PRODUCT OF BREADED NUGGETS CONTAINING PEELED SHRIMP OR OTHER PEELED CATCHPIECES BEARING A SHELL AND PRODUCTION PROCESS

Abstract

Breaded nugget product is presented, containing peeled shrimp or other peeled catch pieces, which contains 40% to 60% breading mixture, which contains breadcrumbs, flours and gruel mixture and 60% to 40% peeled shrimp or other peeled catch mixture, characterized in that the peeled shrimp or other peeled catch mixture contains a mixture of milled shrimp or other catch shell and water, which is used as coloring and binding material of the peeled shrimp or other peeled catch without use of synthetic coloring substances, this mixture not being used as breading material.

Description

[0001] The present invention refers to breaded nugget product that contains peeled shrimp or other peeled shell-bearing catch pieces according to claim 1. It also refers to production method of the product and use of milled shrimp or other catch shell mixture as peeled shrimp or other peeled catch mixture coloring and binding material.

[0002] US4871560 discloses fish products, particularly patties or nuggets, which are formed from waste trimmings and cuttings of frozen whole fish fillets using only fish meat as a natural binding means.

[0003] According to the invention breaded nugget product is proposed, containing peeled shrimp or other peeled catch pieces, which contains 40% to 60% breading mixture, which contains breadcrumbs and flours and 60% to 40% peeled shrimp or other peeled catch mixture, which contains a mixture of milled shrimp or other catch shell and water, which is used as coloring and binding material of the peeled shrimp or other peeled catch without use of synthetic coloring substances, this mixture not being used as breading material.

[0004] In the milled shrimp or other catch shell and water mixture an emulsifier may be also added, e.g. soy lecithin.

[0005] The binding property of the milled shrimp or other catch shell and water mixture derives from the fact that in the shells are contained proteins and fat (40% and 14% respectively for shrimp shell) which during milling in the presence of water create hydrolyzates, which during pre-frying are flocculated due to the heat, resulting in the coalescence of the matrix of the food comprising them.

[0006] The present invention will be better understood by reading the description which will be implemented by means of production examples of a breaded nugget product of whole peeled shrimp pieces.

[0007] In this particular example, shrimp is used as raw material. The shrimp type is preferably Parapenaeus longirostris which is caught mainly in the Mediterranean. Instead of shrimp other peeled shell-bearing catches can be used, such as any species of shrimp, prawn, crawfish or any other crustacean.

[0008] Parapenaeus longirostris shrimp contains one of the higher astaxanthin amounts among the crustaceans, while its biggest amount is found in its shell. Astaxanthin is the coloring substance offering the bright red colour to this particular crustacean species and the one supplying the product with the suitable colour, eliminating the need for synthetic coloring substance use. Moreover, the obtained hue is similar to that of the fresh raw material therefore coloring with astaxanthin enhances the product's impression of freshness. Coloring with astaxanthin may be obtained also in case of use of other crustacean flesh for the making of the nugget paste, as the same coloring substance naturally exists in these animal species as well. However the higher coloring substance concentration in shrimp - particularly in its shell - makes it particularly suitable for using its shell as raw material for nugget paste coloring.

[0009] Parapenaeus longirostris shrimp has also an advantage over the other high seas shrimp species concerning the organoleptic character it gives to the product as: a) Parapenaeus longirostris is caught in a way that causes stress in it thereby accelerating its internal organ autolysis. b) hepatopancreas, internal shrimp organ, contains enzymes that seep towards the muscle tissues of the tail c) the enzymes of hepatopancreas are proteolytic resulting in an increase of the free amino acids in the flesh, d) the free amino acids add a sweet taste, e) the free amino acids react through Maillard and Strecker reactions producing substances that give the characteristic fried / grilled shrimp smell during the pre-frying of the nugget. Moreover, the Parapenaeus species shrimps contain a higher proline amount compared to other catches, which is an essential precursor substance for the production of the aromatic compounds that give the characteristic fried / grilled shrimp smell during the pre-frying of the nugget.

[0010] Furthermore, Parapenaeus longirostris lives in temperate climates therefore it contains psychrotrophic proteolytic bacteria, as well as enzymes acting in low temperatures. This is why during its stay in chilling temperatures proteolysis is performed at a faster pace in contrast to what happens in shrimp species living in warmer climates. Faster proteolysis releases due to ATP hydrolysis nucleotides (AMP, IMP) which add pleasant taste.

