A high-efficiency oil-frying preparation process for a crisp low-fat prepared chicken product

Abstract

This invention discloses a high-efficiency frying process for crispy, low-fat prepared chicken products. The invention relates to the field of chicken product processing technology. The process includes: raw meat processing, auxiliary ingredient preparation, low-temperature chopping, gradient vacuum intermittent tumbling, low-temperature settling, shaping, low-temperature pre-curing, two-stage differential temperature frying, gradient clean air cooling, ultra-low temperature quick-freezing, inspection, packaging, and low-temperature storage. This high-efficiency frying process for crispy, low-fat prepared chicken products effectively inhibits the temperature rise of the raw meat during processing by combining staged low-temperature controlled chopping with gradient vacuum intermittent tumbling. This maximizes the preservation of the natural characteristics of muscle proteins, promotes the full dissolution of myofibril proteins, and forms a dense, uniform, and highly stable gel network structure. This significantly improves the water retention and structural strength of the product, resulting in a delicate, juicy, and tender texture, while also laying a solid structural foundation for subsequent low-oil-absorption frying.

Description

Technical Field

[0001] This invention relates to the field of chicken product processing technology, specifically to an efficient frying process for crispy, low-fat prepared chicken products. Background Technology

[0002] With the rapid development of my country's frozen prepared meat products industry, fried chicken products have become mainstream products in restaurants, supermarkets, and households due to their convenience, crispy taste, and affordable price. Currently, industrial production of fried prepared chicken products generally employs traditional processing techniques, namely raw material handling, chopping, atmospheric pressure tumbling, resting, shaping, single-stage constant-temperature frying, cooling, quick-freezing, and packaging. However, in actual production and product application, existing processes have many insurmountable technical defects, specifically as follows: In traditional processing, the chopping and mixing of raw meat often employs atmospheric pressure, a single rotation speed, and no temperature control. Rapid heating of the minced meat can easily lead to protein denaturation, resulting in a loose internal gel structure and difficulty in controlling water retention and oil holding capacity. During frying, a large amount of oil penetrates the product, resulting in a high fat content, which does not meet the current consumer demand for low-fat, healthy diets. The tumbling process often uses continuous tumbling under atmospheric pressure or continuous tumbling under a single vacuum degree. Insufficient dissolution of muscle protein and uneven penetration of auxiliary materials easily lead to a dry texture, uneven flavor, and insufficient elasticity in the finished product. Furthermore, direct shaping after tumbling results in low structural strength of the blank, making it prone to deformation, cracking, crumbling, and uneven surface during frying, severely affecting the appearance and yield of the finished product.

[0003] In the frying process, existing processes generally employ single-stage constant-temperature frying, which suffers from inconsistent temperature and inefficient time control, making it difficult to simultaneously address the needs for product shaping, browning, crisping, and oil control. If the temperature is too low, the frying time is too long, resulting in products with excessive oil absorption, a soft texture, and insufficient flavor; if the temperature is too high, the surface burns quickly while the inside remains uncooked, leading to uneven crispness and rapid deterioration of the frying oil, increasing production costs and food safety risks. Furthermore, post-frying cooling often relies on natural cooling or ordinary air cooling, which is slow. The products continue to absorb oil at high temperatures, further increasing their oil content, and the cooling process is susceptible to contamination by environmental microorganisms, affecting shelf life and food safety.

[0004] Furthermore, traditional processes lack post-forming pre-curing stabilization treatment, resulting in a loose internal structure of the blank, making it susceptible to damage during transportation and frying. Inaccurate parameter control during quick-freezing leads to slow cooling, larger ice crystals inside the product, causing water seepage after thawing, a deteriorated texture, and an inability to maintain crispness for long periods. The overall process suffers from unclear key control points, poor matching of process parameters, and low levels of automation and continuity, resulting in poor product quality stability, significant batch-to-batch variations, low production efficiency, and high energy consumption, making it difficult to meet the standardized requirements of modern large-scale, efficient, low-fat, and high-quality production.

[0005] Therefore, the present invention provides an efficient frying process for crispy, low-fat prepared chicken products to solve the above-mentioned problems. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides an efficient frying process for crispy, low-fat prepared chicken products, solving the problems mentioned in the background section.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solution: a high-efficiency frying preparation process for crispy, low-fat prepared chicken products, the preparation process including: raw meat processing, auxiliary material preparation, low-temperature chopping, gradient vacuum intermittent tumbling, low-temperature standing, shaping, low-temperature pre-curing and setting, two-stage differential temperature frying, gradient clean air cooling, ultra-low temperature quick freezing, inspection, packaging and low-temperature storage. The chopping process is divided into two stages: low-speed chopping and high-speed chopping. The material temperature is controlled to be no higher than 8°C throughout the chopping process. The tumbling process is carried out intermittently in a vacuum environment.

