METHOD FOR PRODUCE FRIED POTATOES AND FRIED POTATOES OBTAINED BY THIS METHOD

Description

OBJECT OF THE INVENTION

[0001] The present invention relates to a process for the preparation of potato crisps and to potato crisps obtained by this process. It falls within the technical field of the food industry.BACKGROUND OF THE INVENTION

[0002] Nowadays the preparation of French fries, especially in food establishments, involves frying potatoes in portions, either by cutting the portions on site from whole potatoes after peeling, usually, or more frequently, especially in fast food establishments, by frying on site portions of whole potatoes previously cut into strips or wedges (and peeled if necessary), and frozen.

[0003] This approach limits the possibility of enhancing the flavour of the chips obtained by additives.

[0004] In order to overcome this drawback, the applicant also holds invention patent P201731042, relating to a process for the preparation of French fries and to French fries obtained by said process, where the process comprises the following steps carried out in a central kitchen: shape by cutting whole potatoes into potato wedges, fry the potato wedges, inject one or more sauces to the fried potato wedges, freeze the potato portions chopped, fried and injected with one or more sauces; and packaging for distribution; comprising a preparation stage at the place of consumption comprising heating the potato wedges, frying them, injecting them with one or more sauces and freezing them; and where the potato crisps obtained, comprising heated potato portions, previously obtained by cutting up whole potatoes, frying and injecting them with one or more sauces, are preferably in the form of wedges, and the sauces used could be any, for example: sweet sauces, savoury sauces, sweet and sour sauces, cheese-based sauces (Cheddar, Cabrales, etc.), spicy sauces.

[0005] DE 198 59 362 A1 discloses a fried potato stick (potatochip) having an edible filling, wherein the potato stick can be designed with a blind hole extending from one end, which is filled with the edible filling and which is closed at the said end with a stopper (cap) made of potato material. It further discloses that the potato sticks are shock-frozen after frying.

[0006] This invention makes it possible to add different flavours to the potatoes, with the additional advantage that the final preparation of the potatoes on site is much quicker, as it only requires heating, not frying.

[0007] However, sometimes during the preparation stage at the place of consumption, which involves heating the portions of sliced, fried, injected with one or more sauces and frozen potatoes, excessive heat during this stage could cause the filling to come out due to too rapid a rise in temperature, which makes it necessary to be careful and to carefully control the temperature at this stage.

[0008] This drawback is solved by using the process of this invention, which results in a potato that has better properties against this problem.DESCRIPTION OF THE INVENTION

[0009] The process for preparation of French fries of the invention comprises the following stages carried out in a central kitchen: a) heat treatment of the potato by single-layer immersion cooking, vacuum cooking or steaming, at a temperature of between 80-90°C for 7 minutes, b) subject the potato heated in a) to a scan to record its shape and size, c) determine the optimum position of some cuts on the potato model obtained in b) in order to subsequently form a selected number of portions, d) determine on each predetermined portion obtained in c) the position of a hole with a single-entry hole, to be filled later, e) carry out the mechanical emptying of the identified holes in d) by means of a tubular blade to retain inside the potato body or core corresponding to the hole when exiting, recovering a lid for each hole by recovering one of the ends of the extracted core, f) inject or mechanically insert a filler into each hole obtained in e), and plugging each hole with the corresponding lid, g) carry out the mechanical cutting of the injected potato into pre-determined portions, without affecting the determined hollows and filling, h) pre-fry the portions obtained in g), i) cool and deep-freeze of stuffed and pre-fried portions obtained in h), and j) pack already deep-frozen portions, and store and transport to the place of final preparation under appropriate refrigeration conditions; comprising a preparation step of the packed portions at the place of consumption, wherein said preparation step comprises heating the frozen, pre-fried and deep-frozen injected portions; and wherein a granular or powdery coating is applied to the portions before the pre-frying step h).

[0010] The French fries of the invention are characterised in that they comprise wedge-shaped potato portions having a cooked inner texture obtained by steaming at 80-90ºC for at least 5 minutes and a pre-fried outer texture with a granular or powdery coating, said portions comprising a hole with a single-entry hole, a filling and a potato lid obtained from the extracted core.

[0011] The potatoes, prior to the start of the process, are received, for example, in large bags of 1000 kgs, and are stored at a maximum temperature of 5-10 degrees for a maximum of 72 hours before entering the production line, for example by forklift truck or overhead crane, from where they are unloaded into the feed hopper of the cooking line. For its part, packaging for distribution can be done in different formats: for the mass distribution channel, catering and private individuals and any other sector that may require it, while the heating corresponding to the preparation at the place of consumption can be done by any usual means in the kitchen: oven, microwave oven, immersion in oil, hot display case or vending machine, etc.

