METHOD FOR PRODUCE A POTATO MOLD AND POTATO MOLD

Description

[0001] The invention relates to a method for producing a potato molding.

[0002] The dumpling (plural: dumplings) or knödel (plural: dumplings) is a dish made from dough that is eaten as a main course, side dish, or in soup. The two terms "dumplings" and "knödel" actually refer to the same side dish (in southern Germany, they are primarily called "knödel"). Round shapes are called "klöße," while other shapes are called "knödel."

[0003] Frozen, partially pre-fried, potato products are available in grocery stores (Database GNPD [Online] MINTEL: (a) January 15, 2021, "Pre-Fried Dauphine Potatoes, XP55970262; Database Acc. No. 8410915; (b) November 3, 2020, "Real Dauphine Potatoes", XP055970285, Database Acc. No. 8235449; (c) June 29, 2018, "Alphabet Fries", XP055970297, Database Acc. No. 5781633; (d) October 31, 2013, "Halloween Potato Shapes", XP055970313, Database Acc. No. 2234283).

[0004] JPH11018713 A1 relates to a process for making dumplings from potatoes or pumpkin. The process includes peeling the pumpkin or potato skin, mixing the peeled pumpkin or potato with potato starch and corn starch as auxiliary materials, stirring, mixing evenly, feeding the mixture into a molding machine after the mixture has become viscous, forming the mixture into a solid, easily edible shape, introducing the formed material into a heater, heating, stopping the heating, cooling the heated material to approximately ≤20 degrees Celsius, and freezing the material to obtain the final product.

[0005] When exposed to heat, starch can physically bind, swell, and gelatinize many times its own weight in water. When heated with water, the starch swells at 47–57 °C, the layers burst, and at 55–87 °C (potato starch at 62.5 °C, wheat starch at 67.5 °C), starch paste forms. This paste has different stiffnesses depending on the type of starch (cornstarch paste has greater stiffness than wheat starch paste, and wheat starch paste has greater stiffness than potato starch paste). A gelatinous mass is formed.

[0006] At cool temperatures, this effect slowly disappears and the water is released again - this is called retrogradation.

[0007] When preparing potato dumplings, the starchy dumpling dough is heated in a water bath for several minutes, depending on the size of the dumpling. This causes the dumpling to absorb water uncontrollably. If gelatinization hasn't yet begun on the inside, the outer skin may have already swelled so much that the dumpling develops an unpleasant gelatinous layer. If one wanted to preserve such a dumpling, the high water content would cause the dumpling to lose its consistency during preservation, for example, through refrigeration.

[0008] To date, gelatinized dumpling dough cannot be "revived," meaning that dumplings that have already been cooked can only be reheated with considerable loss of quality.

[0009] To facilitate domestic production, dumpling doughs are currently available in which the starch is ungelatinized. However, due to the lack of structural substances, these doughs cannot be permanently formed. Indeed, such a formation would not be permanent. This, however, means that both the forming of the dumpling and the entire cooking process have to be carried out by the customer, which is a time-consuming task.

[0010] The object of the invention is to eliminate or at least reduce the problems of the prior art. In particular, it is intended to provide a dumpling mold that can be pre-cooked and revived without any loss of quality while retaining its shape.

[0011] "Revivable" means that the potato mold can be heated in such a way that a fluffy consistency and flavor similar to a conventionally prepared dumpling is achieved.

[0012] This problem is solved by a method having the features of the independent claims.

[0013] Thus, a first aspect of the invention relates to a method for producing a potato molding according to claim 1. Advantageous embodiments are the subject matter of the dependent claims.

