U.S. patent application number 15/989596 was filed with the patent office on 2018-09-27 for hybrid bacon cooking system.
This patent application is currently assigned to HORMEL FOODS CORPORATION. The applicant listed for this patent is HORMEL FOODS CORPORATION. Invention is credited to Brian E. Hendrickson, Richard M. Herreid, James E. Mino, Brian J. Srsen.
Application Number | 20180271109 15/989596 |
Document ID | / |
Family ID | 44504282 |
Filed Date | 2018-09-27 |
United States Patent
Application |
20180271109 |
Kind Code |
A1 |
Srsen; Brian J. ; et
al. |
September 27, 2018 |
HYBRID BACON COOKING SYSTEM
Abstract
A method of making precooked meat pieces using a hybrid cooking
system comprises preheating meat pieces to a temperature of at
least approximately 140.degree. F. to create preheated meat pieces.
The preheated meat pieces are transferred to an oven heated with an
external heating source. The oven includes internal surfaces, and
the external heating source assists in keeping the internal
surfaces at a temperature below a smoke point of fat from the meat
pieces. The preheated meat pieces are cooked in the oven to a water
activity level of 0.92 or less to create precooked meat pieces.
Optionally, flavoring could be applied to the precooked meat pieces
after the precooked meat pieces have been removed from the oven and
before the precooked meat pieces have cooled.
Inventors: |
Srsen; Brian J.; (Austin,
MN) ; Herreid; Richard M.; (Austin, MN) ;
Mino; James E.; (Austin, MN) ; Hendrickson; Brian
E.; (Oakland, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HORMEL FOODS CORPORATION |
Austin |
MN |
US |
|
|
Assignee: |
HORMEL FOODS CORPORATION
Austin
MN
|
Family ID: |
44504282 |
Appl. No.: |
15/989596 |
Filed: |
May 25, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13207065 |
Aug 10, 2011 |
9980498 |
|
|
15989596 |
|
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|
61372560 |
Aug 11, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23B 4/044 20130101;
A23L 13/428 20160801; A21B 2/00 20130101; A23L 5/13 20160801; A23L
5/15 20160801; A21B 7/00 20130101 |
International
Class: |
A23B 4/044 20060101
A23B004/044; A21B 2/00 20060101 A21B002/00; A23L 13/40 20060101
A23L013/40; A23L 5/10 20060101 A23L005/10; A21B 7/00 20060101
A21B007/00 |
Claims
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27. A method of making precooked bacon pieces using a hybrid
cooking system, comprising: preheating bacon pieces to create
preheated bacon pieces, the preheating forming a barrier with
melted fat around the preheated bacon pieces; transferring the
preheated bacon pieces to a cooking compartment of an oven, the
cooking compartment being heated with steam, the barrier preventing
any condensation that forms from contacting the preheated bacon
pieces under the melted fat and diluting flavor in the preheated
bacon pieces, the cooking compartment including internal surfaces,
the steam assisting in keeping the internal surfaces at a
temperature below 375.degree. F. thereby reducing off flavors
during cooking in the cooking compartment; and cooking the
preheated bacon pieces in the cooking compartment to a water
activity level of 0.92 or less to create precooked bacon
pieces.
28. The method of claim 27, wherein the bacon pieces are preheated
to a temperature of at least 140.degree. F.
29. The method of claim 27, wherein the bacon pieces are preheated
to a temperature of 140.degree. F. to 210.degree. F.
30. The method of claim 27, wherein the bacon pieces are preheated
using a preheating method selected from the group consisting of a
microwave oven, an infrared oven, and hot air.
31. The method of claim 27, wherein the steam is generated in an
external steam generator external to the cooking compartment, the
steam being injected into the cooking compartment and being
approximately 400.degree. F. to 1000.degree. F. when the steam
leaves the external steam generator.
32. The method of claim 27, wherein a steam level in the cooking
compartment is at least greater than 90%.
33. The method of claim 27, further comprising a heating element
within the cooking compartment of the oven to preheat the cooking
compartment.
34. The method of claim 27, wherein the bacon pieces are bacon
slices created from slicing bacon bellies to a thickness of
approximately 0.25 inch or less.
