the disc portion (36) is coupled to a
motor (42) via a suitable transmission mechanism (44) such, for
example, as a gear wheel or chain/sprocket.
[0051] Food substrate entering the connecting tube (40), thus
enters the upstream of the inner tube (30), and an annular seal
(46) is provided between the inner tube (30) and the connecting
tube, for preventing any leakage of food substrate from the
upstream end of the inner tube. Said plastic food substrate then
flows downstream interiorly of the inner tube (30), which
terminates in a planar end face (31) intermediate the downstream
end (16) of the outer tube (10) (see FIG. 4). The wall of the inner
tube (30) is shaped towards its downstream end so as to form an
outlet portion (48) of the bore of the inner tube (30), which
outlet portion has an internal diameter of about 10 mm and is
deflected radially outwardly of the central, longitudinal axis of
the cylindrical portion (32), so that as the food substrate
debouches the inner tube (30), it is directed by the outlet portion
(48) towards the inner surface of the outer tube (10). Said
planar-end face (31) is skewed with respect to the longitudinal
axis of the inner tube, such that the face subtends an angle of
about 45.degree. to an orthogonal section through the bore.
[0052] In operation, said motor (42) is operated to cause rotation
of the inner tube (30) about its central, longitudinal axis within
the outer tube (10), and it will be seen therefore that the food
substrate is dispensed from the inner tube (30) on a circular
locus, and the inner surface of the outer tube (10) forms the
substrate into an helical configuration. Said skewed end face (31)
assists in pitching the extrusion along the wall of the outer tube
(10).
[0053] Said helical extrudate is assisted in retaining its shape by
means of a fluid barrier agent that is introduced between the inner
and outer tubes (10, 30) through a port (50) formed radially in the
flange portion (18) of the outer tube. Labyrinthine seals (52) are
provided to prevent leakage of the fluid from the upstream end (14)
of the outer tube, and a small clearance is allowed between the
inner and outer tubes, so that the fluid flows downstream to
contact the product as it debouches the inner tube. The fluid used
will vary from application to application, but it may also act as a
lubricant between the rotary inner tube (30), and the outer
tube.
[0054] In some embodiments, the fluid may be selected from potable
water, a water-in-oil or oil-in-water emulsion or liquid vegetable
oil. Any edible vegetable that is known by those skilled in the art
to be suitable for use in cooking may be use. As examples may be
cited hydrogenated vegetable oils, Soya oil, rape oil, sunflower
oil, safflower oil, peanut oil or a mixture of such oils. Where an
oil/water emulsion is employed, said emulsion may comprise
approximately equal parts of vegetable oil and potable water,
together with a suitable emulsifier and/or stabilizing agent. Said
fluid may further comprise liquid or solid additives such, for
example, as water or oil-soluble seasonings and flavourings.
[0055] Some of the fluid will adhere to and form a coating on the
external surface of the helical product (54) as discussed above,
but a substantial quantity of the fluid will drip from the product
as it exits the downstream end (16) of the outer tube (10) (see
FIG. 3). Means may be provided for catching the excess fluid and,
optionally, for recycling and re-using it.
[0056] Downstream of the outer tube (10), the helical product is
removed by conventional conveying means for cutting into saleable
lengths. Before cutting, the product is cryogenically cooled to the
point of stiffness or heat-set (e.g. by flash frying). The product
may be dusted before or after cutting with an optional powdered or
ground seasoning or flavouring agent and re-frozen. The product is
intended to be sold frozen and also cooked from frozen. The best
modes of cooking are shallow frying and grilling, but the product
may also be oven baked satisfactory. On cooking, the helical
products in accordance with the present invention are seen to
expand and unwind.
[0057] As mentioned above, it is also possible in accordance with
the present invention to form extrudable plastic food substrates
into multiple helices such, for example, as the double helix
illustrated in FIG. 2. This double helix product is formed from two
different food substrates, indicated as A and B. For the purposes
of clarity, the food substrates A and B are shown respectively as
shaded and unshaded. In practice, it will be appreciated that the
different food substrates forming the multiple helixes may have the
same or different appearances. In some embodiments, a helical food
product in accordance with the present invention comprising a
multiple helix may be made from two or more strands of the same
product mix, in which case the two helices forming the double helix
will naturally have substantially the same colour and texture.
