Process for producing precooked bacon slices

Abstract

A process for producing precooked bacon slices comprising the steps of (a) conveying bacon slices through a spiral oven, (b) indirectly cooking the bacon slices in the spiral oven using a cooking medium which is circulated within the oven at a low rate sufficient to prevent the bacon slices from being displaced on the conveyor, and (c) adding steam to the cooking medium as necessary to at least reduce the percentage or substantially eliminate the presence of air in the cooking medium.

Description

FIELD OF THE INVENTION[0001]The present invention relates to processes for continuously cooking bacon slices to produce precooked bacon strips and other precooked sliced bacon products.BACKGROUND OF THE INVENTION[0002]Because of their thinness, the short cooking time required, and the high fat and water content of the raw product, bacon slices are among the most difficult products to cook consistently. The continuous bacon cooking processes heretofore used in the industry have not been able to provide precooked sliced bacon products having the same texture, bite, mouth feel, color, and appearance as pan-fried products cooked in the home. Thus, a need presently exists for a significantly improved continuous process and system capable of producing such precooked sliced bacon products. A need particularly exists for a process of this type which (a) will provide a production rate similar to the microwave processing systems currently used in the art, (b) will take up less floor space in ...

AI Technical Summary

Benefits of technology

"The present invention provides a spiral oven process for preparing precooked sliced bacon products that meet the needs and alleviate the problems of prior art systems. The process allows for the production of crisp and color-ranged bacon products with a consistent texture and without burned or blackened outer edges. The system has a small footprint and eliminates or minimizes fire risk. The process involves placing the bacon slices on a conveyor of the spiral oven, allowing them to move in a spiral pattern through the oven. The cooking medium circulating in the oven contacts the bacon slices at an average temperature of at least 325°F and at a low flow velocity to prevent displacing the slices. Additional steam is added to maintain the cooking medium at a relative humidity of at least 10%. The process produces a high-quality, home-fried bacon product."

Problems solved by technology

Because of their thinness, the short cooking time required, and the high fat and water content of the raw product, bacon slices are among the most difficult products to cook consistently.

The continuous bacon cooking processes heretofore used in the industry have not been able to provide precooked sliced bacon products having the same texture, bite, mouth feel, color, and appearance as pan-fried products cooked in the home.

Unfortunately, the continuous microwave processes heretofore used for producing precooked sliced bacon products have significant shortcomings and disadvantages.

For one thing, there are significant organaleptic differences between the product produced by a continuous microwave process versus a traditional home-fried product.

In addition, continuous microwave oven systems can be as much as 70 feet or more in length and, thus, take up a great deal of space in the processing facility.

Unfortunately, however, the products produced in the linear circulating air oven systems have been even less crisp and lighter in color than the microwave products.

In addition, the linear circulating air systems have had a tendency to burn or blacken the edges of the bacon slices and have also required an even greater amount of floor space to achieve throughputs approaching those of the microwave systems.

Further, because of the large amount of hot, flammable grease produced when cooking bacon, the fire risk presented by a circulating air oven is very high.

Unfortunately, however, the application of high velocity impingement air to the rather delicate, thinly sliced bacon product traveling through the oven causes the product to be displaced on (i.e., to be moved on or blown off of) the oven conveyor belt.

Also, linear impingement oven systems would still take up a relatively large amount of space in the processing facility and would present an even greater fire risk for bacon cooking.

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