A processing technology for restoring the shape of pre-prepared cooked meat products, such as duck intestines and duck esophagus.

Abstract

This invention relates to the field of pre-prepared poultry by-product meat processing technology. The invention discloses a processing technology for restoring the shape of pre-prepared duck intestines and esophagus, including the following steps: S1, placing fresh duck intestines and esophagus in a container, adding water to soak and stir for 5-20 minutes, then removing them to obtain the cleaned raw materials; S2, placing the cleaned raw materials in a mixed aqueous solution of compound phosphate and papain for at least one marinating. This invention employs segmented tenderizing and water-locking, alkaline soaking combined with vacuum shaping with preservative water, resulting in a full and non-collapsed finished product that can be cooked immediately after opening the bag, eliminating the need for pre-processing in stores and shortening serving time. Only a short, low-temperature blanching process results in minimal water loss, a crisp and tender texture, and no sulfurous odor caused by high temperatures. Natural sorghum red is used for simultaneous dealkalization and coloring, closely resembling the color of fresh produce. Combined with surround-type low-temperature ultraviolet sterilization and preservative water, shelf life is extended. The standardized process facilitates mass production and comprehensively overcomes various defects of traditional raw-freezing and cooked-freezing processes.

Description

Technical Field

[0001] This invention relates to the field of pre-prepared poultry by-product meat processing technology, specifically a processing technology for restoring the morphology of pre-prepared meat products such as duck intestines and duck esophagus. Background Technology

[0002] Pre-prepared processed meat products are non-ready-to-eat products made from fresh (frozen) livestock and poultry meat or their by-products through processes such as cleaning, marinating, conditioning, and packaging. In recent years, poultry by-products, represented by duck intestines and duck esophagus, have become frequently used ingredients in hot pot, maocai, and other catering formats due to their crisp and tender texture and plump appearance after being cooked in hot pot. Their industrial processing technology has attracted increasing attention.

[0003] Currently, the industrial processing of duck intestines and duck esophagus mainly employs two traditional processes. The first is the raw material quick-freezing process, where fresh products are washed and directly frozen for storage. The final product requires multiple steps including thawing, marinating, and cooking, taking over 30 minutes to prepare. Furthermore, significant juice loss occurs after thawing, resulting in a noticeable deterioration in taste. The second is the traditional cooked-frozen process, where fresh products are cooked at high temperatures and then frozen or refrigerated. Reheating at the final product allows for immediate consumption. However, high-temperature processing leads to a water loss rate as high as 30%-40%, resulting in tough, fibrous meat after reheating, along with an unpleasant "canned" taste and sulfurous odor. The product's color is grayish-brown, significantly different from the appearance of fresh products. Therefore, we propose a pre-prepared processing technology to restore the shape of duck intestines and duck esophagus, addressing the aforementioned problems. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a processing technology for restoring the shape of pre-prepared and seasoned meat products such as duck intestines and duck esophagus. This technology solves the problems of existing raw frozen duck intestines and duck esophagus thawing and dehydration, cumbersome store pre-processing, and traditional cooked products losing moisture and becoming dry, having a strong odor, dark color, and collapsing shape at high temperatures.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a processing method for restoring the shape of pre-prepared cooked meat products, specifically duck intestines and duck esophagus, comprising the following steps:

[0006] S1. Place fresh duck intestines and fresh duck esophagus in a container, add water to soak and stir for 5-20 minutes, then remove them to obtain the cleaned raw materials.

[0007] S2. Place the cleaned raw materials in a mixed aqueous solution of compound phosphate and papain for at least one marinating, stirring during the marinating process, to obtain the marinated raw materials;

[0008] S3. After rinsing the marinated ingredients, blanch them in 90-95℃ water for 2-3 minutes until they are just cooked through, and you will get blanched ingredients.

[0009] S4. Soak the blanched raw materials in a sodium hydroxide aqueous solution, stirring during the soaking process to rehydrate them and obtain the rehydrated raw materials.

[0010] S5. Soak the soaked raw material in an aqueous solution containing the coloring agent sorghum red or compound sorghum red to obtain the colored raw material.