[0011] Due to its small size Parapenaeus longirostris is decomposed faster than bigger shrimp species, therefore the precursor compounds for the production of characteristic fried / grilled shrimp smell during the pre-frying of the nugget appear faster in higher concentrations. No other similar size shrimps of high commercial value, caught in a similar way in the high seas, are found.

[0012] The product according to the invention can have the following composition: 1. 40% to 60% breading mixture containing breadcrumbs and flours. Gluten is not contained in these ingredients. The composition can be the following: Breadcrumbs: (rice flour (50-60%), chickpea flour, corn flour (1-5%), salt, dextrose (<1%). Flours: rice flour (90-100%), salt (5-10%), Pepper (1-5%). Gruel flour: corn flour, potato starch, salt. 2. 60% to 40% shrimp mixture containing 93,6% to 94,1% peeled shrimp, binding mixture (potato starch) from 0,5 % to 0 %, psyllium (fibre) 0,28%, monosodium glutamate 0,092% and also 2,75% milled shrimp shell, 2,75% water and 0,028% emulsifier, e.g. soy lecithin. The mixture is presented in gruel form, in which are immersed whole shrimp parts.

[0013] Due to the use of milled shrimp shell mixture as coloring and binding material of the peeled shrimp mixture the according to the state of the art usual binding substance amount of 2,3% to 2,5% by the weight of the shrimp mixture decreases at least at 0,5% and may even be zero. Thus at the same time the shrimp amount increases resulting in richer taste. The same applies if instead of milled shrimp shell milled shell of other catch is used. Instead of peeled shrimp other peeled catch may be used as well.

[0014] Instead of monosodium glutamate other taste enhancer / additive or / and seasoning and spice mixture in form of powder or finely chopped mixture, e.g. (and without being limited to the following) chives, garlic, onion, dill, thyme, pepper, paprika, etc can be used.

[0015] Alternatively the breadcrumbs, flour and gruel composition can be varied so that they have the suitable rheological properties for each particular application. For example, gluten-containing breadcrumbs-flours can be used.

[0016] The production procedure for the particular example (shrimp pieces with milled shrimp shell mixture) comprises the following stages: i. Shrimp peeling and separation from its shell, which is collected and milled in cutter machine. Peeling is performed in a space with a maximum temperature of 12°C. ii. Initially water is heated at a temperature of 60°C and mixed with emulsifier, e.g. with soy lecithin, in hydrocolloid homogenizer. The emulsifier is added in an amount of 0,5% by the water weight. Alternatively an emulsifier may not be used. iii. Then, the water and emulsifier mixture or only the water, if emulsifier has not been added, is chilled at ambient temperature. iv. The milled shrimp shell is mixed with the water-emulsifier solution or, if emulsifier has not been added, with the water in a 1:1 proportion in hydrocolloid homogenizer. Thus mixture is produced for the subsequent coloring and binding of the peeled shrimp. Coloring substances are not added in the mixture.

[0017] The water : emulsifier proportion may be changed depending on the rheological properties of the shell mixture required for each particular application. v. We dissolve sodium citrate anhydrous in an amount of 3,5% in water. vi. In a vacuum tumbler the sodium citrate solution is mixed with whole peeled (fresh or defrosted) shrimp parts in a 0,1:1 proportion for 20' under vacuum 5% at a temperature of 2°C. The shrimp is neither chopped nor milled.