[0014] The method according to the invention is characterized by the following steps: a) Providing a raw potato mass comprising all parts of raw, peeled and crushed potatoes and / or a technically prepared equivalent selected from potato flour, starch flour, potato fibers or dried mashed potatoes, b) Providing a potato mass comprising cooked, peeled and crushed potatoes and / or a technically prepared equivalent selected from potato flour, starch flour, potato fibers or dried mashed potatoes, c) Blending the two masses to form a mixture, d) Cooling the mixture to a temperature of 4 - 15°C, e) Forming a shaped part from the cooled mixture, f) Thermally treating the shaped part by means of a hot steam process to achieve a core temperature in the shaped part of at least 65°C, whereby gelatinization of potato starch components is achieved, so that a water content in the shaped part decreases after the thermal treatment and a blank is formed.

[0015] First, a raw potato mass is prepared, comprising all parts of raw, peeled, and chopped potatoes and / or a technically prepared equivalent. The crushing takes place in particular in such a way that potato fibers remain in the mass, preferably by grating or shredding.

[0016] Furthermore, a potato mass is provided, comprising cooked, peeled, and chopped potatoes and / or a technically prepared equivalent thereof. Crushing or squeezing is preferably used for the crushing. It is further advantageous if the cells are not destroyed, so that the potato starch remains in the cells to prevent unwanted gelatinization. Therefore, pureeing, for example, with a rotating cutting blade or stirring rod, is less preferred.

[0017] The two masses are then blended into a mixture. Optionally, additional ingredients such as potato flour, spices, flour, eggs, and / or milk can be added to the mixture.

[0018] Before forming the mass into a molded part, the mixture is cooled to a temperature between 4 and 15°C. This allows the molded part to be formed in a very precise shape. Forming is preferably carried out by pressing the mixture into a negative mold. For large-scale production, industrially accessible molding using a mold plate machine or drum molding machine is preferred.

[0019] According to the invention, the molded mass is subsequently thermally treated in order to gelatinize starch components in the mixture, wherein the thermal treatment is carried out in such a way that a water content in the molded part decreases after the thermal treatment.

[0020] This results in a dumpling with a rubbery consistency. This consistency is created by the gelatinization of the starch, which leads to the bonding and networking of neighboring particles. However, since no additional water could be absorbed by the mixture, the dumpling does not have a gel-like layer, unlike conventional cooked dumplings. In addition, a coating is applied to the This, in turn, means that the shape of the molded part is almost identical to that of the blank. This opens up a variety of new shapes for potato molds, which differ particularly from those of a normal round dumpling, but also from the well-known duchess potatoes, croquettes, and the like.

[0021] Furthermore, the homogeneous and almost complete gelatinization induces a degradation of digestible starch in the blank. It has been shown that the gelatinization according to the invention leads to an increased fiber content and a reduced proportion of usable carbohydrates in the ready-to-eat final product.

[0022] Advantageously, the molded part according to the invention exhibits an increased shelf life. Experts have confirmed that, when the molded part is packaged without oxygen exclusion, deep freezing is not necessary to ensure a shelf life of 3 or even 6 months. Rather, normal refrigeration is sufficient. The molded part is thus preserved by the manufacturing process according to the invention in such a way that no chemical or other preservatives are required. Furthermore, no increased requirements are placed on transport, such as the uninterrupted maintenance of a (deep) cold chain.

[0023] The thermal treatment is advantageously carried out using a hot steam process, in particular using a combi steamer or spiral cooker.

[0024] A combi steamer, spiral cooker, or convection steamer combines the functions of a steamer, in which food is cooked in a saturated steam atmosphere, with a convection oven, in which cooking occurs with circulating air. Since these appliances allow for a wide range of temperature and humidity settings, they allow for full control of the cooking environment. Furthermore, the relatively high fan speed and the condensation of steam on the food allow for comparatively short cooking times and thus gentle preparation of the food.

[0025] Due to the steam content when using a combi steamer or spiral cooker in the process according to the invention, a small amount of water is released from the mass of the molded part, approximately 2%. To minimize water absorption, the cooking time is kept as short as possible, and the water saturation is set between 60% and 80%. It has been shown that steaming in a temperature range of 115°C to 145°C, particularly between 120°C and 140°C for 75 to 100 seconds, and especially for 85 to 95 seconds, for a 1 cm thick molded part results in sufficient gelatinization with a largely constant water content in the mass of the molded part.