Where different product mixes are used for the component helices of
the multiple helix product however, the different strands may have
different colours and/or textures, particularly where different
kinds of meat are used in the different mixes. Whilst it is
preferred that at least one of the food substrates used in the
multiple helix products is a meat based product, the other strands
of the multiple helix may be formed from non-meat based substrates
such, for example, as cheese or pastry dough substrates. For
instance, it is envisaged that a double helical product in
accordance with the present invention may comprise one strand of a
meat based substrate, and the other strand of a pastry substrate,
so as to form a novel kind of sausage roll product. The visual
appearance of a helical product comprising a multiple helix in
accordance with the present invention may be enhanced by including
food colourings in one or more of the mixes forming the individual
strands.
[0058] A helical product having a multiple helix configuration can
be made using apparatus of the kind shown in FIGS. 5 and 6 in
accordance with the present invention. Said apparatus has a modular
construction, comprising a plurality of components which can be
assembled in different ways to make apparatus suitable for making
multiple helices having different numbers of constituent helices.
With reference firstly to FIG. 6, the assembly comprises a base
block component (110) of generally cylindrical configuration,
having an axial bore (112). Said base block component (110) is
rebated at an upstream end (114) to accommodate an output shaft
(144) of an electric motor (142), such that the output shaft (144)
is disposed coaxially of the bore (112). Conveniently, the base
block (110) is provided with an upstream, integral flange (116) for
fixing the base block component (110) to the motor housing.
[0059] Said base block component (110) is machined at its
downstream end (118) to provide an axially protruding neck portion
(120). The base block component is also equipped with a radially
protruding side arm (122) which is drilled through to provide a
conduit (124) that communicates with the bore (112) within the base
block component (110). Where the conduit (124) is let through the
wall of the base block component (110), said wall is provided with
an annular groove (126) circumferentially around the bore
(112).
[0060] The assembly of FIG. 6 further comprises a plurality of
intermediate components (150). Only one such intermediate component
(150) is shown in FIG. 6. Each intermediate component (150) is
generally cylindrical in configuration and is drilled to provide an
axial bore (152). Said bore is rebated at an upstream end of (154)
of the intermediate component (150), and said intermediate
component (150) is machined at a downstream end (156) to provide a
protruding, axial neck portion (158) having the same dimensions as
the neck portion (120) of the base block component (110). The
rebated part of the bore (152) of the intermediate component (150)
is dimensioned to accommodate snugly the neck portion (120) of the
base block component (110) or the neck portion (158) of another
intermediate component (150).
[0061] Adjacent the rebated part of the bore (152), the
intermediate component (150) is equipped with a hollow side arm
(160) that is similar to the side arm (122) on the base block
component (110) and communicates with the bore (152). It will be
seen from FIG. 6 that the length of the rebated part of the bore
(152) in the axial direction is slightly longer than the length of
the neck portion (120) on the base block component (110) or the
neck portion (158) on the intermediate component (158), so that
when assembled, the neck portion (120,158) defines with the
intermediate component (150) an internal annular groove (162) which
communicates with the conduit within the side arm (160).
[0062] Said assembly further comprises an outlet component (170)
again of generally cylindrical configuration. Said outlet component
(170) is provided with an axially extending bore (172) which is
rebated at an upstream end (174) to accommodate snugly the neck
portion (120) of the base block component (110) or the neck portion
(158) of an intermediate component (150). Adjacent the rebated part
of the bore (172), the outlet component (170) is fitted with a
radially extending side arm (176) of the same kind as provided on
the intermediate and base block components (110,150). As with the
intermediate component (150), it will be seen that the length of
the rebated part of the bore (170) within the outlet component
(170) is longer than the length of the neck portions (120,158) on
the base block and intermediate components (110,150), so that when
assembled, the neck portion (120,158) defines a circumferential
annular groove within the rebated part of the bore (172) which
communicates with the conduit within the side arm (176).
[0063] At an upstream end (178), opposing the downstream end (174),
the outlet component (170) is provided with a longitudinally
extending cylindrical tube portion (180).
[0064] The base block component (110) can be assembled with the
outlet component (170), optionally with one or more of the
intermediate components (150) as shown in FIG. 6 to provide a
continuous, linear bore within the assembly which is defined by the
bores (112,152,172) within the components. The continuous bore is
adapted to receive a nozzle component (180) as shown in FIG. 5.