[0011] S6. The colored raw material is placed into a vacuum bag, and a conditioning water is injected. The bag is then vacuum-sealed to obtain a vacuum-packaged semi-finished product. The conditioning water contains water, sodium hydroxide, colorant, and preservative.

[0012] S7. The vacuum-packed semi-finished product is subjected to ultraviolet sterilization treatment to obtain the sterilized vacuum-packed finished product.

[0013] S8. Place the sterilized vacuum-packed finished product in a -5℃ environment to pre-cool to a center temperature of -0.5℃-0℃ to obtain the pre-prepared prepared duck intestines and duck esophagus.

[0014] Preferably, in step S2, the marinating process is performed twice, specifically including:

[0015] For the first marinating, add the cleaned raw materials to an aqueous solution of compound phosphate and papain, and marinate for 5-20 minutes;

[0016] For the second marinating, the raw materials that have undergone the first marinating are added again to an aqueous solution of compound phosphate and papain, and marinated for 5-15 minutes.

[0017] Preferably, in the aqueous solution of the compound phosphate and papain, the total amount of compound phosphate and papain added is 0.5%-3% of the total weight of the raw materials, and the mass ratio of compound phosphate to papain is (1-3):1.

[0018] Preferably, in step S4, the concentration of the sodium hydroxide aqueous solution is 0.5%-3% (w / w), the soaking time is 10-30 minutes, and the mass ratio of raw material to water during the soaking process is 1:3.

[0019] Preferably, in step S5, the coloring solution is sorghum red or a compound sorghum red made from sorghum red and beet red. The mass fraction of the colorant in the coloring solution is 0.1%-0.5%, the coloring time is 5-15 minutes, and sodium hydroxide dealkalization treatment is performed simultaneously with the coloring treatment.

[0020] Preferably, in step S6, the mass fractions of each component in the maintenance water are: 100 parts water, 0.02-0.1 parts sodium hydroxide, 0.05-0.2 parts colorant, and 0.01-0.05 parts preservative.

[0021] Preferably, in step S6, the vacuum degree after vacuum sealing is -0.08MPa to 0.1MPa.

[0022] Preferably, in step S7, the ultraviolet sterilization is a 360° surround strong ultraviolet sterilization, the sterilization time is controlled to be 5-30 seconds, and the ultraviolet intensity is 90-120μW / cm².

[0023] Preferably, in step S8, the pre-cooling time is 2-6 hours, so that the center temperature of the finished product reaches -0.5℃.

[0024] Preferably, the processing technology further includes actions performed after S8:

[0025] S9. Outbound packing: Pack the pre-cooled vacuum-packed finished products into foam boxes.

[0026] S10. When shipping or warehousing, refrigerated trucks shall be used for transportation when shipping and the goods shall be stored in a cold storage at -5℃ when warehousing.

[0027] Beneficial effects

[0028] This invention provides a processing method for restoring the shape of pre-prepared cooked meat products, specifically duck intestines and duck esophagus. Compared with existing technologies, it has the following advantages:

[0029] This pre-prepared meat product, duck intestines and duck esophagus, is processed using a process that restores their shape through segmented water-locking and tenderizing with phosphates and proteases, followed by alkaline soaking and shaping. It is then vacuum-sealed with maintenance water to ensure that the finished product remains plump and elastic even after long-term storage. It can be directly cooked after opening the bag without the need for thawing, rinsing, or marinating, significantly reducing the store's food preparation time.

[0030] This invention involves only a short blanching process at 90-95℃ to remove the raw meat, without deep cooking, which significantly reduces water loss. The finished product is crisp, tender, and chewy, without any dry or tough texture. It avoids prolonged high-temperature heating, reducing protein deterioration and decomposition, preserving the original fresh aroma of duck intestines and esophagus, and eliminating any unpleasant odors. It uses a combination of sorghum red and natural coloring agents to simultaneously dealkalize and protect the color, resulting in a finished product with a delicate and bright pink color that matches the appearance of fresh duck.