[0026] The added steam prevents the gelatinized blank from drying out and hardening. In this design, water loss and resulting hardening are achieved during a subsequent cooling process (weight loss of approximately 6%).

[0027] If the molding is carried out using a negative mold, the molded part can optionally remain in this negative mold during cooking in the combi steamer. However, the cooking times and / or temperatures are preferably adjusted, especially increased, since the material of the negative mold influences the cooking process due to its inherent thermal conductivity. For example, using a silicone mold as a negative mold at the same temperature requires doubling the cooking time in the combi steamer.

[0028] Especially when using industrial equivalents, a portion of uncooked potatoes in the mass can be omitted. This essentially provides the potato fibers required for the formation of network-like, branched structures for stabilization.

[0029] Industrially produced equivalents in this case are preserved potato extracts, such as potato or starch flour, potato fibres or dried mashed potatoes.

[0030] In a preferred embodiment of the method according to the invention, the raw potato mass comprises a proportion in the range of 10 to 75%, preferably in the range of 10 to 55%, in particular in the range of 20 to 50% of the mixture. For fresh produce, this primarily depends on the potato variety, since the starch and water content, as well as the starch composition, vary depending on the variety. Naturally, this is more predictable for industrially produced equivalents.

[0031] It is particularly advantageous to preserve and temporarily store the blank, particularly by cooling, freezing, vacuum packaging and / or similar means.

[0032] Before consumption, the raw potato dumpling requires a "revival" process. "Revival" means that the potato dumpling can be heated in such a way that a fluffy texture and flavor similar to a conventionally prepared dumpling are achieved.

[0033] Revitalization preferably occurs in a further process step, in which the dumpling is revived by applying heat, particularly by frying, baking, toasting, or in a hot water bath. Depending on the process chosen, the dumpling is either tender on the outside and light on the inside (combination of combi steamer for dumpling production and water bath for revitalization) or with a fine crust and light on the inside.

[0034] Further preferably, the heat exposure during revival takes place for a period of 1.5 to 10 minutes, depending on the selected method. The preferred time period for deep-frying is in the range of 1.5 to 5 minutes, in particular in the range of 2 to 3 minutes.

[0035] The molded part preferably has a thickness in the range of 1 to 5 cm. It has been shown that, particularly at the specified temperatures and times, optimized potato molds are achieved with regard to homogeneity and cooking results. Naturally, the lower limits regarding cooking time and / or temperature should be selected for thinner molded parts, and for thicker molded parts, vice versa.

[0036] It is advantageous to flour the molded part and / or blank before further processing. This stabilizes the water balance, prevents the molded parts or blanks from sticking together, which is already significantly reduced compared to conventional processes, and promotes the formation of a crust with the desired consistency when exposed to heat without water or steam. The formation of the crust can be influenced or controlled by the type of flouring, particularly the coarseness, distribution, and composition of the flour or potato flour.

[0037] In a preferred embodiment, the potato molding produced according to the invention has a ring-shaped or animal-shaped, heart-shaped, star-shaped, etc. basic shape with a maximum thickness or height of 5 cm, in particular 3 cm. The ring-shaped potato moldings, also referred to as dumpling donuts, preferably have an outer diameter of 7 to 10 cm, in particular 8 cm, with an inner diameter of a through opening being 1.5 to 3 cm.

[0038] Alternatively, the potato molding has the shape of a bowl with a homogeneous or inhomogeneous wall thickness of 1 to 3 cm.

[0039] The described embodiments can be advantageously combined with one another, unless explicitly mentioned in individual cases.

[0040] The invention is described in more detail below using examples. Example 1: Production of a blank from 90g potato mass and in the shape of a donut (outer diameter = 8.5 cm / Mass cross-section = 2.5 cm) Manufacturing process for the frying process (comparison)

[0041] The potato mass is prepared to the required consistency.