Said nozzle component (180) is substantially cylindrical, such that
it can rotate within the continuous bore defined by the assembled
components. At an upstream end (182), the nozzle component (180) is
provided with a chuck (184), enabling the nozzle component (180) to
be connected to the output shaft (144) of the motor (142). The
inner surfaces of the base block, intermediate and outlet
components (110,150,170) are provided with suitable fluid-type
rotary bearings (186) for journalling the nozzle component (180)
within the assembly.
[0065] As can be seen from FIG. 5, the assembly of FIG. 5 comprises
only the outlet component (170) and the base block component (110).
The nozzle component (180) is provided with two substantially
parallel, longitudinally extending bores (188). Each of said bores
(188) is open at a downstream end (190) of the nozzle component
(180) to provide an outlet. The other end of each bore (188) is
also open to provide an inlet in the side of the nozzle component
(180). The inlets (192) of the bores (188) are longitudinally
spaced from one another along the axis of the nozzle component
(180) and, in the fitted position, each of the inlets (192) is
disposed within one of the circumferential grooves (126,173)
adjacent a side arm (122,176). Each of the side arms (122,176) can
be connected to a respective pumped supply of a plastics food
substrate and, in use, the food substrates will thus be supplied to
the annular grooves (126,173) around the continuous bore through
the assembly and from there into the inlets of the bores (188)
through the nozzle component (180).
[0066] Typically, the assembly of the invention will comprise a
plurality of different nozzle components, each comprising a
different number of internal bores (188). The end views of a
representative number of different such nozzle components (180) are
shown in FIGS. 7A to 7E. It will be seen that the nozzle (180) of
FIG. 7A comprises three internal bores (188), the axes of which
bores (188) are arranged, in end view, at the apices of an
isosceles triangle. FIGS. 7B and 7C show two different ways of
arranging four parallel bores (188) for extruding a quadruple
helix. FIG. 7D shows another arrangement of a triple extrusion
nozzle (180). In this case, a double helix will be coextruded
around the central, substantially linear core. FIG. 7E shows a
nozzle suitable for extruding a double helix.
[0067] The food substrates are delivered from the bores (188) at
the downstream end (190) of the nozzle component (180) into the
cylindrical tube portion (180) of the outlet component (170). The
tube portion (180) helps the multiple helix to retain its shape
before it is dispensed through the downstream end (178) of the
outlet component (170).
[0068] The outlet component (170) and nozzle component (180) define
an annular recess (192) therebetween juxtaposed the downstream end
(190) of the nozzle component (180). Said annular recess (192)
communicates with an annular groove (194) formed in the inner wall
of the bore (172) extending through the outlet component (170),
which annular groove (194) communicates with an inlet port (196)
which extends through the wall of the outlet component (170). Said
port (196) can be connected to a pumped supply of a fluid barrier
agent of the kind mentioned above such, for example, as vegetable
oil. In use, said fluid barrier agent will be dispensed from the
annular recess (192) onto the product as it is coextruded through
the outlets of the bores (188) within the nozzle, to provide a
coating of fluid around the adjacent turns of the multiple helix.
As mentioned above, this coating will help to prevent reannealing
of the substrates forming the helices.
[0069] In contradistinction to the apparatus shown in FIGS. 3 and 4
for extruding a helical food product having a single helix, it will
be seen that the downstream end of the nozzle component (180) of
the apparatus of FIGS. 5 and 6 is planar and is disposed
orthogonally to the axis of the assembly. The outlets of the bores
(188) within the nozzle component (180) are offset from the central
axis of the nozzle component (180), about which the nozzle
component rotates, so that when the food substrates are dispensed
through the outlets of the bores (188), they are formed into a
multiple helix as the nozzle component rotates. As in the case of
the nozzle component illustrated in FIG. 7D, any bore which is
disposed along the central axis of rotation of the nozzle component
(180) will produce a substantially linear strand of food substrate
that is enveloped within a single or multiple helix, depending on
the number of additional bores that are provided within the nozzle
component.
[0070] It will be seen that after use, the apparatus shown in FIGS.
5 and 6 can be disassembled for cleaning. The apparatus can then be
reassembled in the same way or differently using a different nozzle
component and/or different numbers of intermediate components (150)
for extrusion of a different product.
* * * * *