[0008] Preferably, the raw meat processing includes: sorting, trimming, removing tendons and excess fat, rinsing with water, and draining. The auxiliary ingredients include salt, white sugar, compound phosphate, soy protein isolate, acetylated distarch phosphate, ice water, and compound crispness improver. Each component is weighed according to the preset weight ratio and set aside.

[0009] Preferably, in the low-temperature chopping step, the raw meat is first chopped at a low speed of 800-1200 r / min for 3-5 minutes, and then ice water and compound crispness improver are added and chopped at a high speed of 2800-3200 r / min for 8-12 minutes. After the high-speed chopping is completed, the material temperature is controlled between 4-8℃.

[0010] Preferably, the gradient vacuum intermittent tumbling is carried out in a tumbling machine with a vacuum degree of -0.06MPa to -0.08MPa, with a total tumbling time of 20 to 45 minutes. The operating mode is to tumble for 10 minutes and then pause and let it stand for 5 minutes, and repeat this cycle 2 to 4 times.

[0011] Preferably, the tumbled material is left to stand in a closed settling chamber at a temperature not exceeding 10°C for 8 to 10 hours. The molding step uses a continuous molding machine to press the blank into a block, strip, or block structure, with the molding pressure maintained within the range of 0.3 to 0.6 MPa.

[0012] Preferably, the molded blank is directly sent into a low-temperature setting chamber at a temperature of 0-4°C and kept still for 20-40 minutes for pre-curing treatment, so that a continuous and dense protein curing layer is formed on the surface of the blank.

[0013] Preferably, the two-stage differential temperature frying is divided into a first stage of low-temperature shaping frying and a second stage of high-temperature crisping frying. The first stage frying temperature is 145-155℃ and the frying time is 1.5-2.5 minutes. The second stage frying temperature is 165-175℃ and the frying time is 0.8-1.5 minutes.

[0014] Preferably, the gradient clean air cooling adopts a three-stage progressive cooling channel with an inlet temperature of 20-25°C, a middle section temperature of 10-15°C, and an outlet temperature of 0-5°C. The product runs in the air cooling channel for 3-6 minutes.

[0015] Preferably, the ultra-low temperature quick-freezing adopts a tunnel-type single-freezing machine, the freezing temperature is constant at -32℃, the quick-freezing time is 40 to 65 minutes, the core temperature of the product after quick-freezing is not higher than -18℃, and it is stored in a low-temperature cold storage at -18℃ or below after packaging. Attached Figure Description

[0016] Figure 1 This invention provides a process flow diagram for the efficient frying preparation of crispy, low-fat prepared chicken products.

[0017] This invention provides a highly efficient frying process for crispy, low-fat prepared chicken products. Compared with existing technologies, it has the following advantages: (1) This efficient frying process for crispy, low-fat prepared chicken products utilizes a staged, low-temperature controlled chopping and gradient vacuum intermittent tumbling synergistic treatment. This effectively inhibits the temperature rise of the raw meat during processing, maximizing the preservation of the natural characteristics of muscle proteins, promoting the full dissolution of myofibril proteins, and forming a dense, uniform, and highly stable gel network structure. This significantly improves the water retention and structural strength of the product, resulting in a delicate, juicy, tender, and non-dry internal texture. Simultaneously, it lays a solid structural foundation for subsequent low-oil-absorption frying. Vacuum gradient intermittent tumbling allows salt, spices, and functional additives to penetrate evenly into the muscle tissue, improving flavor uniformity and product consistency, and avoiding problems such as localized excessive saltiness or insufficient flavor.

[0018] (2) This efficient frying process for crispy, low-fat prepared chicken products involves adding a low-temperature pre-curing and shaping step after molding. This allows the raw material to quickly form a dense protein solidification layer on the surface under low-temperature conditions. This solidification layer effectively blocks oil intrusion during frying, significantly reducing the oil absorption rate of the product and achieving truly low-fat production. This makes the finished product more in line with healthy eating trends and enhances the product's market competitiveness. At the same time, low-temperature pre-curing can enhance the structural strength of the raw material, avoiding problems such as deformation, cracking, flaking, and collapse during transportation and frying. This improves the product forming rate and appearance uniformity, reduces production losses, and increases the overall yield.

[0019] (3) The efficient frying process for crispy and low-fat prepared chicken products adopts a two-stage differential temperature frying process. The first stage of low-temperature frying can quickly shape the product, lock in the internal moisture, and avoid excessive oil absorption. The second stage of high-temperature frying can quickly dehydrate, color, and crisp the surface, forming a golden and crispy outer shell. The two stages of temperature and time are precisely matched, which can shorten the overall frying time, improve production efficiency, ensure consistent internal and external maturity and uniform crispness, reduce the damage of high temperature to oil, extend the service life of frying oil, and reduce production costs and energy consumption.