35. A method of making precooked meat pieces using a hybrid cooking
system, comprising: preheating meat pieces in a first cooking
compartment using a preheating method selected from the group
consisting of a microwave oven, an infrared oven, and hot air to
create preheated meat pieces, the preheating forming a barrier with
melted fat around the preheated meat pieces; transferring the
preheated meat pieces to a second cooking compartment heated with a
heating source, the barrier preventing any condensation that forms
from contacting the preheated meat pieces under the melted fat and
diluting flavor in the preheated meat pieces, the second cooking
compartment including internal surfaces, the heating source
assisting in keeping the internal surfaces at a temperature below a
smoke point of fat of the meat pieces thereby reducing off flavors
during cooking in the second cooking compartment; and cooking the
preheated meat pieces in the second cooking compartment to a water
activity level of 0.92 or less to create precooked meat pieces.
36. The method of claim 35, wherein the meat pieces are preheated
to a temperature of at least 140.degree. F.
37. The method of claim 35, wherein the meat pieces are preheated
to a temperature of 140.degree. F. to 210.degree. F. to create the
preheated meat pieces.
38. The method of claim 35, wherein the meat pieces are bacon
slices created from slicing bacon bellies to a thickness of
approximately 0.25 inch or less.
39. The method of claim 38, wherein the internal surfaces of the
second cooking compartment are kept below 375.degree. F.
40. The method of claim 35, wherein the meat pieces are preheated
in the first cooking compartment using the microwave oven.
41. The method of claim 35, wherein the second cooking compartment
is heated with an external heating source, the external heating
source being external to the second cooking compartment.
42. The method of claim 35, wherein the second cooking compartment
is heated with steam.
43. The method of claim 42, wherein the steam is heated with an
external steam generator, the steam is injected into the second
cooking compartment, and the steam is approximately 400.degree. F.
to 1000.degree. F. when it leaves the external steam generator.
44. The method of claim 43, wherein a steam level in the second
cooking compartment is at least greater than 90%.
45. A method of making precooked meat pieces using a hybrid cooking
system, comprising: preheating meat pieces to create preheated meat
pieces, the preheating forming a barrier with melted fat around the
preheated meat pieces; transferring the preheated meat pieces to a
cooking compartment of an oven heated with steam, the barrier
preventing any condensation that forms from contacting the
preheated meat pieces under the melted fat and diluting flavor in
the preheated meat pieces, the cooking compartment including
internal surfaces, the steam assisting in keeping the internal
surfaces at a temperature below a smoke point of fat of the meat
pieces thereby reducing off flavors during cooking in the cooking
compartment; and cooking the preheated meat pieces in the cooking
compartment to a water activity level of 0.92 or less to create
precooked meat pieces.
46. The method of claim 45, wherein the meat pieces are preheated
using a preheating method selected from the group consisting of a
microwave oven, an infrared oven, and hot air.
47. The method of claim 45, wherein the meat pieces are preheated
to a temperature of at least 140.degree. F.
48. The method of claim 45, wherein the meat pieces are preheated
to a temperature of 140.degree. F. to 210.degree. F. to create the
preheated meat pieces.
49. The method of claim 45, wherein the steam is generated by an
external steam generator external to the cooking compartment, the
steam being injected into the cooking compartment and being
approximately 400.degree. F. to 1000.degree. F. when the steam
leaves the external steam generator.
50. The method of claim 45, wherein the meat pieces are bacon
slices created from slicing bacon bellies to a thickness of
approximately 0.25 inch or less.
51. The method of claim 50, wherein the internal surfaces of the
cooking compartment are kept below 375.degree. F.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/372,560, filed Aug. 11, 2010, and U.S.
application Ser. No. 13/207,065, filed Aug. 10, 2011, which are
incorporated in their entirety herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to the cooking of bacon
and, more particularly, to the cooking of bacon using a hybrid
cooking system, which includes preheating the bacon using a first
system and then followed by using a second system to fully cook the
bacon.
[0003] There are several ways of preparing bacon wherein the
producer cooks the bacon prior to sale to the customer or consumer.