[0031] It employs 360° surround low-temperature ultraviolet sterilization, combined with maintenance water and compound preservatives, to extend the refrigerated shelf life without damaging the taste and appearance; the entire set of process parameters is standardized, which can be mass-produced on an assembly line, effectively solving all the pain points of the two existing mainstream processes, and has strong commercial adaptability. Detailed Implementation

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0033] A processing method for restoring the shape of pre-prepared cooked meat products, specifically duck intestines and duck esophagus, includes the following steps:

[0034] S1 puts fresh duck intestines and fresh duck esophagus into a food-grade cleaning container, adds enough water to completely submerge the raw materials, and continuously stirs and cleans for 5-20 minutes to fully remove feces, esophageal mucus, blood, and impurities from the intestines. After cleaning, it is taken out and drained to obtain the cleaned raw materials.

[0035] S2. After draining, the raw materials are immersed in a marinating solution containing compound phosphate and papain for at least one round of stirring and marinating; preferably, a two-stage marinating process is used to fully penetrate the interfibrillary spaces of the intestinal and esophageal walls, achieving deep tenderization and moisture retention.

[0036] For the first marinating step, immerse the raw materials in the compound marinating solution and continue stirring for 5-20 minutes.

[0037] For the second marinating, remove the marinated ingredients from the first marinating process and add them back into a fresh marinating solution with the same proportions. Stir and marinate for 5-15 minutes.

[0038] Marinating solution ratio limits: The total addition of compound phosphate and papain should be 0.5%-3% of the total weight of the raw materials; the mass ratio of compound phosphate to papain should be controlled at (1-3):1. The compound phosphate is a combination of food-grade sodium tripolyphosphate, sodium pyrophosphate, and sodium hexametaphosphate, which enhances the water-holding capacity of muscle cells and reduces water loss during subsequent blanching and storage; papain gently decomposes muscle fiber connective tissue, improving tenderness without damaging the intestinal structure and preventing the meat from becoming tough.

[0039] S3. Rinse the marinated raw materials briefly with clean water to remove any residual marinade. Then, blanch them in 90-95℃ constant temperature hot water for 2-3 minutes. This process only breaks down the surface protein, leaving the internal tissues semi-raw. Quickly remove and drain to obtain the blanched raw materials. Low-temperature, short-time blanching differs from traditional boiling water, as it only coagulates and fixes the surface layer, significantly reducing overall water loss and preventing complete denaturation and contraction of muscle fibers.

[0040] S4. Prepare a 0.5%-3% food-grade sodium hydroxide aqueous solution with a raw material to alkali solution mass ratio of 1:3. Immerse all the blanched raw materials in the alkali solution and stir continuously throughout the process. Soak for 10-30 minutes. The alkali solution gently dissolves the fibers of the intestinal and esophageal walls, stretches out the contracted folds, and restores the hollow, plump shape of the fresh raw materials, solving the problem of intestinal collapse in traditional processes.

[0041] S5. After soaking, there is no need for separate dealkalization with water. The product is directly immersed in the coloring solution for coloring, simultaneously completing the alkali neutralization and dealkalization process. The coloring solution uses single sorghum red, or a mixture of sorghum red and beet red; the total mass fraction of the coloring agent in the solution is 0.1%-0.5%, and the soaking time is 5-15 minutes. Sorghum red is a natural red coloring agent, giving duck intestines and esophagus a fresh, bright pink color, without any artificial synthetic pigment odor; beet red brightens the base color, preventing the finished product from turning yellow or gray; during the soaking process, the weak acid groups of the natural pigment neutralize residual sodium hydroxide on the surface of the raw materials, eliminating the need for a separate water washing and dealkalization process, simplifying the procedure.

[0042] S6. After coloring and draining, the duck intestines and esophagus are packaged into food vacuum bags. Special preservative solution is injected into the bags to completely submerge the raw materials, then vacuum-sealed. The vacuum level is controlled at -0.08MPa to 0.1MPa. The preservative solution is prepared in the following proportions by weight: 100 parts water, 0.02-0.1 parts sodium hydroxide, 0.05-0.2 parts colorant, and 0.01-0.05 parts food preservative. The preservative solution continuously wets the tube walls, maintaining their expanded and stretched shape, inhibiting fading and shrinkage during storage. A trace amount of alkali maintains the fiber swelling state, and the preservative effectively inhibits the growth of microorganisms inside the bag.