[0012] The filler can be any flavoured preparation or mixture of substances, whether in liquid, viscous, semi-viscous, solid or semi-solid form, capable of being injected or introduced mechanically.

[0013] With the process we obtain potato portions with or without skin and heated, previously obtained by heat treatment of single-layer immersion cooking, vacuum cooking or steaming, scanning by artificial vision to record their shape and size , determination on the model of the optimum position of the cuts to form a selected number of segments and the position on each portion of a hole with a single entrance hole, injecting or mechanically inserting each hole with a filling and covering the entrance hole with a potato lid recovered when the hole was made, cutting the portions, wrapping them in spicy coating and pre-frying them, deep-freezing the portions and packaging them for preservation and transport to the place of heating for consumption, achieving subsequent rehydration in a frying pan, fryer, oven or microwave oven, hot display case or vending machine, practically immediately. This results in an explosion of flavour on the consumer's palate.DESCRIPTION OF A PRACTICAL EMBODIMENT OF THE INVENTION

[0014] The process for preparation of French fries of the invention comprises the following stages carried out in a central kitchen: a) heat treatment of the potato by single-layer immersion cooking, vacuum cooking or steaming, at a temperature of between 80-90°C for 7 minutes, b) subject the potato heated in a) to a scan to record its shape and size, c) determine the optimum position of some cuts on the potato model obtained in b) in order to subsequently form a selected number of portions, d) determine on each predetermined portion obtained in c) the position of a hole with a single-entry hole, to be filled later, e) carry out the mechanical emptying of the identified holes in d) by means of a tubular blade to retain inside the potato body or core corresponding to the hole when exiting, recovering a lid for each hole by recovering one of the ends of the extracted core, f) inject or mechanically insert a filler into each hole obtained in e), and plugging each hole with the corresponding lid, g) carry out the mechanical cutting of the injected potato into pre-determined portions, without affecting the determined hollows and filling, h) pre-fry the portions obtained in g), i) cool and deep-freeze of stuffed and pre-fried portions obtained in h), and j) pack already deep-frozen portions, and store and transport to the place of final preparation under appropriate refrigeration conditions; comprising a preparation step of the packed portions at the place of consumption, wherein said preparation step comprises heating the frozen, pre-fried and deep-frozen injected portions; and wherein a granular or powdery coating is applied to the portions before the pre-frying step h).

[0015] A granular or powdery coating is applied to the portions before the pre-frying step, as this increases their resistance to the pressure increase that can occur in the filling due to heating during pre-frying, preventing the filling from slipping out. Such coating comprises e.g. a mixture of spices and / or vegetable flours which also improves the taste. Ideally, the immersion cooking heat treatment is carried out with the potato unpeeled, reducing processing costs and improving flavour and image, as the skin is incorporated into the final product. This single-layer immersion cooking, vacuum cooking or steaming heat treatment is carried out at a temperature of between 80-90 degrees Celsius for 7 minutes, which preserves the skin of the product intact.

[0016] The mechanical emptying of the hollows is carried out by means of a tubular blade, which, on descending, carves the potato and retains the body or core of the potato corresponding to the hollow when the blade comes out; while the recovery of the lid for the hollow is carried out by recovering one of the ends of the extracted core.

[0017] The cuts that determine the portions are made by means of a single cut with a guillotine with radial branches, circular blades or metal wire, obtaining wedge-shaped portions, as this is carried out in a single operation. Ideally, the tubular blade and the guillotine with radial branches, circular blades or metal wire, move vertically over each potato to be processed. Likewise, with this arrangement, the injection of the filling can be carried out by means of an injector needle with a movement in the same direction as that of the tubular blade (vertical).

[0018] As for the pre-frying stage, it is carried out by means of a continuous fryer, allowing the implementation of a continuous production line, and the deep-freezing of the potato portions is carried out at a temperature of at least -35 degrees, also preferably in a spiral freezing tunnel, or in a continuous freezer.

[0019] The filler, on the other hand, can be based on: sweet sauces, savoury sauces, sweet and sour sauces, cheese-based sauces, spicy sauces. cheese creams creams of all kinds of foodstuffs. Fruit crushing Chocolates.