[0020] (4) This efficient frying process for crispy, low-fat prepared chicken products utilizes a three-stage gradient clean air cooling system after frying to rapidly terminate the internal thermal reaction and oil adsorption process, further reducing the oil content of the product. Simultaneously, it avoids the risk of microbial contamination from natural cooling, enhancing product safety and shelf-life stability. Combined with ultra-low temperature rapid freezing at -32℃, the core temperature of the product quickly drops below -18℃, forming fine, uniform ice crystals. This maximizes the preservation of the product's structure, crisp texture, and tender quality, making it less prone to softening, water seepage, or spoilage during long-term frozen storage, significantly improving product stability. Detailed Implementation

[0021] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example

[0022] Crispy Low-Fat Fried Chicken Nuggets (Standard Size) Raw meat processing: Select chicken breast as raw material, sort and trim it, remove tendons, bone fragments and excess fat, rinse with clean water and drain to remove water, and set aside.

[0023] Preparation of auxiliary ingredients: Weigh out salt, white sugar, compound phosphate, soy protein isolate, acetylated distarch phosphate, ice water and compound crispness improver in proportion, mix well and set aside.

[0024] Low-temperature chopping: Put the processed raw meat into a chopper and chop at a low speed of 1000r / min for 4 minutes. Then add ice water and compound crispness improver and chop at a high speed of 3000r / min for 10 minutes, controlling the final chopping temperature to 6℃.

[0025] Gradient vacuum intermittent tumbling: The minced meat and auxiliary materials are fed into a vacuum tumbler and intermittently tumbled at a vacuum of -0.07MPa for 10 minutes, followed by 5 minutes of resting. This process is repeated 3 times, for a total tumbling time of 35 minutes.

[0026] Low-temperature settling: After tumbling, transfer the material to a sealed settling chamber at a temperature below 10℃ and let it stand for 9 hours.

[0027] Molding: The blank is pressed into a block shape using a continuous molding machine, and the molding pressure is controlled at 0.45MPa.

[0028] Low-temperature pre-curing and shaping: The molded blank is immediately sent into a 2℃ low-temperature shaping chamber and left to stand for 30 minutes to form a dense protein curing layer on the surface.

[0029] Two-stage differential frying: First stage: fry at 150℃ for 2 minutes for low-temperature shaping; Second stage: fry at 170℃ for 1 minute for high-temperature crisping.

[0030] Gradient clean air cooling: It adopts a three-stage progressive cooling air cooling channel with an inlet temperature of 22℃, a middle section temperature of 12℃, and an outlet temperature of 3℃, and an air cooling time of 4 minutes.

[0031] Ultra-low temperature quick freezing: Use a tunnel-type single-freezing machine to quick freeze at -32℃ for 55 minutes to make the core temperature of the product ≤-18℃.

[0032] Inspection, packaging and warehousing: After passing the appearance, weight and metal inspection, the product is aseptically packaged and sent to a -18℃ cold storage.

[0033] Example 2 Crispy, low-fat fried chicken strips (long strips) Raw meat processing: Select chicken breast meat, remove tendons and excess fat, wash and drain before use.

[0034] Preparation of auxiliary ingredients: Weigh out salt, white sugar, compound phosphate, soy protein isolate, acetylated distarch phosphate, ice water, and compound crispness improver according to the formula, and mix them together for later use.

[0035] Low-temperature chopping: The raw meat is chopped at 900 r / min for 3.5 minutes, and after adding the auxiliary materials, it is chopped at 2900 r / min for 9 minutes. The final temperature is controlled at 5℃.

[0036] Gradient vacuum intermittent tumbling: vacuum degree -0.06MPa, tumbling for 10 minutes, resting for 5 minutes, repeating 2 cycles, for a total duration of 30 minutes.

[0037] Low-temperature standing: Let stand at 8℃ for 9 hours.

[0038] Molding: Long strip mold is used for molding, and the molding pressure is 0.4MPa.

[0039] Low-temperature pre-curing and shaping: Let stand at 3℃ for 25 minutes.

[0040] Two-stage differential frying: first stage at 152℃ for 2 minutes, second stage at 172℃ for 1 minute.

[0041] Gradient clean air cooling: Three-stage cooling: 23℃→13℃→4℃, air cooling time 4.5 minutes.

[0042] Ultra-low temperature quick-freezing: quick-freeze at -32℃ for 50 minutes, with a core temperature ≤-18℃.

[0043] Inspection, packaging, and low-temperature storage.

[0044] Example 3 Crispy, low-fat fried chicken cutlet (large size) Raw meat processing: Trim, remove tendons and membranes from chicken breast, rinse, and drain to ensure the raw meat is fresh and free of impurities.

[0045] Additive preparation: Weigh the additives according to the production ratio, which contain soy protein isolate and acetylated distarch phosphate to improve structure and crispness.