[0043] S7. Place the vacuum-sealed semi-finished product in a surrounding ultraviolet sterilization channel for all-round sterilization without dead angles; ultraviolet intensity 90-120μW / cm², sterilization time 5-30s. Low-temperature ultraviolet sterilization replaces high-temperature cooking sterilization, which will not damage the crisp and tender taste and full shape of the product, effectively kills microorganisms attached to the outer wall of the bag, and extends shelf life.

[0044] S8. After sterilization, the vacuum-packed semi-finished product is sent to a -5℃ constant temperature pre-cooling room for 2-6 hours. The center temperature of the finished product is controlled to be stable at -0.5℃-0℃ to complete the pre-cooling of the finished product. Low-temperature slow pre-cooling avoids rapid freezing, which may cause ice crystals on the tube wall to puncture the tissue and cause juice loss, and maintains the stable expansion and unfolding shape.

[0045] S9. After pre-cooling to the required standard, the vacuum-sealed finished product is packed into a foam box with an insulation layer. Ice packs are placed inside the box to assist in temperature control and avoid temperature fluctuations during transportation.

[0046] S10. The foam boxes are stored in a constant -5℃ low-temperature cold storage for long-term storage; shipment: sealed refrigerated and insulated transport vehicles are used for full cold chain delivery to catering stores.

[0047] Example

[0048] S1. Take 100kg of fresh duck intestines and duck esophagus mixed raw materials, soak them in clean water, stir and wash for 12 minutes, then take them out and drain.

[0049] S2. The total amount of pickling liquid added is 1.5% of the total weight of raw materials, and the ratio of compound phosphate to papain is 2:1; First pickling: stir for 12 minutes; Second pickling: stir for 10 minutes;

[0050] S3. Blanch in 92℃ hot water for 2.5 minutes, until the surface of the raw material is slightly tightened and cooked through, then remove immediately;

[0051] S4, sodium hydroxide aqueous solution mass fraction 1.5%, raw material alkali solution mass ratio 1:3, stir and soak for 20 min;

[0052] S5, compound sorghum red (sorghum red: beet red = 3:1), total colorant mass fraction of coloring solution is 0.3%, soak for coloring for 10 minutes, and neutralize and dealkalize simultaneously;

[0053] S6. Preservative water ratio: 100 parts water, 0.05 parts sodium hydroxide, 0.1 parts compound sorghum red, 0.03 parts potassium sorbate preservative; vacuum degree -0.09MPa sealing, the preservative water completely submerges the raw materials;

[0054] S7, UV intensity 100μW / cm², surround irradiation for 15s;

[0055] Pre-cooling in a -5℃ cold storage for 4 hours (S8) resulted in a stable core temperature of the finished product at -0.3℃.

[0056] S9. Pack in a foam box with ice in a sealed container;

[0057] S10, stored in a cold storage at -5℃, and shipped via refrigerated and insulated trucks using cold chain delivery.

[0058] Finished product test results: Appearance: The intestines are stretched and hollow, without collapse or wrinkles, and the color is pink and uniform; Taste: After 10 seconds of hot pot, they are crisp, tender and chewy, without being tough or mushy; Water loss rate: 7.2%; Storage: After 60 days of storage at -5℃, there is no blackening, stickiness or fading, and no odor; Store use: Open the bag and cook directly without any pretreatment.

[0059] This method uses phosphate and protease to lock in moisture and tenderize the product, then soaks it in alkaline solution to set its shape, and uses a vacuum-sealed water solution to protect its shape. The finished product remains plump and elastic even after long-term storage. It can be directly cooked after opening the bag without the need for thawing, rinsing, or marinating, which greatly reduces the store's food preparation time.

[0060] This invention involves only a short blanching at 90-95℃ to remove the raw ingredients, without deep cooking, which significantly reduces water loss and results in a crisp, tender, and chewy finished product without a dry or tough texture.

[0061] Avoid prolonged high-temperature heating, reduce protein deterioration and decomposition, preserve the original fresh aroma of duck intestines and duck esophagus, and eliminate unpleasant odors;

[0062] Using sorghum red compound natural coloring agent to simultaneously dealkalize and protect the color, the finished product has a delicate and bright pink color that is consistent with the appearance of fresh produce.