This is referred to as precooked bacon. One typical way of making
precooked bacon is to use microwave heating. Typically, multiple
microwave ovens are arranged in series with a conveyor running
through them to form a continuous cooking system. This provides for
a fast cooking process and provides an economical way of producing
precooked bacon. However, there have been instances where the
appearance and the texture of the precooked bacon, cooked by
microwave, could be improved. For example, the finished product
tends to be tough in texture and has char marks on the slices
proximate the locations of the cure solution injection sites.
Another way of making precooked bacon is to use continuous spiral
ovens with a heated gas such as hot air or steam which is
circulated in the oven to heat and cook the bacon slices. Such
ovens commonly use electrical heating elements or thermal oil heat
exchangers to heat the circulating gas. These heating surfaces are
typically much hotter than the target temperature for the
circulating gas to increase the efficiency of heat transfer. For
example, an oven with an air temperature setting of 350.degree. F.
would have the heating surface temperature of at least 450.degree.
F. However, such systems also may have issues with texture and
retention of flavor. Although the texture is somewhat improved and
char marks are eliminated by using electrically or thermal oil
heated spiral ovens with steam, it has been noted, for example,
that the flavor changed in a negative way by having an off flavor
and the flavor intensity of the cure solution was noticeably
reduced.
[0004] Further, smoke is typically applied to bacon bellies before
slicing and cooking in microwave ovens. These ovens typically have
conveyor belts on top of the bacon to hold the bacon in place on
the lower transport conveyor belt. Therefore, it is not possible to
add smoke in the microwave oven since the top and bottom belts
prevent the smoke from reaching the bacon slices. Smoke can be
applied to the bacon belly or to the slices in a heated spiral oven
during cooking. When smoke is applied before slicing and cooking
only the edges of the sliced bacon have significant smoke flavor.
Whether applied before cooking or during the cooking of the slices,
the smoke can darken the meat and/or develop a bitter flavor
because of reactions that occur at the high temperatures of bacon
cooking. Smoke applied to sliced bacon in a continuous oven also
loses a significant amount of flavor and aroma with the heat and
high air flow in the continuous oven. In addition, there are
problems with smoke coating the inside of the oven.
[0005] For the reasons stated above and for other reasons stated
below, which will become apparent to those skilled in the art upon
reading and understanding the present specification, there is a
need in the art for an improved bacon cooking system.
BRIEF SUMMARY OF THE INVENTION
[0006] The above-mentioned problems associated with prior devices
are addressed by embodiments of the present invention and will be
understood by reading and understanding the present specification.
The following summary is made by way of example and not by way of
limitation. It is merely provided to aid the reader in
understanding some of the aspects of the invention.
[0007] One embodiment method of making precooked meat pieces using
a hybrid cooking system comprises preheating meat pieces to a
temperature of at least approximately 140.degree. F. to create
preheated meat pieces. The preheated meat pieces are transferred to
an oven heated with an external heating source. The oven includes
internal surfaces, and the external heating source assists in
keeping the internal surfaces at a temperature below a smoke point
of fat from the meat pieces. The preheated meat pieces are cooked
in the oven to a water activity level of 0.92 or less to create
precooked meat pieces.
[0008] One embodiment method of making precooked bacon pieces using
a hybrid cooking system comprises preheating bacon pieces with a
microwave oven to a temperature of at least approximately
140.degree. F. to create preheated bacon pieces. The preheated
bacon pieces are transferred to an oven heated with steam from an
external steam generator. The oven includes internal surfaces, and
the steam assists in keeping the internal surfaces at a temperature
below 375.degree. F. The preheated bacon pieces are cooked in the
oven to a water activity level of 0.92 or less to create precooked
bacon pieces.
[0009] One embodiment method of flavoring meat pieces comprises
cooking meat pieces with a heat source to a water activity level of
0.92 or less to create precooked meat pieces and applying flavoring
to the precooked meat pieces after the precooked meat pieces have
been removed from the heat source and before the precooked meat
pieces have cooled. The flavoring is applied using an applicator
selected from the group consisting of a vaporizer and an
atomizer.