[0018] Instead of the tumbler, other mixer with or without blades and with or without vacuum use may be used. vii. In the tumbler the shell mixture is added (stage 4) in an amount of 6% by the peeled shrimp initial weight and mixed for 20' under vacuum 5% at a temperature of 2°C. viii. In the tumbler binding substance mixture is added in an amount in the range of from 0,5% to 0% by the shrimp mixture weight, 0,3% psyllium (fibre) and 0,1% monosodium glutamate. The amounts are calculated based on the peeled shrimp initial weight. Then the content is mixed for 20' without vacuum at a temperature of 2°C. Thus, a mixture containing whole immersed in gruel shrimp parts is produced which we will call shrimp paste. ix. The shrimp paste is fed in forming machine. Nuggets in predetermined shape, e.g. in big shrimp or meatball shape, containing whole shrimp parts exit the die of the machine at a temperature ranging from -2 to 0°C. x. The nuggets are pre-floured. xi. Passing through gruel 'curtain' follows. The gruel mixture has been produced by means of flour-water mixing in a 1:1,72 proportion. This proportion ensures that the product will have a solid form and be able to maintain its shape and forming. Moreover, either chemically modified starch or / and cellulose or / and beta-glucan derivatives can be added in the gruel, in amounts indicated by the food law as well as salt. xii. Breading in gluten free breadcrumbs and flour mixture follows. Composition: Breadcrumbs: (rice flour (50-60%), chickpea flour, corn flour (1-5%), salt, dextrose (<1%). Flours: Rice flour (90-100%), salt (5-10%), Pepper (1-5%). xiii. Then the breaded pieces are pre-fried with sunflower or any other kind of oil suitable for frying in spray fryer. It refers to a method of spraying, during which the product is sprayed with oil on both sides so that its taste is sealed from the spices and herbs obtained during the breading and the product is formed so that it will be ready for packaging. Alternatively the frying may be performed by means of tank or curtain fryer. xiv. The pre-fried products pass through blast freezer tunnel. They may exit the tunnel at a temperature of either -18°C (frozen products) or 0°C (chilled products). Different temperature results in: different package, other preparation method on the part of consumer and different life cycle of the product. xv. Packaging follows. Concerning chilled products in particular, they can be packaged in modified atmosphere (indicatively nitrogen 70% - carbon dioxide 30% mixture).

[0019] During the production of the nuggets shrimp shell for the production of other catch nuggets, or other catch shell for the production of shrimp nuggets, or other catch shell for the production of the same or other catch nuggets, can be used according to claim 10.

[0020] The breaded nugget product according to the invention does not suffer the usual quality drawbacks of breaded products. In particular there isn't any breadcrumbs to find inside the product but only the shrimp or other catch with a minimum amount of binding substances, thus increasing the shrimp or other catch amount in the final product. There aren't also any artificial taste enhancers or coloring substances in its composition. Due to pre-frying by means of spraying with hot oil for a minimum amount of time, avoidance of acrylamide forming is obtained. Moreover spraying with oil 'seals' the product pieces preventing the escape of shrimp or other catch humidity during pre-frying. Thus, the product remains externally crusty, while being internally juicy. Another advantage lies in the fact that the breadcrumbs is not detached from the product piece surface during the pre-frying procedure, as preferably it is not immersed in oil.

Claims

1. Breaded nugget product containing whole peeled shrimp or other peeled catch pieces, which contains 40% to 60% breading mixture, which contains breadcrumbs, flours and gruel mixture and 60% to 40% peeled shrimp or other peeled catch mixture, characterized in that the peeled shrimp or other peeled catch mixture contains a mixture of milled shrimp or other catch shell and water, which is used as coloring and binding material of the peeled shrimp or other peeled catch without use of synthetic coloring substances, this mixture not being used as breading material.

2. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 1, characterized in that the mixture of milled shrimp or other catch shell and water contains emulsifier in an amount of 0,5% by the water weight.

3. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 1 or 2, characterized in that the breading mixture has the following composition: Breadcrumbs: (rice flour (50-60%), chickpea flour, corn flour (1-5%), salt, dextrose (<1%). Flours: rice flour (90-100%), salt (5-10%), pepper (1-5%), wherein the gruel mixture has been produced by flour-water mixing in a 1:1,72 proportion.

4. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 1, 2 or 3, characterized in that the peeled shrimp or other peeled catch mixture has the following composition: 93,6% to 94,1% % peeled shrimp or other peeled catch, binding substance mixture ranging from 0,5 % to 0 %, psyllium (fibre) 0,28%, taste enhancer / additive or / and seasoning and spice mixture in powder or finely chopped mixture form 0,092%, 2,75% milled shrimp shell or milled other catch shell and 2,75% water, wherein the peeled shrimp or other peeled catch mixture is in the form of gruel in which are immersed whole shrimp or other peeled catch parts.

5. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 4, characterized in that the peeled shrimp or other peeled catch mixture further contains emulsifier in an amount of 0,5% by the water weight.

6. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 4 or 5, characterized in that the taste enhancer / additive is monosodium glutamate.

7. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 1, 2, 3, 4, 5 or 6, characterized in that the peeled shrimp or other peeled catch mixture contains a mixture of milled shrimp shell or milled other catch shell and water and optionally emulsifier in an amount of 0,5% by the water weight.

8. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 1, 2, 3, 4, 5, 6 or 7, characterized in that the product contains peeled shrimp pieces and that a mixture of milled shrimp shell and water is used as the peeled shrimp coloring and binding material.

9. Breaded nugget product of whole peeled shrimp or other peeled catch pieces according to claim 8, characterized in that the shrimp type is Parapenaeus longirostris.

10. Use of mixture of milled shrimp or other catch shell and water in a 1:1 proportion with or without emulsifier in an amount of 0,5% by the water weight as coloring and binding material of peeled shrimp or other peeled catch mixture.

11. Peeled shrimp or other peeled catch piece-containing breaded nugget production method characterized by the following stages: i. Peeling of the shrimp or other shell-bearing catch, collection of the shells and milling of them in cutter machine, wherein peeling is performed in space with maximum temperature of 12°C ii. Heating of water at a temperature of 60°C and optionally mixing of the water with emulsifier in hydrocolloid homogenizer, wherein the emulsifier is added in an amount of 0,5% by the water weight iii. Chilling of the water and emulsifier mixture or only the water if emulsifier has not been added at ambient temperature iv. Mixing of the milled shrimp or other catch shell with the water-emulsifier solution or, if emulsifier has not been added, the water in a 1:1 proportion in hydrocolloid homogenizer, to produce mixture for the subsequent coloring and binding of the peeled shrimp or other catch v. Dissolution of sodium citrate anhydrous in an amount of 3,5% in water vi. Mixing of the sodium citrate solution with whole peeled shrimp parts or pieces of the other catch in vacuum tumbler in a 0,1:1 proportion for 20' under vacuum 5% at a temperature of 2°C vii. Addition in the vacuum tumbler of the mixture for the coloring and binding of the peeled shrimp or other catch in an amount of 6% by the peeled shrimp initial weight and mixing for 20' under vacuum 5% at a temperature of 2°C. viii. Addition in the vacuum tumbler of binding substance mixture in an amount in the range of from 0,5% to 0% by the shrimp or other catch mixture weight, 0,3% psyllium (fibre) and 0,1% monosodium glutamate or other taste enhancer / additive or / and seasoning and spice mixture in powder or finely chopped mixture form, wherein the amounts are calculated based on the peeled shrimp or other catch initial weight and mixing of the content for 20' without vacuum at a temperature of 2°C, resulting in the production of mixture containing whole shrimp parts or pieces of the other catch that are immersed in gruel ix. Feeding of the mixture that contains whole immersed in gruel shrimp parts or pieces of the other catch in forming machine, wherein at a temperature in the range of from -2 to 0°C whole shrimp part or other catch piece-containing nuggets exit the machine die in predetermined shape x. Pre-flouring of the nuggets xi. Passing through gruel «curtain», wherein the gruel mixture has been produced by means of flour-water mixing in a 1:1,72 proportion and wherein either chemically modified starch or / and cellulose or and beta-glucan derivatives may be optionally added to the gruel, in amounts indicated by the food law as well as salt. xii. Breading of the nuggets in breadcrumbs and flour mixture. xiii. Pre-frying of the nuggets with sunflower or any other kind of oil suitable for frying in spray fryer and xiv. Passing of the pre-fried nuggets through blast freezer tunnel wherein they exit at a temperature of either -18°C (frozen products) or 0°C (chilled products).

12. Peeled shrimp or other peeled catch piece-containing breaded nugget production method according to claim 11, wherein instead of the vacuum tumbler other mixer with or without blades and with or without vacuum use is used.

13. Peeled shrimp or other peeled catch piece-containing breaded nugget production method according to claim 11 or 12, wherein the breading mixture has the following composition: Breadcrumbs: (rice flour (50-60%), chickpea flour, corn flour (1-5%), salt, dextrose (<1%). Flours: rice flour (90-100%), salt (5-10%), pepper (1-5%).

14. Peeled shrimp or other peeled catch piece-containing breaded nugget production method according to claim 12 or 13, wherein the mixture for the coloring and binding of the peeled shrimp or other catch contains a mixture of milled shrimp or other catch shell and water and optionally emulsifier in an amount of 0,5% by the water weight.

15. Peeled shrimp or other peeled catch piece-containing breaded nugget production method according to claim 14, wherein the shrimp type is Parapenaeus longirostris.