[0042] The potato mass is processed while chilled.

[0043] The potato mass is pressed into a (donut) shape.

[0044] The potato mass is removed from the mold.

[0045] The pressed blank is placed in a deep fryer.

[0046] The oil temperature should be between 150°C and 160°C.

[0047] After reaching a crispy surface and a minimum temperature of 65°C in the core, the blank (in donut shape) is removed from the oil bath (for the production of a frozen product after approx. 3 minutes depending on the power of the fryer).

[0048] The product is chilled / frozen and packaged. Preparation of the fried dumpling donut using a deep fryer

[0049] Deep fry frozen product at 150 to 175°C for 3-4 minutes. Preparation of the fried dumpling donut by baking

[0050] Bake frozen product in the oven at 220°C for 18-20 minutes depending on the appliance setting. Inventive manufacturing process using combi steamer or spiral oven

[0051] The potato mass is prepared to the required consistency.

[0052] The potato mass is processed while chilled.

[0053] The potato mixture is placed into a (donut) mold, floured or unfloured, and can either be left in or removed again.

[0054] The mixture is placed with / without a mold in a combi steamer or spiral oven.

[0055] The combi steamer or spiral oven is switched on using the hot steam method at 130°C and a water vapor saturation of approximately 60% for 4 minutes.

[0056] Complete gelatinization is achieved at a core temperature of 65°C.

[0057] The breading achieves a similar crispy surface effect as when deep-fried.

[0058] The product is removed from the combi steamer and removed from the mold after sufficient cooling to approx. 40°C.

[0059] The product can now be packaged chilled / frozen. Preparation of the dumpling donut produced by means of a hot steam process by means of a deep fryer

[0060] Deep fry frozen product at 175°C for 3-4 minutes. Preparation of the dumpling donut produced by means of a hot steam process by baking

[0061] Bake frozen product at 220°C for 18-20 minutes depending on the appliance setting.

[0062] Mashed potatoes (mashed potatoes) can be molded under special conditions by adding a portion of raw potato combined with potato flour (starch) and thawed after freezing without any significant loss of quality. The raw potato portion is required in its natural form in grated form (2-5 mm) or from industrially produced potato fiber. This mixture is then manually pressed or extruded at a temperature between 4 and 15°C to produce a shaped blank with a dough diameter of at least 2 to a maximum of 5 cm. The resulting intermediate product is then subjected to a first deep-frying process at 150-160°C for 2-3 minutes for comparison purposes, depending on the shape and dough diameter. The final product can then be frozen or, after a second deep-frying process of 3-4 minutes, offered for consumption.

[0063] According to the invention, the superheated steam process (combi steamer) is advantageous for commercial purposes instead of the initial deep-frying process. As a guideline, approximately 90 seconds per 1 cm of dough diameter at 130°C can be assumed to reach a core temperature of 65°C necessary for complete pasting. However, the shape of the product and the molder must be taken into account. For example, using a silicone mold requires twice as much time due to the reduced thermal conductivity.

[0064] After appropriate cooling (from approximately 40°C), the blank retains its shape and can be stored in the refrigerator or freezer, breaded or unbreaded, for the final consumer. This ensures an extended shelf life of the product.

[0065] The manufacturing process, as a chilled / frozen blank, offers aesthetic (variety of shapes), time-saving, energy-saving and health-promoting advantages for the catering industry and the private end consumer.

[0066] Using the process described above, a consumer, for example, requires approximately 3 minutes of preparation time at 175°C in a deep fryer for a 90g shaped donut. A dumpling dish can then be prepared in a very short time, for example, by placing smoked salmon with horseradish and dill in the center of the plate. Current preparation times range from 18 to 30 minutes using a prepared, frozen dumpling. Additional time must be allowed for when preparing from scratch.

[0067] Otherwise, the raw material can be prepared in the oven. For example, a dinosaur-shaped dumpling (approx. 90g) can be baked at 200°C for 15-18 minutes and then served.