[0010] One embodiment externally heated oven comprises an oven
compartment, a fan in fluid communication with the oven
compartment, and an external heat generator operatively connected
to the oven compartment. The external heat generator is controlled
by an oven temperature control system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention can be more easily understood, and
further advantages and uses thereof can be more readily apparent,
when considered in view of the detailed description and the
following Figures in which:
[0012] FIG. 1 is a schematic diagram of a hybrid bacon cooking
system according to the principles of the present invention;
[0013] FIG. 2 is a graph showing a comparison of precooked bacon
texture under three different bacon cooking systems;
[0014] FIG. 3 is a table showing a lab analysis of finished
precooked product under various systems;
[0015] FIG. 4 is a photograph of precooked bacon that has been
prepared using only a microwave system; and
[0016] FIG. 5 is a photograph of precooked bacon prepared using the
hybrid system of the present invention.
[0017] In accordance with common practice, the various described
features are not drawn to scale but are drawn to emphasize specific
features relevant to the present invention. Reference characters
denote like elements throughout the Figures and the text.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In the following detailed description, reference is made to
the accompanying drawings, which form a part hereof, and in which
is shown by way of illustration embodiments in which the inventions
may be practiced. These embodiments are described in sufficient
detail to enable those skilled in the art to practice the
invention, and it is to be understood that other embodiments may be
utilized and mechanical changes may be made without departing from
the spirit and scope of the present invention. The following
detailed description is, therefore, not to be taken in a limiting
sense, and the scope of the present invention is defined only by
the claims and equivalents thereof.
[0019] Embodiments of the present invention provide a hybrid
cooking system for meat pieces, which includes preheating the meat
pieces using a first system and then followed by using a second
system to fully cook the meat pieces to a water activity level of
0.92 or less.
[0020] Although the term "bacon slices" is used throughout this
description, it is understood that other types of meat pieces such
as, but not limited to, bacon pieces, breakfast strips, and turkey
bacon could be used.
[0021] By using electrically heated spiral ovens with steam, it has
been noted, for example, that the flavor changed in a negative way
by having an off flavor and the flavor intensity of the cure
solution was noticeably reduced. As a result of the present
invention, it has been determined that the off flavor was the
result of the fat atomizing into the oven compartment and
contacting the hot surfaces of the electrical heating elements that
can reach temperatures of approximately 1000.degree. F. Because the
smoke point of bacon fat is approximately 375.degree. F., the fat
contacting the electrical heating elements burned and created smoke
within the oven compartment, which negatively affected the flavor
of the cooked bacon.
[0022] The inventors of the present invention found that using an
external heat source of superheated steam, rather than internal
electrical heating elements and steam, eliminated the off flavor.
The external heat source of superheated steam kept the surfaces
within the oven below the 375.degree. F. smoke point of bacon fat
and provided a more efficient heat transfer of steam for cooking.
In addition, using an external heat source significantly reduces
the risk of fire within the oven.
[0023] To address the dilution of the cure flavor, the inventors of
the present invention determined that by including a preheating
step using a microwave oven, the cold slices of bacon were heated
enough to reduce the amount of condensation that formed on the
slices of bacon as they entered the superheated steam oven and the
fat that melted during the preheating step formed a barrier around
the slices of bacon so that any condensation that did form was kept
from contacting the bacon under the fat so that the flavor under
the fat barrier was not diluted and washed off.
[0024] Optionally, to enhance the flavor of the bacon slices, it
was determined by the inventors of the present invention that
adding smoke or flavor after the bacon slices were fully cooked to
the desired water activity level, in a vaporized/atomized form, the
aroma and delicate flavors of the smoke or flavor are retained on
the bacon slices since the bacon slices are warm enough to have the
smoke or flavor adhere quickly thereto but are in the process of
cooling down so the volatile aromas are not lost.