[0020] The product obtained is potato crisps comprising heated potato portions, previously obtained by heat treatment of single-layer immersion cooking, vacuum cooking or steaming, scanning to record their shape and size, determination on the model of the optimum position of the cuts to form a selected number of segments and of the position on each portion of a hole with a single inlet hole, injecting or mechanically inserting of each recess with a filler and plugging of the inlet hole by means of a potato lid recovered when the recess is made, cutting of the portions such portions are ideally wedge-shaped, and may or may not comprise a granular or powdery coating, which may be a mixture of spices and / or vegetable flours and pre-frying of the same, deep-freezing of the portions and packaging for preservation and transport to the place of heating for consumption.

[0021] The filling of the portions can be based on: sweet sauces, savoury sauces, sweet and sour sauces, cheese-based sauces (Cheddar, Cabrales, etc.), spicy sauces. cheese creams creams of all kinds of foodstuffs. Fruit crushing Chocolates.

Claims

1. Procedure for the preparation of French fries characterised in that it comprises the following sequence of steps carried out in a central kitchen: a) heat treatment of the potato by single-layer immersion cooking, vacuum cooking or steaming, at a temperature of between 80-90°C for 7 minutes, b) subject the potato heated in a) to a scan to record its shape and size. c) determine the optimum position of some cuts on the potato model obtained in b) in order to subsequently form a selected number of portions, d) determine on each predetermined portion obtained in c) the position of a hole with a single-entry hole, to be filled later, e) carry out the mechanical emptying of the identified holes in d) by means of a tubular blade to retain inside the potato body or core corresponding to the hole when exiting, recovering a lid for each hole by recovering one of the ends of the extracted core, f) inject or mechanically insert a filler into each hole obtained in e), and plugging each hole with the corresponding lid, g) carry out the mechanical cutting of the injected potato into pre-determined portions, without affecting the determined hollows and filling, h) pre-fry the portions obtained in g), i) cool and deep-freeze of stuffed and pre-fried portions obtained in h), and j) pack already deep-frozen portions, and store and transport to the place of final preparation under appropriate refrigeration conditions; comprising a preparation step of the packed portions at the place of consumption, wherein said preparation step comprises heating the frozen, pre-fried and deep-frozen injected portions; and wherein a granular or powdery coating is applied to the portions before the pre-frying step h).

2. Procedure for the preparation of French fries according to claim 1 wherein the coating comprises a mixture of spices and / or vegetable flours.

3. Procedure for the preparation of French fries according to any of the previous claims, where the cuts that determine the portions (step g) are made by means of a single cut with a guillotine with radial branches, circular blades or metallic threads, obtaining wedge-shaped portions.

4. Procedure for the preparation of French fries according to claim 1 where the tubular blade and the guillotine with radial branches, circular blades or metal wires have vertical movement over each potato to be processed.

5. Procedure for the preparation of French fries according to claim 1 where the injection or mechanical introduction of the filling (step f) is carried out by means of an injection needle with a movement in the same direction as that of the tubular blade.

6. Procedure for the preparation of French fries according to any of the previous claims, where the pre-frying step (h) is carried out by means of a continuous fryer.

7. Procedure for the preparation of French fries according to any of the previous claims where the deep-freezing of the potato portions (step i) is carried out at a temperature of at least -35 degrees.

8. Procedure for the preparation of French fries according to any of the previous claims, where the deep-freezing of the potato portions (step i) is carried out in a spiral freezing tunnel, or in a continuous freezing process.

9. Procedure for the preparation of French fries according to any of the preceding claims wherein the filling is selected from: - sweet sauces, - savoury sauces, - sweet and sour sauces, - cheese-based sauces, - spicy sauces. - cheese creams - creams of all kinds of foodstuffs. - Fruit crushing, and - Chocolates.

10. French fries characterised in that they comprise wedge-shaped potato portions having a cooked inner texture obtained by steaming at 80-90°C for at least 7 minutes and a pre-fried outer texture with a granular or powdery coating, said portions comprising a hole with a single-entry hole, a filling and a potato lid obtained from the extracted core.

11. French fries according to claim 10 wherein the coating is a mixture of spices and / or vegetable flours.

12. French fries according to any one of claims 10 or 11, wherein the filling is selected from: - sweet sauces, - savoury sauces, - sweet and sour sauces, cheese-based sauces, - spicy sauces. - cheese creams - creams of all kinds of foodstuffs. - Fruit crushing, and - Chocolates.