[0063] It employs 360° surround low-temperature ultraviolet sterilization, combined with maintenance water and compound preservatives, to extend the refrigerated shelf life without damaging the taste and appearance; the entire set of process parameters is standardized, which can be mass-produced on an assembly line, effectively solving all the pain points of the two existing mainstream processes, and has strong commercial adaptability.

[0064] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A processing method for restoring the shape of pre-prepared seasoned meat products, specifically duck intestines and duck esophagus, characterized in that: Includes the following steps: S1. Place fresh duck intestines and fresh duck esophagus in a container, add water to soak and stir for 5-20 minutes, then remove them to obtain the cleaned raw materials. S2. Place the cleaned raw materials in a mixed aqueous solution of compound phosphate and papain for at least one marinating, stirring during the marinating process, to obtain the marinated raw materials; S3. After rinsing the marinated ingredients, blanch them in 90-95℃ water for 2-3 minutes until they are just cooked through, and you will get blanched ingredients. S4. Soak the blanched raw materials in a sodium hydroxide aqueous solution, stirring during the soaking process to rehydrate them and obtain the rehydrated raw materials. S5. Soak the soaked raw material in an aqueous solution containing the coloring agent sorghum red or compound sorghum red to obtain the colored raw material. S6. The colored raw material is placed into a vacuum bag, and a conditioning water is injected. The bag is then vacuum-sealed to obtain a vacuum-packaged semi-finished product. The conditioning water contains water, sodium hydroxide, colorant, and preservative. S7. The vacuum-packed semi-finished product is subjected to ultraviolet sterilization treatment to obtain the sterilized vacuum-packed finished product. S8. Place the sterilized vacuum-packed finished product in a -5℃ environment to pre-cool to a center temperature of -0.5℃-0℃ to obtain the pre-prepared prepared duck intestines and duck esophagus.

2. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: In step S2, the pickling process is performed twice, specifically including: For the first marinating, add the cleaned raw materials to an aqueous solution of compound phosphate and papain, and marinate for 5-20 minutes; For the second marinating, the raw materials that have undergone the first marinating are added again to an aqueous solution of compound phosphate and papain, and marinated for 5-15 minutes.

3. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: In the aqueous solution of the compound phosphate and papain, the total amount of compound phosphate and papain added is 0.5%-3% of the total weight of the raw materials, and the mass ratio of compound phosphate to papain is (1-3):

1.

4. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 2, characterized in that: In step S4, the concentration of the sodium hydroxide aqueous solution is 0.5%-3% (w / w), the soaking time is 10-30 minutes, and the mass ratio of raw material to water during the soaking process is 1:

3.

5. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: In step S5, the coloring solution is sorghum red or a compound sorghum red made from sorghum red and beet red. The mass fraction of the colorant in the coloring solution is 0.1%-0.5%, the coloring time is 5-15 minutes, and sodium hydroxide dealkalization treatment is carried out simultaneously with the coloring treatment.

6. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: In S6, the mass fractions of each component in the maintenance water are: 100 parts water, 0.02-0.1 parts sodium hydroxide, 0.05-0.2 parts colorant, and 0.01-0.05 parts preservative.

7. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: In step S6, the vacuum degree after vacuum sealing is -0.08MPa to 0.1MPa.

8. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: In S7, the ultraviolet sterilization is a 360° surround strong ultraviolet sterilization, the sterilization time is controlled to be 5-30 seconds, and the ultraviolet intensity is 90-120μW / cm².

9. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: In S8, the pre-cooling time is 2-6 hours, so that the center temperature of the finished product reaches -0.5℃.

10. The processing technology for restoring the morphology of pre-prepared cooked meat products (duck intestines and duck esophagus) according to claim 1, characterized in that: The processing technology also includes steps performed after S8: S9. Outbound packing: Pack the pre-cooled vacuum-packed finished products into foam boxes. S10. When shipping or warehousing, refrigerated trucks shall be used for transportation when shipping and the goods shall be stored in a cold storage at -5℃ when warehousing.