[0025] In one embodiment, referring to FIG. 1, there is generally
disclosed at 10 a hybrid bacon cooking system. Bacon bellies, which
have been treated with a cure solution well known in the art and
may or may not be heat processed, are sliced using a Grote slicer
20, or other suitable slicer, and the bacon slices are carried on a
belt 30 into a microwave oven 40. Preferably, the bacon bellies are
sliced at a thickness of 0.25 inch or less. In the microwave oven
40, as will be described more fully hereafter, the sliced bacon is
preheated to a temperature of at least approximately 140.degree. F.
to 210.degree. F. An example of a suitable microwave oven that
could be used is the AMTek Microwave System, Model # MWO 2404-75,
manufactured by Applied Microwave Technology, Inc. of Cedar Rapids,
Iowa. The preheated bacon slices are then transferred onto a
conveyor 50 that is part of a superheated steam oven 60.
[0026] An example of a suitable superheated steam oven 60 that
could be used is a Mini Spiral Oven manufactured by Unitherm Food
Systems, Inc. of Bristow, Okla., that has been modified by
eliminating the use of the electrical heating elements and using
externally heated steam instead during cooking. The superheated
steam oven 60 includes a superheated steam generator 61 that
supplies the superheated steam to the superheated steam oven 60. An
example of a suitable superheated steam generator is Model #
WH-753496DS manufactured by Applied Thermal Systems, Inc. of
Brooklyn Park, Minn. The superheated steam is injected at a rate
sufficient to maintain the desired temperature into the steam oven
60 through the factory steam inlet port 62 and an additional
secondary steam inlet port 63 positioned proximate the factory
steam inlet port, and the steam is distributed through the steam
oven 60 by the factory steam distribution manifold and a secondary
steam distribution manifold, which are operatively connected to the
respective inlet ports 62 and 63, to accommodate the higher steam
flow to maintain the desired oven temperature at maximum production
rates. The secondary steam distribution manifold was added
diagonally along the bottom of the steam oven 60. Because the Mini
Spiral Oven was modified, an additional inlet and manifold were
added so that the factory steam inlet port was not overloaded. It
is recognized that the additional inlet and manifold may not be
needed if another type of oven is used or if an oven is
manufactured for this purpose. It is also recognized that the oven
could be a batch type oven or be part of a continuous cooking
system.
[0027] The temperature within the steam oven 60 is controlled by
controlling the heating elements of the generator 61 and by
controlling the flow rate into the oven 60. More specifically, the
temperature within the steam oven 60 is controlled by sending a
temperature setpoint value from the oven control panel 60a to the
superheated steam generator temperature control panel 61a. The oven
control panel 60a adjusts the temperature setpoint signal to
maintain the target temperature inside the steam oven 60. It is
recognized that another type of oven temperature control system
could be used such as, but not limited to, a single control panel.
Any excess steam escapes the steam oven 60 via the conveyor inlet
and outlet openings and is carried away by exhaust hoods located
above each opening. The superheated steam is approximately 400 to
1000.degree. F. when it leaves the generator 61, and the steam
equilibrates within the oven 60 to the desired temperature. The
superheated steam is not re-circulated but rather fresh superheated
steam is used. The oven 60 includes a fan 64 in fluid communication
with the steam oven 60 to circulate the gas/steam, which is
exhausted out of the oven 60. The heating elements within the oven
60 are not used except optionally to preheat the oven prior to
introducing bacon. The bacon slices are cooked in the steam oven 60
to a water activity level of 0.92 or less to create precooked
bacon.
[0028] Optionally, a smoke generator 70 and/or a flavor atomizer 80
may be added to the precooked bacon after it has exited the
superheated steam oven 60 on a conveyor 90 in a cabinet. An example
of a suitable smoke generator is Model # R54 manufactured by
GERMOS-Fessmann GmbH & Co KG of Remshalden, Germany. To create
the smoke within the cabinet, hardwood chips were used in the smoke
generator at a burn rate of 25 pounds per hour. An example of a
suitable flavor atomizer is Red Arrow Power Smoker, Model #100
Deluxe, manufactured by the Red Arrow Equipment Company, Inc., of
Manitowoc, Wis. An example of a suitable flavor for use with the
flavor atomizer is maple flavor or honey flavor from WILD Flavors,
Inc. of Erlanger, Ky. applied as an atomized fog within the
cabinet. Alternatively, a solution of 30% sugar, 10% salt, and 60%
water could be atomized at a flow rate of 4 gallons per hour
through the Red Arrow Power Smoker. The smoke from the smoke
generator and the atomized flavor are applied while the product is
still hot so that it absorbs well as the bacon cools. Because the
flavoring of smoke and/or flavor is applied after the bacon has
been fully cooked and because the flavoring is in
vaporized/atomized form, the volatile aromatic notes are retained.