[0068] It is also worth mentioning that the dumpling according to the invention or the potato molding according to the invention keeps the food warm for longer due to its compacted surface.

[0069] The desired shape is achieved by adding potato fibers (natural or industrial), which are subjected to increased pressure at a corresponding dough temperature. The subsequent heating process forms a stable outer framework through water removal and starch hardening. Inside the blank, the network structure, which is derived from the 20-50% raw potato content, is activated at a temperature of 62.3°C. This means that the starch granules contained within swell, burst, and liquefy. This leads to a gelatinization of the potato fibers, thus achieving a dimensionally stable inner structure. Water loss during the production process (weight loss of approximately 10%) supports the solidification of the blank.

[0070] With the superheated steam process, the dough doesn't need to be refrigerated. The cooking time for a dough blank naturally depends on the shape and thickness of the blank. This can be cooked with or without a mold (metal, silicone).

[0071] The temperature during steaming is between 120 and 150°C, with 60% to 80% water saturation. Steaming continues until the product reaches a core temperature of at least 65°C. Due to the added steam, the water loss from the product is 2% by weight.

[0072] This prevents the gelatinized blank from drying out and hardening.

[0073] In this process, water loss with resulting solidification occurs during the subsequent cooling process (weight loss approx. 6%).

[0074] Cooling takes place at a temperature of approximately -40°C for 15 minutes in a blast freezer. This achieves a core temperature of +1°C and an external temperature (surface temperature) of -1°C for the blank. Finally, the product is packaged. The product adjusts to the desired transport and storage temperature of approximately 4 to 7°C in the packaging.

[0075] A 90g dumpling heart with a thickness of 3.5cm and an outer diameter of 6cm is pressed through a drum forming machine or molding machine, then heated in a spiral cooker or combi steamer at 125°C with 65% steam content for 8 minutes to an internal temperature of approximately 80°C. A weight loss of 2% is observed. It is then cooled in a blast freezer at approximately -40°C until the product reaches an internal temperature of +1°C and an external temperature of -1°C. Packaging takes place.

Claims

1. A method for producing a molded potato product, comprising the following steps in the indicated order a) providing a raw potato mass comprising all parts of raw, peeled and chopped potatoes and / or of a technically prepared equivalent selected from potato flour, starch flour, potato fibres or dried mashed potatoes, b) providing a potato mass comprising cooked, peeled and chopped potatoes and / or of a technically prepared equivalent selected from potato flour, starch flour, potato fibres or dried mashed potatoes, c) blending the two masses to form a mixture, d) cooling the mixture to a temperature of 4 - 15 °C, e) shaping a molded product from the cooled mass, f) thermally treating the molded product by means a superheated steam method to achieve a core temperature in the molded product of at least 65°C, whereby a gelatinization the potato starch components is caused, so that the water content in the molded product decreases after heat treatment and a blank is produced.

2. The method according to claim 1, wherein the thermal treatment in step f) is carried by means of a combi-steamer or spiral stove.

3. The method according to any one of the preceding claims, wherein the potato raw mass has a proportion in the range from 10 to 75 %, preferably in the range from 10 to 55 % and in particular in the range from 20 to 50 % of the mixture.

4. The method according to any one of the preceding claims, further comprising a step g) in which the blank is revived by heat application, in particular by means of deep-frying, baking, toasting or in a hot water bath, in order to provide a ready-to-eat product.

5. The method according to claim 4, wherein the heat application takes place for a duration of 3 to 10 min.

6. The method according to any one of the preceding claims, wherein the molded potato product has a thickness in the range from 1 to 5 cm.

7. The method according to one of claims 4 to 6, wherein the deep-frying in step g) is carried out at a temperature in the range from 140 to 170 °C, in particular in the range from 150 to 160 °C and / or for a period of time in the range from 1.5 to 4 min, in particular 2 to 3 min.

8. The method according to any one of the preceding claims, wherein the molded product after step e) is floured before further processing.