[0046] Low-temperature chopping: chop at low speed of 1100r / min for 4 minutes, then chop at high speed of 3100r / min for 11 minutes, with a final temperature of 7℃.

[0047] Gradient vacuum intermittent tumbling: vacuum degree -0.08MPa, tumbling for 10 minutes, resting for 5 minutes, repeating 4 cycles, for a total duration of 45 minutes.

[0048] Low temperature standing: Temperature ≤10℃, stand for 10 hours.

[0049] Molding: Large sheet molding, pressure 0.5MPa.

[0050] Low-temperature pre-curing and setting: Let stand in a low-temperature setting chamber at 0~4℃ for 40 minutes.

[0051] Two-stage differential frying: first stage at 155℃ for 2.5 minutes, second stage at 175℃ for 1.5 minutes.

[0052] Gradient clean air cooling: gradually cool down to 5℃, then air cool for 6 minutes.

[0053] Ultra-low temperature quick-freezing: quick-freeze at -32℃ for 65 minutes, with a core temperature ≤-18℃.

[0054] Inspection, packaging, and storage in a -18℃ cold storage.

[0055] Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.

[0056] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0057] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for the efficient deep fat frying of a crispy, low-fat, cooked chicken product, characterized by: The preparation process includes: raw meat processing, auxiliary material preparation, low-temperature chopping, gradient vacuum intermittent tumbling, low-temperature standing, shaping, low-temperature pre-curing and setting, two-stage differential temperature frying, gradient clean air cooling, ultra-low temperature quick freezing, inspection, packaging and low-temperature storage. The chopping process is divided into two stages: low-speed chopping and high-speed chopping. The material temperature is controlled to be no higher than 8°C throughout the chopping process. The tumbling process is carried out intermittently in a vacuum environment.

2. The efficient frying process for crispy, low-fat prepared chicken products according to claim 1, characterized in that: Raw meat processing includes: sorting, trimming, removing tendons and excess fat, rinsing with water, and draining. The auxiliary ingredients include salt, white sugar, compound phosphate, soy protein isolate, acetylated distarch phosphate, ice water, and compound crispness improver. Each component is weighed according to the preset weight ratio and set aside.

3. The efficient frying process for crispy, low-fat prepared chicken products according to claim 1, characterized in that: In the low-temperature chopping step, the raw meat is first chopped at a low speed of 800-1200 r / min for 3-5 minutes, and then ice water and compound crispness improver are added and chopped at a high speed of 2800-3200 r / min for 8-12 minutes. After the high-speed chopping is completed, the material temperature is controlled between 4-8℃.

4. The efficient frying process for crispy, low-fat prepared chicken products according to claim 1, characterized in that: The gradient vacuum intermittent tumbling is carried out in a tumbling machine with a vacuum of -0.06MPa to -0.08MPa, with a total tumbling time of 20 to 45 minutes. The operating mode is to tumble for 10 minutes, then pause and let it stand for 5 minutes, and repeat this cycle 2 to 4 times.

5. The efficient frying process for crispy, low-fat prepared chicken products according to claim 4, characterized in that: After tumbling, the material is left to stand in a closed settling chamber at a temperature not exceeding 10°C for 8 to 10 hours. The molding process uses a continuous molding machine to press the blank into block, strip, or block structure, with the molding pressure maintained within the range of 0.3 to 0.6 MPa.

6. The efficient frying process for crispy, low-fat prepared chicken products according to claim 5, characterized in that: After molding, the blank is directly sent into a low-temperature setting chamber with a temperature of 0-4℃ and kept still for 20-40 minutes for pre-curing treatment, so that a continuous and dense protein curing layer is formed on the surface of the blank.

7. The efficient frying process for crispy, low-fat prepared chicken products according to claim 1, characterized in that: The two-stage differential temperature frying is divided into a first stage of low-temperature shaping frying and a second stage of high-temperature crisping frying. The first stage frying temperature is 145-155℃ and the frying time is 1.5-2.5 minutes. The second stage frying temperature is 165-175℃ and the frying time is 0.8-1.5 minutes.

8. The efficient frying process for crispy, low-fat prepared chicken products according to claim 1, characterized in that: The gradient clean air cooling system adopts a three-stage progressive cooling channel with an inlet temperature of 20-25℃, a middle section temperature of 10-15℃, and an outlet temperature of 0-5℃. The product runs in the air cooling channel for 3-6 minutes.

9. The efficient frying process for crispy, low-fat prepared chicken products according to claim 1, characterized in that: The ultra-low temperature quick-freezing uses a tunnel-type single-freezing machine with a constant freezing temperature of -32℃ and a quick-freezing time of 40 to 65 minutes. After quick-freezing, the core temperature of the product is no higher than -18℃, and it is stored in a low-temperature cold storage at -18℃ or below after packaging.

Images