Preferably, the flavoring is applied for 10 to 20 seconds and it is
vaporized/atomized, not sprayed. The finished product, after the
optional flavoring has been added, is then transferred, via
conveyor 100, where it is then cooled and packaged by any suitable
means well known in the art.
[0029] Although superheated steam is described herein, it is
recognized that any other suitable external heat source could be
used such as, but not limited to, nitrogen or air as long as the
grease/fat is filtered so that it does not come into contact with
the heating surface.
[0030] Preheating the sliced bacon with a microwave oven, or other
suitable heating methods such as infrared or hot air, prior to
fully cooking the sliced bacon in a superheated steam oven
minimizes condensation on the sliced bacon surfaces. The preheating
begins to melt the fat portion of the sliced bacon which encases
the sliced bacon in melted fat. The melted fat acts as a barrier
that, along with the increased temperature of the bacon slice,
minimizes the amount of moisture condensation on the surface of the
sliced bacon when the sliced bacon is cooked in the superheated
steam oven and reduces the amount of condensation that contacts the
bacon under the melted fat. The cooking process time of the hybrid
cooking system is less than that of just the superheated steam
oven. See Example 1 below for an example of the reduced processing
time.
Example 1
[0031] Raw bacon slices, sliced to 7 slices per inch, were cooked
in a superheated steam oven at an oven temperature of 375.degree.
F. The cooking time was eight minutes to reach a water activity
level of approximately 0.85. Raw bacon slices, sliced to 7 slices
per inch, were also cooked using a hybrid system including a 14 kW
preheat microwave oven for 55 seconds and then a superheated steam
oven at a temperature of 350.degree. F. for five minutes, which
resulted in a precooked bacon with a similar water activity level
of approximately 0.85. The overall processing time for the hybrid
system was 5 minutes 55 seconds as compared to 8 minutes for the
superheated steam oven only.
Example 2
[0032] Referring now to FIG. 2, precooked bacon was made using
three different methods. The first method was a microwave oven, the
second method was a superheated steam oven, and the third method
was a hybrid system in accordance with the present invention
wherein both a microwave oven and a superheated steam oven were
used. The microwave oven only precooked bacon had a texture
measured in pounds of force per cm.sup.2 of 15.6 for the lean area
and 6 for the fat area. The superheated steam only precooked bacon
had a texture measured in pounds of force per cm.sup.2 of 13.2 for
the lean area and 5.7 for the fat area. However, the hybrid system
precooked bacon had a texture measured in pounds of force per
cm.sup.2 of 10 for the lean area and 5.2 for the fat area thereby
showing an improvement in texture of the final precooked bacon
product.
Example 3
[0033] Referring now to FIG. 3, there is a lab analysis of four
different systems. The first is labeled "AP Microwave Oven" and it
is for a microwave only system. The second is labeled "R&D
Super Heated Steam (SHS) oven" and utilizes superheated steam only.
The third is labeled "R&D SHS oven with atomizer", which is
also a superheated steam only system with an atomizer added.
Finally, the fourth is labeled "R&D Microwave/SHS Hybrid
system", which is the system in accordance with the present
invention. The analysis of each product shows a similar water
activity level (Aw) of approximately 0.85. From the analysis of the
percentages of moisture, salt, and sugar content, it can be seen
that for the hybrid system in accordance with the present invention
there is increased retention of moisture, salt, and sugar when
compared to the other cooking systems.
Example 4
[0034] Referring now to FIGS. 4 and 5, it can be seen that the
appearance of the precooked bacon shown in FIG. 5, which was made
by the hybrid system in accordance with the present invention, is
superior to the microwave only system shown in FIG. 4 in that there
is the elimination of char marks, typical in microwave only cooking
systems.
Example 5
[0035] Another test was conducted to compare the flavor and aroma
of precooked bacon cooked in a standard continuous spiral oven with
precooked bacon cooked using the hybrid cooking system in
accordance with the present invention.
[0036] For this test, the same bacon was used in both cooking
systems. The belly type was Item No. 23508 obtained from the
Austin, Minn. plant of Hormel Foods Corporation. The slice
thickness was 7 slices per inch.
[0037] The settings for the process using the standard continuous
spiral oven, Mini Spiral Oven manufactured by Unitherm Food
Systems, Inc. of Bristow, Okla., were 30 slices per minute at 7
slices per inch. The oven temperature was set at 350.degree. F.,
and internal electrical heating elements were used to maintain this
temperature. Steam was injected into the oven at 5 pounds per
minute which produced a steam level in the oven of at least greater
than 90%, and the recirculation fan speed was set at high (60 hz).
The cook time was 8.8 minutes.
[0038] For the process using the hybrid cooking system, an AMTek
Microwave System, Model # MWO 2404-75, manufactured by Applied
Microwave Technology, Inc. of Cedar Rapids, Iowa, was used for the
preheating step and a Mini Spiral Oven manufactured by Unitherm
Food Systems, Inc. of Bristow, Okla. that was modified by
eliminating the use of the electrical heating elements and
externally heated steam instead was used to maintain the oven
temperature. The source of the externally heated steam was a
Superheated Steam Generator, Model # WH-753496DS, manufactured by
Applied Thermal Systems, Inc. of Brooklyn Park, Minn. The settings
for this process were 20 slices per minute at 7 slices per inch.
The power setting for the microwave oven was 9 kw, and the time
setting for the microwave oven was 53 seconds. The superheated
steam oven temperature was set at 350.degree. F. Steam was injected
into the oven at approximately 10 pounds per minute at 700.degree.
F., and the recirculation fan speed was set at high (60 hz). The
cook time in the superheated steam oven was 7.7 minutes.
[0039] Samples of finished product were taken from each process.
Bacon slices were placed on parchment paper and packaged using a
nitrogen gas flushed Mulivac roll stock machine. The samples from
the oven only cooking system were numbered in the order in which
they were produced so that samples from the beginning, middle, and
end of the test could be identified. For all sample packages
submitted to the sensory panel, there were 10 slices per sheet of
parchment paper and there were 2 sheets of parchment paper placed
in each package. A total of 65 packages were collected and numbered
in the order in which they were produced. Package numbers 1 through
5 were submitted as the beginning of the test cook, package numbers
25 thru 30 were submitted as the middle of the test cook, and
package numbers 60 thru 65 were submitted as the end of the test
cook.
[0040] A set of four samples were submitted for a Descriptive
Evaluation Panel, which comprised of 8 people trained to taste
various attributes in bacon. Testing was done over three days. The
four samples were 1) spiral oven only cooking system using
electrical heating elements at the beginning of 90 minute run; 2)
cooking system from 1) at the middle of 90 minute run; 3) cooking
system from 1) at the end of 90 minute run; and 4) hybrid cooking
system at the end of 180 minute run.
[0041] The samples were placed on parchment lined trays and heated
in an oven, which was preheated to 400.degree. F., for four
minutes. The heated bacon was placed directly under warming lamps,
equipped with red infrared heat lamps, for serving. The bacon was
not drained or blotted. The bacon was served warm and, for each
serving, the panelist was given one slice of bacon on a paper
plate. The panelists evaluated each product, one at a time, and
returned the unused portion of the product. Each product evaluation
was followed by a 5 minute rest interval, during which time the
panelist was provided with a cracker and water with lemon for
rinsing her/his mouth. The panelists evaluated each product four
times according to a balanced serving order. All four products were
analyzed through Analysis of Variance.
[0042] The following Tables 1 and 2 summarize the aroma and flavor
attributes evaluated by the Descriptive Evaluation Panel.
Appearance, texture/mouthfeel, and aftertaste/aftereffects
attributes were also evaluated by the panel, but because these were
not the primary focus of the present invention, only the aroma and
flavor attributes are being described herein. The higher the
attribute score number, the more intense the attribute was
perceived by the panel members. The positive aroma attributes are
smoke aroma, sweet aroma, and salt aroma. The negative aroma
attributes are fat aroma, old meat aroma, burnt aroma, and
artificial aroma. The positive flavor attributes are smoke flavor,
sweet flavor, and salt flavor. The negative flavor attributes are
fat flavor, old meat flavor, and artificial flavor.
TABLE-US-00001 TABLE 1 Means for Aroma Attributes Spiral Oven with
Spiral Oven with Spiral Oven with Hybrid Attribute Electrical
Elements, Electrical Elements, Electrical Elements, Oven,
Description Beginning of Run Middle of Run End of Run End of Run
Smoke Aroma 25.47 22.22 19.84 29.22 Fat Aroma 18.47 21.22 20.22
18.66 Sweet Aroma 11.91 7.94 8.66 13.41 Old Meat Aroma 4.75 6.78
10.31 4.28 Salt Aroma 6.31 6.12 4.56 7.47 Burnt Aroma 3.47 3.91
2.88 3.62 Artificial Aroma 4.88 5.44 8.94 5.28
TABLE-US-00002 TABLE 2 Means for Aroma Attributes Spiral Oven with
Spiral Oven with Spiral Oven with Hybrid Attribute Electrical
Elements, Electrical Elements, Electrical Elements, Oven,
Description Beginning of Run Middle of Run End of Run End of Run
Smoke Flavor 21.72 21.41 19.12 29.22 Salt Flavor 19.84 20.75 19.72
30.03 Sweet Flavor 12.72 13.91 12.16 18.16 Fat Flavor 19.56 23.56
24.59 24.06 Old Meat Flavor 5.62 5.25 8.91 3.47 Artificial Flavor
5.16 4.50 8.38 5.00
[0043] The results of the Descriptive Evaluation Panel indicated
that there is a detectable off flavor created in the electrically
heated spiral oven test samples, and the off flavor increased in
intensity as the test run progressed. There was also a noted
reduction in the salt and sugar flavor intensity in the
electrically heated spiral oven test samples when compared to the
hybrid system test samples.
[0044] Generally, with regard to the electrically heated spiral
oven test samples, over the run from beginning to end, the samples
decreased in smoke aroma, had lighter lean color, and had a more
uniform, rectangular shape. Samples from the beginning of the run,
as opposed to the middle and the end of the run, appeared leaner,
less greasy, and shorter in length and they had less juicy fat
texture, required more chewing to swallow, and had less fat
aftertaste. Samples from the middle of the run, as opposed to the
beginning and the end of the run, appeared more rippled/wavy and
were crisper.
[0045] Generally, on average, the test samples from the hybrid
process had more smoke aroma, had longer slice length, were less
rubbery, had more juicy fat texture, had more smoke and salt flavor
and aftertaste, had lower water activity levels, and had higher
sugar/sucrose and salt/sodium contents.
[0046] It was determined that keeping the surface areas within the
oven compartment below the smoke point of bacon fat, below
375.degree. F., resulted in producing precooked bacon with reduced
off flavors. To accomplish this, externally heated steam was used
to provide the energy required to fully cook bacon. The superheated
steam quickly equilibrates to the desired oven temperature without
creating surface temperatures above 375.degree. F. within the oven
compartment.
[0047] It was also determined that preheating the bacon slices
prior to entering the superheated steam oven improves the flavor
intensity of the finished bacon.
[0048] The above specification, examples, and data provide a
complete description of the manufacture and use of the composition
of embodiments of the invention. Although specific embodiments have
been illustrated and described herein, it will be appreciated by
those of ordinary skill in the art that any arrangement, which is
calculated to achieve the same purpose, may be substituted for the
specific embodiment shown. This application is intended to cover
any adaptations or variations of the invention. Therefore, it is
manifestly intended that this invention be limited only by the
claims and the equivalents thereof.
* * * * *